Integrated System Build & Test
Table of Contents
Team Vision for Integrated System Build & Test PhaseDuring this phase the team completed several key milestones in manufacturing and assembly. The main components for the mechanical structure were all completed and then assembled. The Seat was also finish sanded and inserts installed for future assembly and installation on the base.
Seat Assembly Instructions
1.) The laser cut template is aligned on the composite toilet seat and clamped to the top to hold the seat and template in place. The holes in the template are then opened up to 1.0 [in] in diameter.
2.) Four composite insert bushings (1.0 [in] OD, 0.75 [in] ID) are then inserted into the previously drilled holes.
Mechanical Base Assembly Instructions
The components from the subsystem build and test phase were taken and assembled as follows:
1.) The Base Mount and Base Mount Plate were gathered for assembly.
2.) The previously mentioned components were joined together with (4x) 8-32x1.00" alloy steel socket head screws.
3.) Steps one and two are then repeated for the second Base Mount Sub-Assembly.
4.) The Base Mount is then bolted to the Base Extender Plate using (3x) 10-32x1.00" alloy steel socket head screws.
5.) Repeat step four for the second mount.
6.) The Base Mount+Extenders now need to be mounted to the Base Plate. This is accomplished by torquing in (3x) 10-32x1.75" alloy steel socket head screws.
7.) Repeat step 6 for second Base Mount+Extender.
Completed Mechanical Base Assembly
1.) The Toilet Seat is then bolted to the Base Assembly using (4x) 3/4-16x3.0" alloy steel socket head screws.
2.) Once Alignment is achieved, the bushings are then JB Welded into the composite toilet seat.
Risk and Problem Tracking
The previous phases risk about the holes not aligning with the threaded holes in the base plate was realized during the first assembly attempt.
The two upper left holes in the composite seat did not align at all with the threaded holes in the Base Plate. Due to the incredibly tight fit between the insert and the bolt, one of the only ways to alleviate the issue was to pull the holes into alignment by oblongating them. The holes are no longer circular, but the bolts now align with the receiving threaded holes in the plate. The gaps between the inserts are then subsequently filled with JB Weld.
- The last risk this project faces is failing to be ready for Imagine RIT. There are still several components that need to be manufactured.