Subsystem Build & Test
Table of Contents
We spent the secondary phase of MSD II ensuring we had functional subsystems for the upcoming system integration. Many of the tasks included creating incremental subsystem implementations, finalizing lead times, and ordering remaining items. At the same time preliminary subsystem testing was started and more sponsors were searched for, and additional parts were received thanks to EVT.
MSD II Plan
Test Plan Summary
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.
Budget/Ordering StatusAll materials have been ordered, unless they are delayed intentionally. We're holding off on some less essential pieces of the frame -- the plexiglass shielding, and aluminum shelving until we secure an additional funding source. The up to date budget summary is below, and the full bill of materials is available for reference as needed.
Subsystem Assembly and Design
Bench and Coupling Subsystem
Bench Motor Mounting
- Motor Mounting to the Bench Subsystem --- Design Completed
- Extra T-Slot to be used for sliding motor mounting
- Sliding with proper locking on slots will allow for chain tension
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):
The direct mounting bracket is shown below. We still need to finalized hole measurements due to the worn state of the casing:
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.
The PERM motor has a similar mounting bracket:
Ordering StatusThe purchase order for the T-Slot and Fasteners have been placed. Stock for the aluminum shaft as well as the angle bracket will be ordered this week.
Risk and Problem Tracking
- Budgetary Risks Linger - need to close the $200 gap
- Losing an expensive component
- dSPACE hardware issues - currently being handled alongside dSPACE support staff.
Updates Since Last Review
- We have batteries.
- Golf cart motor is spinning
- Go kart motor is spinning
- Controller is now voltage controlled