The document provides details of Integrated Designs' final design review for their project to add an integrated clutch system to Cal Weld's position welder turntable. The proposed solution uses a dog clutch engaged by a shifter fork and lever to allow the turntable to freely rotate without electromagnetic interference from the motor. The design was prototyped using 3D printing and stainless steel components. Stress analysis and cost estimates were provided to demonstrate the viability of the integrated clutch system solution.

1. Final Design Review:
Integrated Designs
Team 14:
Solution Analyst: Edgar Lozano
Safety Officer: Bernie Gabriel
Chief Financial Officer: Nicholas Balaban
Design Engineer: 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. About Universal Calweld
● Serving the industry for over 30 years located in Fremont, California
● Builds high purity assemblies and integrated systems for high technology
industries
● Provides manufacturing and engineering service to a variety of industries
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4. Project Background
Sponsor: Greg Rozema
Faculty Advisor: Ala Qattawi
● Turntables need an integrated
clutch
● Allows welders to freely rotate
a part or assembly
● High frequency motors
interfere with welding
equipment
4
http://www.mkproducts.com/support/Manuals/091-0677D_
CobraTurn_DigTurntable_Lores.pdf

5. Problem Description
● Industry standards
○ High surface polish of 5-10 Ra
○ Weld integrity of leaking gas at no greater than 10–9
cm3
/s
● Turning the motor on and off causes electromagnetic interference with the
TIG welding equipment
● Motor must be on in order to rotate the component being welded
○ No free rotation
● Integrated Clutch will solve these issues
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6. Current System Layout
CobraTurn Digital Turntable Framework
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http://www.mkproducts.com/support/Manuals/091
-0677D_CobraTurn_DigTurntable_Lores.pdf

7. Constraints/Requirements
● Integrated clutch must fit within
the given housing assembly
● Turntable must run correctly with
maximum 10RPMs and 300lb
max load
● Must be able to rotate freely with
the integrated clutch
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8. Constraints/Requirements
● Must not interfere with turntable
gas lines
● Must use reliable steels to prevent
frequent maintenance
● Design has to be cost effective
8http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_
DigTurntable_Lores.pdf

9. Final Design Project Block Diagram
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Team Contributions
CAD Drawing | Prototype Design | Report | Prototype Testing
Stress Analysis | Machining | Poster | Report | Prototype Testing
Calculations | Prototype Animation | Report | Prototype Testing
Purchasing | Calculations | Poster | Report | Prototype Testing
Josh McHugh
Bernie Gabriel
Nicholas Balaban
Edgar Lozano
John Leung
Report | Prototype Testing

10. Solution Implementation
● Clutch will be implemented above
the worm gear
○ Sharing the same shaft
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● The shifter fork assembly will be
on a shaft parallel to the clutch

11. Modifications to the Current System
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12. Design System- Dog Clutch
● Dog Clutch will have set of teeth
to mate with the worm gear
● C-clip will be used to keep worm
gear in place
● Dog clutch will be connected to
the turntable shaft through splines
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13. Design System- Lever
Engaging and Disengaging Dog
Clutch:
● Shifter fork is fixed to an external
shaft
○ Locks in place using a detent ball
and spring mechanism
● Shifter fork → Dog Clutch
○ Actuates the dog clutch to
engage the worm gear driven by
the motor
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14. Implemented System Design
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15. Equipment List
● Dog Clutch
● Modified Worm Gear
● Shifter Fork
● Shaft for Fork
● Plate for Lever Assembly
● Detent ball/Spring
● C-clips
● Machined Splines
● Bolt for lever plate
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16. Design System Cost Analysis
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● Cost of dog clutch
and modified worm
gear: $1950

17. Full Implementation
● Assuming Cal Weld Purchases
enough materials for 50 prototype
assemblies, it will cost a total of
$7,335 to implement our design.
● Assembly time: one hour per
turntable, assuming all parts are
made
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18. Stress Analysis
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Pressure on Fork Shift: 10 N/m2

19. Prototype Description
● Lever assembly will use a pin instead of J-B Weld to hold the shifter fork
● Both the worm gear and dog clutch will be made of 440 stainless steel
● C-clip will be placed on top of the worm gear
● Components are to scale except the turntable shaft and housing assembly
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20. Prototype Simulation
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21. Prototype Rationale
● Prototype provides:
○ Visual representation for our final design
○ Technical understanding of our problem
● Simulating manufacturability
○ Machining
○ Purchasing
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22. Measures Taken
● Quality: Stainless steel tested to shown positive for desired application
● Reliability: Analysis of tolerances, stresses, and lifetime (AGMA Equations)
○ Proper lubrication to prevent grooves from getting worn out
● Safety: Depth of splines and machine shop protocols
○ Dog clutch lever designed to eliminate any concerns
● Changed shape of grooves on worm gear
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23. Project Deliverables
● Prototype dog clutch lever
design (3D Printed model)
● CAD Drawings including
dimensions
● Mechanical Installation Guide
● List of Components needed to
create the design
● Final Report
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24. Future Recommendations
● Keep all tolerances to about
±0.5mm
● Maintain proper lubrication
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http://www.sprint-uk.com/

25. Questions?
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http://gph.is/1gSo4RG