Phase 2-Beginning the Build
Table of Contents
System & 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
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:
- Time to assemble and disassemble system in the dyno room
- Inspect the idler system after loading due to running the dyno and Hot Wheelz Motor
- System meets all requirements according to the Formula Hybrid 2016 rule book
- 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.
- Emergency test buttons are operational
- Data is properly exported
- Graphic User Interface is working as expected
- Voltage senor is reading properly and calibrated
- Current sensor is reading properly and calibrated
- Module Analog Throttle Output Functions Correctly
For more information regarding the specifics of these test plans view the link below.
Hot Wheelz Motor MountFollowing 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.
Hot Wheelz Power System Cart
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.
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.
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.
Sensors and Data Acquisition
For more detailed information about the tests below, Please refer to Detailed Test Plans
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%.
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.
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.
GUIDisplayed 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.
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.
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.
Below is a snapshot of the predicted and actual risk trend.
Team Project Plan & Individual Plans
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.
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|