Problem Statement
A way for Opterus R&D to validate a hing torque specification to its desired value in order to ensure a level of quality to the consumer
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Background
The Lenticular Offset Composite hinge stores strain energy as it bends, and releases the energy to deploy solar arrays. A test stand is needed to measure the torque produced by these LOC hinges.
Theory
Throughout its range of motion, the composite hinge will experience a local maximum holding torque and a global maximum at its folding angle limit.
Early Prototyping
Utilizing 3D printing, our team was able to create rapid prototype models to validate design choices.
Alpha Prototype
Using cheaper hardware substitutes, our team was able to gather data early on in the design process to make informed decisions about later model iterations.
Design for Manufacturing
All machined components were made in-house by our team using manual machining processes. Our team learned the importance of designing with manufacturability in mind.
Versatility
Opterus makes hinges varying in length, width, and thickness. Our team was able to create a universal solution that can accept all hinges currently in their product line.
Final Design
After numerous prototypes and many hours of machining, the team was able to deliver a working product to the customer.
Data Collection
The team was able to collect data on a variety of hinges, successfully validating the behavior of the hinges when compared to FEA and the old Opterus test fixture.