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  1. mrpi

    Thermal Study Help Needed! Initial Temperature from thermal study time step always goes to '1'

    Hello, I apologize if this has been discussed in the past but my searches did not turn up anything. I am running a set of transient thermal studies, and I would like Study 2 to use the temp profile results from Study 1 etc. I see the check box for "Initial Temperature from thermal study' box...
  2. mrpi

    Advice on having a custom fan made?

    I'm designing a custom motor for an industrial grinder. This is a brushless servo motor intended to replace a synchronous AC motor. Due to mounting constraints, I would like to install the cooling fan on the non-drive end of the motor shaft. All my previous experience is defense products in...
  3. mrpi

    Gear Bore sizing?

    I'm using three straight spur gears to move a gearbox away from a pivot. This is in a low speed lift application, and the gearbox OD is larger than the allowable pivot diameter. It basically just flips a [heavy] panel 180°. Backlash is not critical as it moves from stop-to-stop, but I am a...
  4. mrpi

    Adding material to a complex curved surface?

    I have a part that was made using lofts, the surface is a shallow complex curve. This part was provided to me as a "split" type feature and I do not have the curves that generated the original lofts. I found that I need a little more material in the middle of the part. Basically what I want to...
  5. mrpi

    Overall density of stator laminations??

    I'm trying to estimate the transient heating of brushless DC motor stator. (run it for 90 seconds, how hot will it get). I was going to assume the heat is generated in the windings (copper) and is transmitted by conduction to the laminations (steel) then into the stator housing (aluminum). I...
  6. mrpi

    Run Time Error and Study-1 Failed

    My (new) Machine: Win 7 SW Office Premium 2010 x64 Edition SP 4.0 I just installed Simulation last night to double check some heat-sink calculations I had done. I had previously been using a different machine running SW 2009 and Cosmos without issue, so I figured this new machine would be a...
  7. mrpi

    How do I apply fan performance curves to a heat sink?

    I have designed an air-cooled motor housing equipped with cooling fins. Due to the short time available from concept to prototype, I did very brief analysis before choosing the fin height, width, and length. I chose these to be quite conservative based on the amount of heat loss expected from...
  8. mrpi

    Axially Flexible Shaft Coupler

    I'm having a problem coupling a ball-screw actuator to a gearbox. Attached is an exploded view of the assembly. Note that the Worm Drive Gearbox is provided with a hollow output bore, the Custom Machined Shaft has a keyway and key on it to engage the hollow output bore. The key feature here is...
  9. mrpi

    Shaft Brake Centering: Bushing or Bearing???

    We currently manufacture a system that uses a shaft-brake to fix the rotation of a gear-box drive train. The output of the gear-box is a hollow keyed shaft. I have designed a 25mm shaft to be made from 17-4 H1150 to pass through the hollow shaft. One end of the 25mm shaft is the output, the...
  10. mrpi

    Gear Housing Tooth Clearance question

    Hello, this question is related to my other post regarding idler gear mounting. Design Background: I have designed a pinion-idler train housing that mounts to a customer-supplied driven gear housing. My idler gear sticks part way out of my housing in order to accomplish this. All the gears in...
  11. mrpi

    Idler Gear bearing selection

    Hello, Im designing a motor/gearbox that mounts to a (customer-supplied) linear actuator via a gear train. Design Background: Basically my gearbox has a pinion gear mounted to the output shaft, and in order to interface with the linear actuator, we include an idler gear (they call it a...
  12. mrpi

    "DIN 20/40-16" spline question

    I was looking over some gear boxes for a design and saw that one of them offered a splined output shaft. I am mounting a spur gear directly to the output shaft of the gearbox and this brought up several questions: 1. The spline looks convenient because it is smaller radially than a shaft and...
  13. mrpi

    Free convection of horizontal circumferential fins

    Ok, I have designed an electric motor housing to operate with forced cooling. For demonstration purposes, our customer would like to operate the motor without the cooling system. The cooling system consists of fans and shrouds to duct the cooling air over the fins on the housing. I need to...
  14. mrpi

    Estimating break-away force for an interference fit?

    I have a 45mm ball bearing shrink fitting onto a 303 shaft. The ball bearing has an ID of 45mm at P6 tolerance. The shaft has an OD tolerance of k5 as recommended by the bearing manufacturer (SKF). This makes for an interference of: maximum = 0.013mm minimum = 0.002mm How can I estimate the...
  15. mrpi

    Forced Convection of a motor housing, need some ideas

    I had asked a question about experimentally determining heat transfer coefficients in a motor housing earlier and this is a related project. I need to provide cooling to a motor dissipating ~200+W (could be 2x that number, I'm not sure yet). I had originally designed the motor housing with...
  16. mrpi

    Experimental determination of transfer coefficient

    First a little background: I designed a billet aluminum forced-air cooled brushless permanent magnet electric motor housing (finned) and I also designed a sheet metal shroud to direct cooling air around the motor housing. I did hand calculations to verify that it had sufficient cooling...
  17. mrpi

    Linear Rail design

    I'm mocking up a linear rail that is part of a "lift" system. I would like to use the type of linear rail Pacific Bearing sells that is self lubricating and suitable for "harsh environments" as this system will be used outdoors. The linear rail slider itself is "pulled and pushed" by a...
  18. mrpi

    Fixing Tooth Brake to Shaft

    Hello, I'm working on a design that uses a worm-type gear reduction unit. The output "shaft" of the gear reducer is in fact a 25mm hollow shaft provided with am 8mm keyway. I use a 25mm keyed shaft placed through the worm reducer hollow shaft to transmit the output torque. A little about the...
  19. mrpi

    Individual Gas Constant Units (lbm & lbf)

    I was evaluating supersonic nozzle performance when I had a question about the units for the Gas Constant "R". The Imperial units are: [ft-lbf]/[lbm-°R] What gave me a bit of trouble when balancing the choked mass flow equation is the relationship bewteen lbf and lbm. (I typed the equation...

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