P15280: Hot Wheelz Test Bench
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Phase 2-Beginning the Build

Table of Contents

System & Sub-System Test Plan Matrix

System and Sub-System Test Plan Matrix

Problem Tracker & Test Plans

The 6-step problem solving template will be used to help quickly mitigate any problems that arise during the build/test/integrate phase should they present themselves

Link to Problem Tracker

To ensure that our system is working properly and meets engineering requirements test plans were created to ensure our system meets expectations.

The following is a list of tests that will be run throughout senior design II:

  1. Time to assemble and disassemble system in the dyno room
  2. Inspect the idler system after loading due to running the dyno and Hot Wheelz Motor
  3. System meets all requirements according to the Formula Hybrid 2016 rule book
  4. Cart is below maximum weight limit and can be maneuvered from the Hot Wheelz team room to the dyno room without extensive physical strain. The cart must also clear all corner radii from the Hot Wheelz room to the dyno room.
  5. Emergency test buttons are operational
  6. Data is properly exported
  7. Graphic User Interface is working as expected
  8. Voltage senor is reading properly and calibrated
  9. Current sensor is reading properly and calibrated
  10. Module Analog Throttle Output Functions Correctly

For more information regarding the specifics of these test plans view the link below.

Link to Detailed Test Plans

Mechanical Systems

Hot Wheelz Motor Mount

Following the completion of the design, the motor mount could be constructed! By utilizing scrap steel from Klien, I was able to get the pieces of the mount cut out on the water jet. Following that, I had to machine out the holes to remove burrs and tight fitting issues as well as preparing the pieces for welding by cutting 45 degrees along the edges for the weld bead. By cutting these the weld will be stronger due to more penetration into the base material. Below are pictures of the mount during weld and completion.
Welding Setup of The Motor Mount

Completed Motor Mount

Hot Wheelz Power System Cart

Assembled Cart

Assembled Cart

Mounting & Components

Mounting & Components

The Powertrain cart has been assembled! All subsystems such as the motor, batteries and chain idler will be placed entirely on the cart for ease of transportation, maneuverability, assembly, and disassembly when moving the cart from the Senior Design floor to the dynamometer for testing. One handle of the cart will be modified to include a platform to mount the motor which will allow the motor to be located at a similar height to the dynamometer table.

Also, mounting platforms for the motor and batteries have been re-designed based on the customer change. Updated CAD images above show what will be built in the upcoming weeks.

Power Transmission

Plan for week 5: Order idler and power transmission parts. Source raw materials from machine shop. Visit steel supplier to source steel for idler structure construction. Begin construction of idler.

Review of accomplishments: Idler, motor, dyno sprockets, springs, and chain were ordered and have arrived. All raw materials sourced from machine shop. Machined parts in machine shop. Mocked up assembled system shown below.

Idler System at Present Time

Idler System at Present Time

Video of Sprocket Suspension System

Plan for week 9: Machine dyno sprocket to fit on dynamometer shaft. Create test plan for completed MSD project, set-up in dyno room. Finish idler machining and debug finished idler.

Electrical Systems

Sensors and Data Acquisition

For more detailed information about the tests below, Please refer to Detailed Test Plans

Current transducer testing

Current transducer testing

Current Test Data

Current Test Data

The photo above contains the setup for testing the current transducers. 8 Vdc is supplied to power the sensor. Different input voltages are applied and connected to the 10W resistor(to generate different currents) and through the current sensor. The current received by the sensor is amplified by the amount of loops (N). In this case there are 20 loops. The output is hooked up to a multimeter and reads as Vdd/2+4.3mV*N*current. Referring to the results table below, the error ranged from 0-10%.

Thermocouple testing

Thermocouple testing

Thermocouple Test Data

Thermocouple Test Data

The picture above contains the setup for testing thermocouples. Two thermocouples are hooked up to the data acquisition modules and the cooking thermometer shown is used to verify the output. Ice is applied to the bowl of water until the temperature reached ~0 degrees Celsius. The temperature is captured at 5 different points and can be seen in the table above, the error ranges from 0 to 1.4 degrees Celsius between the two thermocouple outputs and the cooking thermometer.

Voltage Transducers

Voltage Transducers

The picture above are the two DC and AC voltage transducers. For unknown reasons, there is no output from the output pin and will need to be sent back to manufacturer for testing.

GUI

Displayed below is the screen capture of the completed graphical user interface. Two different test modes are available. When starting, the user selects either a manual test or automated.

If the test is manual, the user begins the test by pressing start and controls the throttle, load torque and linear acceleration rate of the dyno motor through the sliders in the center of the screen. When the test is running the real time sampled data should be displayed to the right.

