TESTING
Testing for this system will look into the requirements for this project. There are 3 main measurable requirements in this project an output rpm test, backlash test, and a torque test. The other requirements will be pass/fail tests. The output rpm test was measuring the feed rate the output shaft measures and compare it to the calculated values to achieve the 1 foot per minute requirement. The output rpm also confirms the drive train ratio from the process of the calculations. The backlash test was a way of confirming the alignment of the spur gears and compared to the recommended values given from industry standard tolerances. The torque test is to confirm that 2500 ft-lbs of torque is enough power to crush the strips of carbon fiber. The system failed the test of being able to continuously feed carbon fiber strips in without ceasing.
Output RPM Test
This test is verifying the rpm output in the primary crushing wheel shaft. This test is to show the current drive train can provide the minimum feed rate of 1 foot per minute in the crushing wheel shaft.
Fig 1: Output RPM Test data table
Backlash Test
This test is to verify the backlash on the spur gears that transfer power between crushing wheel shafts. This test is done to show that these spur gears have the proper amount of engagement in the teeth to help minimize failure in the gear teeth
Fig 2: Backlash Test data table
Torque Test
This test is to simulate the minimum torque acting upon the shafts by constructing a torque lever arm at a length of 18 feet. This test can verify the necessity of the 2500 ft-lbs of torque. If the torque exceeded the minimum torque to crush the carbon fiber, the lever was reduced in length and a fish scale was mounted on the end till the carbon fiber was crushed.
Fig 3: Torque Test data table