Manual

Manual
Orbital Motion Simulator
Haytham Ali
Kjetil Fjeld
Anders Gunbjørnsen
Heidi Kallerud
Martin Sandberg
Fredrik Thoresen
May 26, 2016
Høgskolen i Sørøst-Norge

2
Table of Contents
Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 User Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Assembly 4
Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Required Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Assembling Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Usage 16
General Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjusting Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Maintenance 20
Lubrication of Slew Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubrication of Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubrication of Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspection of Fixture Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replacement of Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3
Abstract
The manual is an essential document for the product’s practical use. When designing a product the
designer should always have usability fresh in mind. The product should have good usability, in order to
satisfy the customer. This document aims to explain the usage and assembly of the product.
It is very common for complex products to be an assembly of parts or smaller components. Very rarely
is a complex product composed of just one part. In the case of the OMS it consists of several parts that
have to be put together. This document will help explain how to accomplish that in a way that safeguards
the products functionality and make sure that the product is possible to put together in a time efficient
manner. The manual will also contain a Bill of Materials (BOM), which is a detailed overview of all the
parts needed in the assembly.
Important aspects such as safety and maintenance will be addressed. Safety is the most important aspect
regarding both the usage and assembly of the product, making it a central part of the manual. Maintenance
will obviously also play a prominent role. Without proper maintenance the product will start to deteriorate,
which will create repercussions in both functionality and safety.
Conclusively, this manual will serve as a user guide. It is a technical communication document that
includes assembly, usage and maintenance; the products operational life. It will make the user capable of
assembling the product, and also put it in to use, with proper safety and maintenance as a base.

4 1. User Manual
1 User Manual
1.1 Assembly
This section will address the assembly procedure of the OMS. This involves the bill of materials, the
assembling sequence and the safety procedures. Since the system consists of several different parts, a
thorough description of how to perform the assembling sequence is beneficial to the customer. The safety
procedures for the assembling process is also described in this section.
Bill of Materials
The BOM contains of all the parts needed to assemble the OMS.
Figure 1.1: Bill of Materials

1.1 Assembly 5
Required Items
The following items are needed in order to assemble the OMS:
• Torque wrench
• Torx tools
• Socket wrench set
• Lubrication
• Crane
Assembling Sequence
The following assembly sequence is recommended:
1. Mount the pinion and drive shaft to the angled gear, since they are press fits. Make sure to
put lubrication to the parts that will be rotating and transfer power.
Figure 1.2: Step 1.

6 1. User Manual
2. Mount the angled gear assembly to the base.
Figure 1.3: Step 2.
Figure 1.4: Step 2.

1.1 Assembly 7
3. Mount the slip ring to the base.
Figure 1.5: Step 3
4. Mount the base to the motion table, using a preload torque of 200 Nm.
Figure 1.6: Step 4.

8 1. User Manual
5. Connect the output wires to the slip ring and guide them to the openings in the bottom of
the base.
6. Mount the reader head to the reader head bracket.
Figure 1.7: Step 6.
7. Mount the reader head bracket to the gearbox.
Figure 1.8: Step 7.

1.1 Assembly 9
8. Mount the encoder ring to the sensor mount
Figure 1.9: Step 8.
9. Mount the cable bridge to the sensor mount and install the bolts that are used to fasten/position
the cable bridge to the power-train disc. This concludes the sensor mount sub assembly.
Figure 1.10: Step 9.

10 1. User Manual
10. Mount the sensor sub assembly to the slip ring using the guide pins on the slip ring, mind to
guide the wires through it.
Figure 1.11: Step 10.
11. Mount the slew bearing to the base, mind that it is positioned correct in regards to the pinion.
Figure 1.12: Step 11

1.1 Assembly 11
12. Mount the power-train disc to the sensor sub assembly. Make sure to guide the wires from
the slip ring through the designated wire hole on the power-train disc.
Figure 1.13: Step 12.

12 1. User Manual
13. Mount the power-train disc to the bearing.
Figure 1.14: Step 13.
14. Put the rubber gasket in place, at the end of the drive shaft.
Figure 1.15: Step 14.

