P15280: Hot Wheelz Test Bench
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Systems Design

Table of Contents

For all documents created and utilized by the team during the systems level design phase visit the following link:Systems Level Design Documents.

Benchmarking

The team has been doing a great deal of benchmarking to generate ideas for our design. February 19th the team visited the dyno located in the GIS building on RIT's campus. Our main objective was to view the graphical user interface, the load varying application and other features that current dyno's feature. The photos below show a few of our findings.
Description of the Dyno

Description of the Dyno

User Interface of the Dyno

User Interface of the Dyno

User Interface of the Dyno

User Interface of the Dyno

The Dyno Itself

The Dyno Itself

The Load is varied by the Eddy Current Brakes

The Load is varied by the Eddy Current Brakes

The team has also found similar projects done on the web which is helping to generate design concepts for the containment and modeling of the bench itself as seen in the photo below:

Similar Test Bench Design

Similar Test Bench Design

Other resources the team has used as benchmarking can be found at the links below:

A similar testing unit available for purchase: http://www.brusa.eu/en/products/measurement-test-equipment/test-benches/motor-test-bench.html

Illinois Institute of Technology EV Test Bench: http://share.iit.edu/handle/10560/3226

Schnieder Electric EV Motor Test Bench: http://www2.schneider-electric.com/documents/product-services/en/training-workstations/energy-control/powder-brake-speed-controller-bench.pdf

Functional Decomposition

These are the functions the test bench is required to complete and will be used in further concept development

These are the functions the test bench is required to complete and will be used in further concept development

Morphological Chart

The team brainstormed possible solutions to the needed functions for the test bench and organized them into a Morphological Chart for further use in concept development.

The team brainstormed possible solutions to the needed functions for the test bench and organized them into a Morphological Chart for further use in concept development.

Concept Development

Using the Morphological Chart,the team brainstormed four potential concepts utilizing different solutions.

Using the Morphological Chart,the team brainstormed four potential concepts utilizing different solutions.

Pugh Chart

Based on the concept selection seen above the team developed criteria which could be used in a Pugh Chart to analyze the pros and cons of each concept, making sure to rotate the datum so that each concept was being compared to each other. Once the team discussed the options we circled in red the devices and methods we want to proceed with in the final concept selection.
Based on the concepts that were generated we compared them to each other by rotating the datum. This helped us to identify the best attributes of each concept. We then decided that the best concept was actually a mix of all of our ideas, as seen circled in red, multiple solutions can be used within the same concept for the best result.

Based on the concepts that were generated we compared them to each other by rotating the datum. This helped us to identify the best attributes of each concept. We then decided that the best concept was actually a mix of all of our ideas, as seen circled in red, multiple solutions can be used within the same concept for the best result.

 This is the comparison charts that were made to analyze the best and worst concepts.

This is the comparison charts that were made to analyze the best and worst concepts.

Systems Architecture

Based on the concept selection process the team narrowed down the options for a systems level design.
Systems Level Circuit Design

Systems Level Circuit Design

This is a CAD Model of our proposed test bench enclosure that will feature the rotating test components secured under the bench and a user interface and controls on top.

This is a CAD Model of our proposed test bench enclosure that will feature the rotating test components secured under the bench and a user interface and controls on top.

This other cart will be mobile and will hold the unit under test. Using this design will allow for a modular design that is applicable to multiple powertrain applications.

This other cart will be mobile and will hold the unit under test. Using this design will allow for a modular design that is applicable to multiple powertrain applications.

Feasibility

One of the main constraints of the project is the ability to apply a variable load to the RIT Hot Wheelz powertrain system. In order to properly source a load varying method it is important to know the loads that need to be varied. Click here to view a summary of the feasibility analysis for a load varying device. All of the detailed calculations for the various loading situations can be found by clicking here.

Due to the high speeds the motors are expected to turn at the team also completed feasibility calculations to ensure the components could capture the data and display the data in near real time conditions. Click here to view a summary of the feasibility analysis for the electrical components.

Risk Assessment

Our team has identified possible risks that need to be accounted for in the design, build and use of the test bench. We have given each risk a different level of importance so that we know what to focus our efforts on in order to avoid to minimize error and accidents throughout the process. Click here to view our most current list of potential risks.

Systems Design Review

Our team assembles a conclusive presentation at the end of each review to summarize our work. Phase 2: Systems Design Review Presentation

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