Lindsay Epstein

Shirley Lu
2.77 Spring 2019

FPGA 5: Changing the Loop

By turning the handle (coupler), the structural loop size can be changed
as the movable beam support moves closer/farther from the other,
stationary beam support. The moment of inertia (invoking parallel axis
theorem) can be changed by rotating the beam from its “tall”
orientation to its “flat” orientation. The deflection of the beam is
directly influenced by the structural loop (open or closed) and the
moment of inertia of the beam (large or small).
Deterministic Design Process
Functional Req. Design Parameter Analysis & Ref. Risks & Counter Measures
Demonstrate - Changeable Beam deflection All principles not “felt”
parallel axis structural loop calculation Choose simplest system that
theorem, clearly includes all
- Changeable FUNdaMENTALs
structural loops book Beam deflection too small to
moment of inertia
measure  Use material with
low E and large structural loop
Stay within time - Simple and quick DFM and DFA,
limit fab availability of Hard to fabricate  Design
machines with fewest components,
- Set up to combine simplest machining operations
with FPGA 7

Want distinct differences in

Close form Error measurable with Beam deflection
deflection Large changes in
solution basic tools (calipers) calculations
structural loop and moment of
inertia 1
Design Sketches / Concepts

1 system with multiple potential structural loops and moments of inertia

2
MODEL: Beam Deflection with fixed end(s)

3
Analysis
Critical Analysis:
- Deflection of beam with fixed ends – open or closed loop, variable moment of inertia (I)

Large I Small I 4
DETAILED DESIGN Slide – attached to the movable beam support
Beam – HDPE bar to show visible deflection; and seated in the channel to follow St. Venant’s
2 arrangements (tall, flat) to show effect of Principle and prevent any wedging/jamming of
moment of inertia on deflect; holes for the movable support
hooking spring scale
Handle (motor coupler) –
to turn lead screw that
moves the movable beam
support; will attach to
stepper motor for FPGA 7

Bearing blocks – to
support lead screw

Base – stacked acrylic to

Beam’s supports – left is stationary, and right is movable to change structural loop get desired depth of
- Make closed loop tighter as you bring them closer as long as force is in between the channel
supports
- Change to open structural loop if you move it close to the stationary support and
force applied is now on the right of movable support)
- Allows for 2 arrangements of beam (different moment of inertia) 5
 MANUFACTURING
Simple fabrication while effectively demonstrating
FPGA principles
- Parts are laser cut (no post-processing operations
required) or bandsaw + drill only
- Standard fasteners in clearance holes for ease of
assembly

Most Critical Part: Moving Beam Support

- Cross-shaped cutout for different moment of inertia
arrangements of beam
- Close fit so that support acts as fixed, not
simply supported
- Tapped holes to mate to the nut of the lead screw
to move support, effectively changing structural
loop
- Clearance holes to mate with slide to not violate St.
Venant’s Principle 6
 Measured vs Theory

MEASUREMENTS
Closed Loop

I
F
a

Open Loop

7
SUMMARY
TIME BUDGET
- General trend in data measured
matches expected values
- Possible sources of error: Category Time [hours]
- Small deflection in certain cases Design (Individual + Peer Review + Final) 2.5
made measuring with ruler CAD 2.5
inaccurate Analysis 1.5
- Analysis assumed beam ends are Fabrication + Assembly 13.5
fixed but in reality there is some Testing 1
clearance between the beam and Documentation 2
their slots in the beam support, Total 23*
allowing for a slight slope at the
supports
*Total is higher than the usual because we
designed FPGA 5 to also be used for FPGA 7 8