1.1 Assembly 13
15. Connect the Motor adapter to the motor.
Figure 1.16: Step 15.
16. Mount the motor bracket to the base.
Figure 1.17: Step 16.

14 1. User Manual
17. Connect the motor to the motor bracket, mind that the rubber gasket is in its correct position.
Figure 1.18: Step 17.
18. Mount the offset disc to the power-train disc in its max offset position, in order to be able to
mount the RWS to it.
Figure 1.19: Step 18.

1.1 Assembly 15
Safety Procedure
The most logical starting point is what to do when the system is delivered, and put to use. The first thing
that commences when the systems is delivered is the assembly. The assembling sequence is described in
section 1.1 and explains the order in which the system is put together. However this section will focus
only on the safety aspect related to the assembly. It is expected that the assembling sequence is known
before the safety section is read.
When assembling the system there are several aspects that relate to safety. Safety in this sense aims to
prevent the risk of permanent damage to the system or interfaced units, at the same time the safety relates
to human interaction. Human interaction is the most important safety aspect, this includes minimising the
risk of human casualties.
There are two essential themes when describing the systems safety precautions regarding the assembling:
• Bolt Fastening
The systems assembling is based on bolt fixtures. When fastening the different components
it is important to fasten the bolts with proper preload, in order to prevent the stationary parts
from moving and at the same time prevent permanent damage to interfaced components. Further
information regarding bolts in general is provided in the design document under chapter ??.
The recommended preload to the bolts are as follows:
– Base to motion table: 200 Nm
– Bearing to Base: 12 Nm
– Power-train disc to bearing: 30 Nm
– Offset disc to power-train disc: 90 Nm
It is important to apply proper lubrication to the bolts before fastening since they are made of steel
and the threaded holes in the interfaced components consists of an Aluminium alloy. Aluminium
and steel have a tendency to get stuck together when in close contact as a result of corrosion, this
phenomenon is called seizing. When Aluminium and steel are in close contact under a static load
over longer periods of time, a layer of Aluminium oxide is created and as a result the bolts may be
hard to loosen. PERMATEX® #133 Anti-Seize lubricant [1] is suggested. This lubricant may be
a bit excessive for this application, but the project team do not want to take any chances when it
comes to performance.

16 1. User Manual
• Lifting Operations
The assembly of the components requires the parts to be positioned together, this is done by lifting
the components in to place. Certain components are to be lifted by hand, in accordance with
MIL-STD-1472G, this standard is only valid for individual components in the assembly. All
components are approved for lifting by hand.
However, it is recommended to use a crane in any instance of lifting, in order to avoid damage to
limbs as a result of lifting heavy objects, or wrong lifting technique. If the system as an entirety is
to be moved the use of a crane is required, because the weight being to large.
Under no circumstances shall any personal be positioned under the object being lifted by
the crane.
1.2 Usage
This section will describe the general usage of the system. In order to get the system to perform as desired,
a proper guide for usage is required. If the product is used in an incorrect manner it will have an effect on
both the safety regarding the product, and also the general functionality. It is therefore crucial that proper
usage is applied.
The usage of the product has three main categories related to each other. First an foremost there is the
safety aspect, this will create the foundation for proper usage. Furthermore there is the maintenance, this
is important to address both before and after the usage. Lastly there is the usage itself, how to maneuver
the system in to performing the desired task.
General Disassembly
When a test is finished and the OMS shall be moved there are two ways to go about this. Either the
base can be unbolted from the motion table and lifted off as a whole by a crane, or the OMS can be
disassembled in three parts.
First, the offset disc must be unbolted from the power-train disc and lifted away. Then the bearing (with
the power-train disc still attached) can be unbolted from the base and lifted away. Lastly, the base can be
unbolted from the motion table and moved away by hand.

