Fan Load Testing Study 2.0
Problem statement
Milwaukee Tool is looking for a way to measure torque from an applied load on rotating power tools to test life cycles. The current system consists of servo motors, AC motors, and eddy current brakes (electromagnetism) to test the tools. Although these systems have sufficed for now, the methods are expensive, difficult to employ across multiple tool platforms, and are unreliable in high speed applications (20,000 – 30,000 rpm). To remedy these deficiencies, previous engineers proposed using a fan to generate torque. In addition to the cost savings of using a fan, they handle well at high speeds and can be applicable for a wide range of tools due to their simplicity. Their research concluded that the torque would increase with an increase in fan blades, curvature of the blades, and increased size of the fan itself. The previous project was successful in getting the foundation of the test fixture built, but the testing that was completed was not sufficient and there were many inaccuracies between the predicted torque values and experimental values. To improve upon this project, we are going to design and test new fans/fan housings with the goal of developing a model to accurately relate the torque load produced and the rpm of the power tool. With an accurate relationship, Milwaukee Tool will be able to easily select the desired torque needed for the test of a specific power tool and select a fan that will suffice. While the ultimate goal is to develop a fan and housing system that could handle tools with a high rpm (e.g. angle grinders), our team is going to first focus on slower tools (hand drills) to get proper equations and eventually apply them to the faster motors. Even though this is mainly a continuous improvement project and has cost savings at the forefront, developing a common system for all lines of power tool torque testing would standardize the process and be extremely helpful for the operators running the tests.
Team members
Breck Duncan – leader
Maria Korkos – communicator
August Pfaff – accountant
Jack Doubek – admin
Client
Andrew Winans, Milwaukee Tool