P16262: EV Team Motor Test Stand
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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.

Golf Cart DC Series Motor

Golf Cart DC Series Motor



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

Budget/Ordering Status

All 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.
Most Recent BOM

Most Recent BOM

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

The 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

Updates Since Last Review


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