P16262: EV Team Motor Test Stand
/public/

Integrated System Build & Test

Table of Contents

We spent the fourth phase of MSD II primarily dealing with budgetary issues, alongside development of subsystems whose parts had recently become available. The spline was worked on to attempt to resize the shaft and remove the spline gear. The IGBT bus bar was designed, and the IGBT was tested under low power conditions. The safety circuitry was developed and tested. Circuits were finalized and soldered. Relays were tested.

MSD II Plan

Team Member Term Plan

Team Member Term Plan


Test Plan Summary

High Level Test Plan

High Level Test Plan


The general approach for our test plans is a subsystem-up approach. Some of the major systems, such as the load generator, require the safety and sensing subsystems to already be in place. Diagnostic testing is done behind the scenes and is not considered part of the commissioning testing. The detailed test plans for the major engineering requirements can be found at the following link: note that some are "specified" and won't need to be tested.

Test Plans

Voltage Controlled Throttle

RPM Circuit Testing

Subsystem Assembly and Design

Bench and Coupling Subsystem

Bench Motor Mounting

Bench and Coupling Assembly

Bench and Coupling Assembly


Motor Bracket and Drivetrain

In order to properly support the golf cart motor, we not only needed a mounting bracket but another bracket and bearing to center the armature inside the casing (preventing friction):

Golf Cart Support Bracket

Golf Cart Support Bracket


The direct mounting bracket is shown below. We still need to finalized hole measurements due to the worn state of the casing:

Golf Cart Motor Bracket

Golf Cart Motor Bracket


The Golf Cart Motor contains an old spline design to couple the shaft into the motor. Because this design is not currently manufactured, we will need to have our own shaft machined. Discussion with the machine shop confirms this kind of design can be successfully made, and simulation showed aluminum (much easier to machine) will successfully handle the load with a wide safety margin. The shaft will couple to the same sprocket as on the PERM with a standard keyway.

Shaft and Spline Design

Shaft and Spline Design


The PERM motor has a similar mounting bracket:

PERM Motor Bracket

PERM Motor Bracket


Ordering Status

All lead time components are ordered.

Risk and Problem Tracking

Budget Request

Thanks to a sponsorship by RIT's Student Government for $1000, as well as the donation of the Poly shielding from Curbell Plastics, we now have the funds to successfully finish purchasing the remaining items on our BOM. Many of these critical items have already been purchased, with the rest being taken care of this week. This will allow us to move forward with the new revised project plan.

Updates Since Last Review


Home | Planning & Execution | Imagine RIT

Problem Definition | Systems Design | Subsystem Design | Detailed Design

Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Integrated System Build & Test with Customer Demo | Customer Handoff & Final Project Documentation