P14361: Engineering Applications Lab Modules
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Build, Test, Document

Table of Contents

This Page Contains all documentation for Testing, Safety, Build Plan and Progress Tracking. For all Documents take a look at our DDR_Documents and our Google Drive Files.

Papers and Documents

Test, Debug, safety plan

Here is a Word Document with a quick over view for the build, test and safety plans.

A3

public/Photo Gallery/A3RAIL.JPG public/Photo Gallery/A3THRUST.JPG Here are the A3 Documents for both modules.

Problem Tracking

Click Here to view the problem tracking list

Final Paper Drafts

Here are the Final Paper Drafts

Build, Test, and Integrate

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Software

Click Here to get Software used.

Youtube

YouTube Link

Test Plans & Test Results

Railgun Launcher

This File contains the detailed test plan and expected results for the Railgun Launcher as shown bellow:
  1. Test variac to assure that part is functioning properly (W7, +/- ?)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Output Socket
    • Expected Test Results: Percentage of max output which is determined by the placement of the dial.
  2. Test resistors to assure they are functioning properly (W7)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Resistor Terminal ends
    • Expected Test Results: Resistor ohmic value should fall close to listed resistance.
  3. Test switches to determine if they are working properly (W7)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Load resistor terminal ends
    • Expected Test Results: Voltage should cut out completely when opened. Voltage should flow when closed
  4. Test custom connection cord used between variac and module to determine proper functionality (W7)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Connection end that connects into module
    • Expected Test Results: Voltage value should match output of variac setting
  5. Test AC/DC converter to determine proper functionality (W7)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Load resistor terminal ends
    • Expected Test Results: Voltage output should be around max voltage input
  6. Once assembled, test charging sub-system to determine functionality and debug any problems that may reveal themselves (W8)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Load resistor terminal ends
    • Expected Test Results: Voltage values should be around the 10 volt range and the max current that should be seen at this point is around 190m amps.
  7. Once assembled, test bleeding circuit to determine functionality and debug any problems that may reveal themselves (W8)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Load resistor terminal ends
    • Expected Test Results: Maximum voltage value seen in the circuit should be the max voltage amount stored in the capacitor bank. The max amount of current seen flowing through the bleeding circuit should be around 50m amps range.
  8. Once switches are assembled into charging circuit and bleeding circuit test both to determine that the switches work once integrated into systems (W8)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Load resistor terminal ends
    • Expected Test Results: Voltage should cut out completely when opened. Voltage should flow when closed.
  9. Once charging and bleeding circuit sub-systems are assembled and tested capacitors can be tested to determine proper functionality (W9)
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Capacitor resistor terminal ends
    • Expected Test Results: Capacitors should charge up close to full power at 3 times constants. Capacitors should come close to full discharge by 3 time constants
      • NOTE: Capacitor will be tested starting with just one then adding one more with each successful test
  10. First test firing of the system will be done once the following conditions are met:
    • Safety Note: Proper Personal Protection Equipment
    • Debugging and multiple successful tests of other sub-systems
    • Proper catching rig is developed and built
    • Proper safety equipment is working by testing staff
  11. Once the previous conditions are met test firing will be done to insure that the module is working properly and analyze the data from each test fire to determine the efficiency.
    • Safety Note: Proper Personal Protection Equipment
    • Test Points: Distance car travels after launch.
    • Expected Test Results: The car should travel a certain distance depending on the voltage input from the user and the efficiency rating of the system.

Click Here to view the Railgun Test Summary from 11/20

Click Here to view the Railgun Rod Spacing Data

Thrust Module Test Plan

  1. Test DAQ Device (W7)
    • Test Points: Test speed controller and servo motor using DAQ device
      1. Motor tested will be a servo motor from HiTEC (borrowed equipment)
      2. Speed controller will be a ESC for smaller RC Helicopter setup (borrowed equipment)
      3. Power will come from a DC Power Supply
    • Expected Test Results:
      1. DAQ device will successfully send a PWN signal to the servo at expected positions.
      2. The same signal from the daq will control the output of the speed controller based on the DC power supply input voltage
  2. Test Speed Controller (W7)
    • Test Points: Repeat Test 1 changing to the purchased Speed controller and optima batteries
      1. Speed controller will be the Hacker x-110
      2. DAQ Device will remain the same
    • Expected Test Results: voltage output from Hacker Speed controller will be varied between 0-24Vdc based on daq signal to speed controller
  3. Test Motor (W8,SZ PLATE W7)
    • Test Points: Repeat Test 2 adding the Motor (no propeller/Purchased Motor)
      1. Motor will be the Hacker A60 (with Adapter plate to table)
      2. Speed controller will remain the Hacker x-110
      3. DAQ Device code will be altered to control motor speed
      4. RPM will be verified via tacomotor
    • Expected Test Results: Motor will respond according to the DAQ setting
  4. Test E-Stops (Button and Pull cable, W7)
    • Test Points: Connecting DC power supply to relay and test both button and pull cable e-stops
    • Expected Test Results: When the estop button and pull cable are engaged, no voltage passes through the relay.
  5. Integrat Load Cell to the DAQ (Need Load Cell/Code, W8)
    • Test Point: Code for load cell to read forces acting on it (known weight)
    • Expected Test Results: Code will acquire forces acting on the load cell and output it into a manageable format.
  6. Test all elements together (End of W8)
    • Test Point: All elements together (Battery, Hacker Motor/Speed Controller, Load Cell and DAQ)
      • NOTE: No propeller will be connected at this point
  7. Test with Propeller (Post Frame build up, Tuesday W9)
    • Test Points: Test Propeller and record data
      • This test will include the following
        1. e-Stop test
        2. Data Acquisition testing via DAQ device
        3. Speed controlling test via DAQ device
        4. RPM confirmation (Tachometer)
    • Expected Test Results:
      1. E-Stop works as designed stopping propellor
      2. Data is correctly interpreted and displayed by the Labview code
      3. RPM of the motor is as expected from the setting applied to the the Speed controller
  8. Test Different Propellor to Compare (W11-DEMO)
    • Test Point: Repeat Test 7 with alternative propellor
    • Expected Test Results: Expect to see a correlation between size and pitch of propellor

Railgun Module Build

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Thrust Module Build

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First Test Video - YouTube Link


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