1.2 Usage 17
Safety Procedure
The most important aspect of any manual is the safety instructions. The aspect of safety will manifest
itself in both usage and assembly. This section will address the safety related to the direct usage of the
system. The following guidelines are presented in terms of safety for the active usage of the OMS.
Fixtures
Before putting the system to use it is crucial that every bolt is examined and confirmed that all bolts
are properly fastened, in accordance with the recommendations in the assembling section 1.1. This is
examined using a torque wrench to measure preload.
Adjustments
When adjusting the offset on the device, the external load of the RWS shall never be active. Meaning that
the RWS’s weight has to be taken care of by a crane.
In order to adjust the offset all bolts have to be removed except the offset center bolt. This enables the
offset disc to be adjusted into position, without the danger of the disc falling down and causing physical
damage to personnel.

18 1. User Manual
Adjusting Offset
The system has 5 different positions regarding the offset. The first one allows the RWS to be located at
the center position, i.e. 0 cm offset. Positions two to five allows the RWS to be located at an offset of
maximum 40 cm, with 10 cm increments between each position. The position that has to be used when
mounting the RWS to the offset disc is the the fifth one, that allows an offset of 40 cm.
As mention in subsection 1.2, the RWS has to be carried by a crane when adjusting the offset.
The following sequence is recommended when adjusting the offset:
1. Remove the bolts connecting the offset disc to the power-train disc except for the center bolt
that is just slightly loosened, this allows the offset disc to be rotated.
Figure 1.20: Step 1.

1.2 Usage 19
2. Rotate the offset disc into the desired position. Mind to rotate the offset disc cautiously and
follow the movement with the crane. The position is found by matching the aligning bolt
with the hole on the drive-train disc.
Figure 1.21: Step 2.
3. Tighten the bolts when the desired position has been reached.
Figure 1.22: Step 3.
4. The system is now ready for use.

20 1. User Manual
1.3 Maintenance
This section will describe the general maintenance of the system. Since the OMS consists of several parts
that rotates, lubrication plays a big role. Inspection of fixture points in regards of deformation is also
brought up in this section.
Lubrication of Slew Bearing
Lubrication of the slew bearing shall be done as specified by SKF in their catalogue [3] using LGEP 2 [2]
or an equivalent oil.
Lubrication of Pinion
To get access to the pinion the offset disc must be removed first, then the power-train disc can then be
unbolted from the bearing.
The pinion interface must be regreased every 12th week. Before regreasing the gear, the teeth should be
cleaned of any impurities. The lubricant can be brushed or sprayed onto the gear or by any other suitable
method. The grease applied must have a base oil viscosity of at least 500 mm 2 /s at 40°C, have good
adhesive properties and a high resistance to water washout [3].
Lubrication of Bolts
All off the fixtures in the assembly comes in the form of bolts. Like described in safety under assembly
1.1, the bolts may get stuck together as a result of corrosion. An appropriate countermeasure is lubrication.
PERMATEX® #133 Anti-Seize lubricant [1] is suggested. This lubricant is applied to all bolt fixtures in
the assembly, and is important in order to ensure easy assembly, and disassemble.
Inspection of Fixture Points
The most critical points of the product is the fixture points. Whenever the OMS is assembled or
disassembled an inspection is performed on all fixture points. The inspection will involve detecting
hazardous deformation in the material. This will prevent any unforeseen deformation in the member.
This inspection is performed at any assembly or disassemble.

REFERENCES 21
Replacement of Bolts
TR005 in the testing document indicated that the bolts can withstand the testing conditions during one
year. This means that the bolts in the OMS assembly have to be replaced after this time period, in order
to maintain safe test conditions.
References
[1] Chemical Concepts (undated), PERMATEX® #133 Anti-Seize Lubricant [online]. Available: http:
//www.chemical-concepts.com/permatexr-133-anti-seize-lubricant.html, [accessed:
11.05.16].
[2] SKF (undated), High Load, Extreme pressure grease [online]. Available:
http://www.skf.com/group/products/lubrication-solutions/lubricants/
high-load-extreme-pressure-grease/index.html, [accessed: 16.05.16].
[3] SKF (undated), Slewing bearings catalogue [online]. Available: http://www.skf.com/binary/
tcm:12-182061/Slewing%20bearing%20catalogue%20-%2006115_2_SV_tcm_12-182061.
pdf, [accessed: 17.03.16].