The team presented their critical design review for a position welder turntable clutch system. The team aims to create a functional clutch mechanism that engages and disengages the turntable within the given housing constraints. Their proposed solution uses a dog clutch engaged by a lever-actuated fork shifter assembly. Calculations were presented to analyze the gear dynamics, fork shift deflection, and detent ball-spring lock. A prototype is being machined and will undergo testing to validate the design meets the project requirements within budget and on schedule.

1. Critical Design Review:
Integrated Designs
Team 14:
Team Lead: John Leung,
Solution Analyst: Edgar Lozano,
Safety Officer: Bernie Gabriel
Chief Financial Officer: Nicholas Balaban
Cad Designer: Josh McHugh
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2. Mission Statement
Integrated Designs aims to create a functional and viable solution to Cal Weld’s
Position welder by incorporating a system to engage and disengage the
turntable. Our project plans to assist the welders for a more comfortable and
efficient way of working to provide their consumers with quality products.
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3. Table of Contents
I. Project Background
II. Project Plan
III.Prototype Design Concept
IV.Design Analysis
V.Project Schedule
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4. I.Project Background
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5. About Universal Calweld
● Been around for over 35 years located in Fremont, California
● Designs high purity components, subsystems, and components
● Provide manufacturing and engineering service to a variety of industries
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6. Project Background
Sponsor: Greg Rozema
Faculty Advisor: Ala Qattawi
Design Challenge:
● Skilled workers from Cal Weld
need precision equipment
(Turntables) to weld components
● High Precision and purity welds
used for semiconductors and
production
6
http://www.mkproducts.com/support/Ma
nuals/091-
0677D_CobraTurn_DigTurntable_Lores.

7. Project Background
Cobra Digital Turntable Framework
http://www.mkproducts.com/support/Manuals/091-
0677D_CobraTurn_DigTurntable_Lores.pdf
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8. Constraints/Requirements
http://www.mkproducts.com/support/Manuals/091-
0677D_CobraTurn_DigTurntable_Lores.pdf
● Cannot redesign the entire
system because of the cost
● Integrated clutch must fit within
the given housing assembly
● Design has to be cost effective
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9. Design Constraints/Requirements
● Given width for worm gear
housing: 56.3mm
● Given length for worm gear
housing: 34.5mm
● Given depth for worm gear
housing: 50mm
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10. Objective
● Current Turntable lacks a
mechanism or clutch that
disengages the turntable.
● Our design must not interfere
with the welding process and
maintain free mobility
● Must also satisfy all constraints
"The Engineering Design Process." The Engineering Design
Process. N.p., n.d. Web. 20 Feb. 2016.
<http://www.sciencebuddies.org/engineering-design-
process/engineering-design-process-steps.shtm
10

11. II: Project Plan
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12. Why solution one wasn’t chosen
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● Difficult to maintain overtime
● Isn’t user friendly because of
constant movement of the motor
● Orientation of worm makes
solution not possible

13. Why solution two was chosen
"LEGO Technic Transmission Driving Ring and Clutch Gear." YouTube.
YouTube, n.d. Web. 20 Feb. 2016.
<https://www.youtube.com/watch?v=mMsUIhGick0>.
● User friendly by using lever rod
to shift gear
● Practical way to disengage the
motor
● Minimal and simple
maintenance
13

14. Solution- Implementation
Dog Clutch will be implemented
above the worm gear
Sharing the same shaft
The shifter fork assembly will be on
a shaft parallel to the dog clutch
shaft.
14

15. Solution- Clutch
Picture of how the dog-clutch will look like
● Dog Clutch will have set of teeth
to lock with worm gear.
● Dog clutch will be connected to
the turntable shaft through
splines
● C-clip will be used to keep gear
in place
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16. Solution- Lever
Engaging and Disengaging Dog
Clutch:
Fork shifter is fixed to an external
shaft
Locks in place using a detent ball and
spring mechanism
Fork shifter -> Dog Clutch
Actuates the dog clutch to engage the
worm gear driven by the motor 16

