Integrated System Build & Test
Table of Contents
Team Vision for Integrated System Build & Test PhaseWhat P16486 wanted to do during this phase:
- Complete ordering parts and fabricate all necessary components
- Integrate all subsystems into Environmental Test Chamber
- Commence testing of thermal conductivity
What P16486 did during this phase:
- All parts were ordered
- Fabricated Mechanical Components: Tray and drawer slides in addition to the aluminum cylinder for the heater element
- Half Sphere mold was completed and is ready for testing
Test Results Summary
Please click here for an updated Test Plan
Please click here to review the Engineering Requirements
The following was modified on the ETC:
- Sides of the ETC were drilled and tapped to install drawer slides
- Drawer was drilled to fit the heater and get sandwiched by the flange
- Neoprene was measured to help insulate the previously planned areas
- Water tub and humidifier were installed
- Could get the humidity to 95% - Success!
Results and Conclusions
Testing the Heater
- The Heater will be sufficient for thermal conductivity tests. It heats the aluminum cylinder uniformly, resulting in 1-dimensional heat transfer along the radial axis to help derive an R-value.
Testing the Sensors
-Temperature Sensors can read the varying temperatures from the heater and will therefore practically assist in deriving a thermal conductivity value.
- 2 humidity sensors bought originally and testing
commenced with humidifiers (S4). In doing so, 1 sensor
failed during test with humidifier #2, so a 3rd one
ordered. During humidifier #2 test (refer to S4 results),
1 humidity sensor read up to a relative humidity of
approximately 95% after 5 minutes of running both the
humidifier and fan.
- Humidity Sensor Results: humidity sensor ordered (in addition to another one being shipped) should suffice for humidity test.
Testing the Fan and Humidifier(s)
- The fan was tested in combination with S4, the humidifier.
- Fan result: Fan works sufficiently on low speed in moving mist produced from humidifier and will suffice for humidity test.
- Humidifier 1 - (12-LED Water Fountain Pond Atomizer Air Humidifier)- did not mist and did form humidifier as was prescribed by product description; test failed in which the humidifier did not turn on and failed to work.
- Humidifier 2 - (Aluminum Mist Maker Fog Maker for Water Fountain Pond Rockery Fishtank Vase Birdbath) - Humidifier works and mists, causing humidity in ETC
- We incorporated testing of the second humidifier with the fan to see how the subsystems integrate and work together.
- Result: The fan and humidifier integration should suffice for humidity test.
Testing the Interface
- Told user to enter K test or Humidity test and then ran the temperature - Input temperature into interface - Utilized fake equation to see if K value could potentially be extracted
- More sophisticated math library added which allows for double precision floating point values, which will help with accuracy and rounding errors - Further added user input of sample thickness in order to accommodate future expandability by allowing different sample thicknesses -Conclusion: Interface disconnected from ETC works well and user can input all necessary parameters
Micro-controller capability can hold 56 kB of data
- 48K designated for recording samples, which allows for 3000 samples
- For example, if we have a sample taken every 30 seconds, that is 1500 minutes of data (or 25 hours)
- Still have to store code
Risk and Problem Tracking
Problems faced during this phase
1)Tray was too large, and the slides were too thick.
Solution: Use flat screws, and press the slides against the wall of the ETC
2) Heater doesn't fit inside the Aluminum Block, the top of the heater had a bigger diameter than the base. It made the threading of the base to the aluminum block impossible
Solution: Drill a bigger hole in the block, and use a flange to assemble the block to the heater, altogether with the tray.
3) Fasten the sensor to the aluminum block in order to measure heat.
Solution: Use a mouse trap spring to conduct the rotation of the sensor arm.
Please find the updated Risk Management
Plans for next phase
As a team, we want to have almost all of the building phase complete, and begin initial tests to eliminate and fix any issues with the ETC. We also want to have all molds completed so we can begin initial testing.