If a simulated test mode is selected, the simulation profile text box gets enabled and the user is able to input a test profile. The format of each line should be XXX XX XXX XXX. The first three characters are the throttle position, a value ranges from 000 to 100. The second two characters are the applied load in ft-lbs, this value can range from 00 to 20.The third set of characters represents the linear acceleration rate, a value that ranges from 039 to 999. The final three characters represent the length of time in seconds that the previous three variables are applied, this value ranges from 010 to 999.Once the simulation profile has been completed, the user selects start and the software sifts through each profile and stops execution after the last profile is completed. As with the manual test, data is collected and displayed.

Once a test is complete, the user is able to export the recorded data into a .csv file by opening the menu and selecting export to excel.

GUI Screen Shot

GUI Screen Shot

Power Distribution

Recap of previous phase: all components (power supply, voltage regulator, protection diode) have been tested then mounted onto the PCB. The results can be found here. Screw terminals for connectors were also installed. BNC-Molex connector for connection between sensors and DAQ were assembled. Below is a snapshot of connectors that were assembled.

Installed Connectors

Installed Connectors

Plans for next phase: package PCB into enclosure; start assembling harnesses to provide power to sensors.

Risk Management Chart

For the full spreadsheet of Risk Management, please click the link below.

Risk Management Document

Below is a snapshot of the predicted and actual risk trend.

Risk Management Chart

Risk Management Chart

Team Project Plan & Individual Plans

Green Columns represent Phase 2 tasks, Phase 3 tasks are in Orange

Green Columns represent Phase 2 tasks, Phase 3 tasks are in Orange

Our full project plan can be seen by clicking the link below. The team and individual plans for phase 2 have also been identified in the table below for clarity.

Link to Project Plan

Maura Jennifer Eric Vladimir Henry Dixon
Week 3-5
  • Acquire Raw Materials for motor mount- Completed
  • Machine and Weld Motor Mount together- Completed
  • Update project plan and timeline according to individual and team plans- Completed
  • Coordinate scheduling for shared use of dynamometer through the Machine Shop- Completed
  • Connect with Hot Wheelz team and our customer to determine planned dates for powertrain delivery- Completed
Weeks 6-8
  • Continuously Monitor Project Management Plan
  • Order Mounting Components for the Motor
  • EDGE Updates
  • Start Poster Templates
Week 3-5
  • Receive & Assemble Cart Completed
  • Battery Heat Sink Calculations Completed
  • Battery Enclosure Design Completed
  • Update CAD for Cart Completed
Weeks 6-8
  • Order all wooden components for Cart
  • Order all remaining team parts
  • Continuously track budget
  • Machine Mounting components
  • Assemble the battery and motor mounting platforms onto the cart
  • Get updated heat information from supplier and adjust battery box as needed
Week 3-5
  • Order all Idler parts Completed
  • Source required steel from steel supplier, check machine shop for raw materials Completed
  • Begin construction Completed
Weeks 6-8
  • Monitor System Test Matrix
  • Final Assembly of the Idler
  • Begin Sprocket Machining
Week 3-5
  • Develop backend for GUI In Progress
  • Develop frontend for GUI Completed
  • Perform quality assurance on GUI In Progress
  • Bit Error Rate test Not Completed
  • Analog throttle voltage test Not Completed
Week 6-8
  • Refine GUI
  • Bit Error Rate test
  • Analog throttle voltage test
Week 3-5
  • Test power supply Completed
  • Start assembling connectors Completed
  • Start putting together power distribution circuit on breadboard Completed
Weeks 6-8
  • Monitor Risk Management Tracking
  • Finalize and finish assembling connectors and harnesses
  • Finish assembling power distribution circuit
  • Package power supply and circuit into enclosure
Week 3-5
  • Acquire raw materials for sensor testing Completed
  • Test functionality of voltage, current, temperature sensors All completed except voltage sensor
Weeks 6-8
  • Work on mounting sensors to cart
  • Finalize Voltage sensor testing, follow up with manufacturer
  • Work with Vlad to integrate sensors with his GUI/program

Budget

Total Project Budget
$3,500.00
Estimated Project Budget
$3,000.00
Total Spent to Date
$2,456.62
Total Remaining
$1,034.38
Expected Buffer Budget
$500.00

Action Items & Lessons Learned

Following the Gate Review in MSD I there was a list of action items that needed to be resolved in order to move forward with the project. Below is a table of these items and the progress that has been taken to resolve the issue.

Action Item Resolved/Work in Progress Comments

Confirm Powertrain components that will be used in Hot Wheelz Car

Resolved Hot Wheelz provided our team with the components we need to design around.
Approved Parts Need to be Purchased Resolved All parts have been ordered and have arrived as planned.
Hot Wheelz team needs to provide schematics of their powertrain Resolved Hot Wheelz has provided all purchased component information as well as dates for the components to arrive

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