17. III: Prototype Design
Concept
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18. Prototype Design
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19. Prototype Design
Dog Clutch Disengaged with lever
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Dog Clutch Engaged with lever

20. IV: Design Analysis
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21. Calculations
● Based on our
measurements at
CalWeld
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22. Calculations
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Lead of worm: 5.3mm
Lead angle (γ): 3.86 °
Circular Pitch of Worm- 5.3mm
Pitch Diameter of Worm - 25mm
Pitch Diameter of Worm Gear- 45mm
Sliding Velocity (Vs): 51.64 ft/min
Pressure angle (ϕ)- 14.5°
Tangential speed of worm gear (VG): 4.642 ft/min
Tangential force on worm gear (WG
t ): 11468.45 lbf
WG
t with nd of 1.2: 13762.14 lbf
Reliability assumed by AGMA equation: 12hrs/day,
5days/week ---- 8 years
Torque at worm gear (TG): 31.90 lbs*in
Horsepower of the Motor: 0.8 Hp
Diametral pitch for worm gear (Pt ): 0.4444 teeth/mm
● Using our measurements taken, we
were able to understand the dynamic
system we are interacting with.
● With our new gear design, we aim to
replicate these parameters with the
creation of a new gear or by modifying
the old one

23. Fork Shift Calculations
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24. Fork Shift Calculations
Deflection with nd = 1
● xsl = -0.000025319
Deflection with nd = 1.2
● xsl = -0.000030383
Deflection with nd = 1.5
● xsl = -0.000037979
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Selected dimensions for width, thickness
and length satisfy both our space and
reliability constraints.

25. Detent Ball-Spring Lock Calculations
S= Side Force Required to push the ball out of it’s
groove.
F=Force of the spring onto the detent ball
R= Reaction Force from the groove onto the ball.
A= Countersink angle
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https://www.carrlane.com/catalog/index.cfm/294250
71F0B221118070C1C513906103E0B05543B0B012
009083C3B285356444A2D020609090C0015312A3
6515F57425B

26. We plan to use:
3/16” detent ball
Spring rate=20.3lb/in
max compressed length = 0.5in
initial length of 15/16”
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Detent Ball-Spring Lock Calculations

27. Simulation
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Pressure on Fork Shift: 10 N/m2

28. Simulation Analysis
The deflection of the fork
Negligible
Area of the fork shift near the shaft
Area will experience the most stress and wear on the fork
Maintenance discretion:
Replace fork shift
Machine the cracks
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29. Prototype Equipment List
● Dog Clutch
● New Worm Gear
● Fork Shift
● Shaft for Fork
● Plate for Lever Assembly
● Detent ball/Spring
● C-clips 29

30. Cost Analysis
● 6061 Aluminum Plate Stock. 1”x6”x6” $69.40
● 304 Stainless Steel Plate Stock. ⅜”x6”x6” $59.90
● 302 Stainless Steel Precision Ball. 3/16” Diam. $9.66 (pack of 100)
● Compression Spring. 20.3 lb/in.
$16.22
● 316 Stainless Steel Rod. ⅜” Diam. 1’ L $3.41
● Retaining Ring. Bore Diam 20mm $5.26
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31. Economy to Scale
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32. V: Project Schedule
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33. Project Block Diagram
Completed
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In-Progress Scheduled
CAD Drawing
Stress Analysis
Calculations
Purchasing:
(Lever Assembly)
Purchasing:
(Clutch Parts)
Final Report
Machining
Prototype Testing
Josh McHugh
Bernie Gabriel
Nick Balaban
Edgar Lozano/Nick Balaban
Nick Balaban
John Leung
Outsource/Bernie Gabriel
Entire Team
Final Poster
Entire Team

34. GANTT Chart
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35. Measures Taken
Quality: Material chosen (strong steels)
Reliability: Analysis of interference, tolerances, stresses, and Lifetime
Safety: Depth of splines and machine shop protocols
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36. Questions?
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http://gph.is/1gSo4RG