P10221: Baja 1 (Baja Driveline Test Development)


List of Potential Risks

The table below presents the potential risks that the team may face during the course of this project.

List of Risks
# Project Management Risks Importance Owner Resolved?
1 Time and resource allocation. This includes sharings resources (e.g. dyno) with other team members. 2 Team Y
2 Budget constraints on design concepts. 4 Team Y
3 Testing procedures conflict with Baja competition rules. 1 Team Y
4 Necessary sensors not within budget. 6 Matt Y
5 Parts are ordered too late. 4 Jeff Y
6 Design does not meet customer needs. 6 Team Y
7 Dependence on third-parties for provision of resources. 6 Team Y
6 Deviation from project timeline. 6 Jeff Y
8 Failure of team dynamics. 3 Team Y
9 Human Factor 3 Team N
# Technical Risks Importance Owner Resolved?
1 Non-familiarity with available data acquisition hardware and LabView software. 3 Chuck Y
2 Lack of detailed specifications of some resources. (e.g. dyno) 9 Jeff, Chuck Y
3 Using a large-scale unvalidated dyno on a small-scale engine (e.g. high internal friction of dyno) 6 Jeff, Chuck Y
4 Inconsistent readings from sensors or resolution/tolerance levels are not within required range. 6 Brian, Chuck Y
5 Output voltages of available sensors are not within range of data acquisition hardware. 3 Chuck Y
6 Operating conditions of test platform (i.e. temperature, RH etc) exceeds that of available sensors. 4 Team Y
7 Issues with spin direction of the dyno. 2 Matt Y
8 Drive system failure (includes excessive mechanical losses, misalignment etc). 3 Team Y
9 Sensor placement issues (e.g. O2 sensor not in ideal place). 3 Jeff, Chuck Y
10 Mechanical failure in components. 3 Brian Y
11 Control Mode Failure 6 Brian Y
12 Inability to validate results. 9 Team Y
13 Conflicting customer needs (engine tilt versus stability). 2 Team Y
14 Vibrational issues with test stand. 6 Matt Y
# Safety Risks Importance Owner Resolved?
1 Concerns with flammable liquids and toxic fumes. 6 Matt Y
2 Control Mode Failure 6 Brian Y
3 Physical injuries from unshielded surfaces and moving parts. 3 Chuck Y
4 Human factor. 9 Chuck N

More detailed risk document with mitigation actions available at Complete Risks (Excel document)

Newly Identified/Mitigated Risk as of Week 9 Review

Team will temporarily acquire MAF sensor from Mr. Wellin to measure MAF, and then correlate air flowrate from oxygen sensor. Fuel flow rate sensors will be spec'd out but not purchased.

Team will investigate mounting techniques and contact vendor (KISTLER) for more documentation. This will be addressed by Week 11 of MSD 1.

The BNC-2095 and the SCXI-1104 (mounted on the SCXI-1001 rack) has 2Hz filters across all 32 analog input channels and is multiplexed i.e. can read one channel at a time and is connected to the PCI-6034E DAQ card. This setup limits the sampling rate of the DAQ card and restricts compatible analog inputs to steady-state (slow varying) signals. For all measurements except cylinder pressure, this is NOT an issue. This risk can be mitigated by replacing the BNC rack and SCXI-1104 with another module from John Wellin, however the latter module does NOT have inputs for thermocouple modules (TNC-2095). The team has to stick with this setup! The cylinder pressure will be to see if it is compatible with this setup, else analog output from the sensor will be directly connected to the PCI-6034E DAQ card through a feedthrough block.

Team will investigate all sources of excitations, and conduct more stress analysis to help decide whether to use threaded bolts or pins.

The SCXI-1001 chassis is electrically grounded, the SCX1-1104 has overvoltage protection up to +/-42V which prevents shorting out the DAQ card. Only UNgrounded thermocouples will be used for this project, since the SCXI-1102C module has signal ground referencing features. The TC-2095 (which is hooked up to the SCXI-1102C module) boosts shielded front-mount terminal block and high voltage attenuation capabilities.

Has been resolved by Guide.

Has been resolved. Team will not be testing during that period. The focus will be on sensor acquisition, integration and validation, as well as LabVIEW/Software programming.