P17221: FSAE Composite Tube Fabrication
/public/

WBS_Testplans

Table of Contents

Engineering Requirements

Legend

DV = Design Value

TV = Threshold Value

IV = Ideal Value

MV = Measured Value

Green = Complete

Yellow = Preliminary testing indicates that this value is easily attainable, still needs to be formally tested

Red = Preliminary testing indicates that this will be hard to obtain, still needs to be formally tested

ER# Engr. Req. Unit DV TV IV MV Notes Test
1 Operator Safety Operator does not need to interact with moving machine Yes Yes Yes Yes Requirement is met. Motion control will be accomplished remotely. n/a
2 Part Size Capacity Inches (DxL) 6"x30" 3"x24" 6"x30" ??? Our original part capacity projections did not include the large turn around areas that we have now determined that we need. Part length may be affected but with the revised payout eye location, drive shafts of sufficient length will be able to be manufactured. n/a
3 Power Draw Requirements W 1000 20A at 110V = 2.2k 10A at 110V = 1.1k 517 The max value that is even possible because of fuses in the supplies is <1kW. ER03
4 Max Wrapping Angle Degrees 10 45 5 45 The crossfeed motor has no difficulty providing the torque required to wrap at this angle. See Problem Tracking for the latest information. D02
5 Wrapping Angle Precision Degrees 1 5 1 ??? Requires a completed tube for test. D02
6 Filament Tension lbs 0-10 Adjustable 0-2 ??? We have deferred testing this requirement until we have resolved all issues with the tensioning system as the addition of new pulleys and wiper systems will affect the final output tension. n/a
7 Step Required for Operator to Run Integer 10 15 1 ??? We are still actively working to reduce the required steps for setting up the machine and running it as we are testing the machine. # of Steps will be evaluated after final revision of user manual.
8 Total Machine Cost Dollars 1503 2000 1000 1046.75 This value is the actual value spent. While are well under budget, we have had delays with ordering through our customer due to budgeting priority for the Formula SAE vehicles . Better forecasting with the customer may have resulted in a tighter budget constraint in MSDI Costing
9 Max Tow Width Supported Inches 0.5 0.125 0.5 0.5 The tensioning system has been using tow up to 3/8in with no problems. We expect that the machine would function similarly with 1/2 in tow n/a
10 Max Spindle Speed RPM 100 50 150 471.2 We tested this ER and found the motor stalled at a much higher speed than the ER. GUI and GRBL limits set to ER and well below actual motor limit. n/a
11 Max Spindle Acceleration rad/s^2 120 80 120 34.9 We tested this ER and found that we have not required a higher setting and experience smoother motor operation with a lower limit. GUI and GRBL limits set to value shown. Value is set in GRBL
12 Spindle Speed Precision RPM 0.5 1 0.5 ??? This is very accurate. We just need to document it. This still needs to be formally tested.
13 Spindle Position Precision Deg/1k Rev 2 5 2 <3 after 1000 revolutions Further accuracy can be obtained through microstepping if necessary, but the current value is deemed sufficient for now. This still needs to be formally documented.
14 Max Feed Speed Inches/Minute 100 10 100 ??? We tested this ER and found that we easily met it without the motor stalling. GUI and GRBL limits set to ER and well below actual motor limit. This still needs to be formally documented.
15 Crossfeed Speed Precision Inches/Minute 0.2 0.5 0.1 ??? We tested this ER and found that we easily met it without the motor stalling. GUI and GRBL limits set to ER and well below actual motor limit. This still needs to be formally documented.
16 Machine Has Resin Bath Y/N Y Y Y Y After testing we may have found that we should have better planned out the specifications for the resin bath. The resin bath has required changes to make it wider and deeper along with a revised dip roller setup. Lack of published data made it hard to forecast these issues. n/a
17 Spool Capacity lbs 10 5 10 >10 The machine was loaded with the max spool weight and had no issues. n/a

Many engineering requirements can be met easily based on preliminary testing. These just need to be formally tested/documented after the bugs are worked out of the machine.

Subsystem Test Plans

E01: Motor Direction Test

E02: Motor Precision Test (No load)

E03: E-Stop Test (n/a, no e-stop is required)

Note on E05, E06, and E07

C01: Crossfeed Backlash Measurement

T01: Spool Unravel Test

T02: Spool Capacity Test

T03: Tension Output from Spool

T04: Tension Output from Eye Hook

D01: Mandrel Runout Test

D02: Wrap Angle Test Plan

Full System Test Plan

Acceptance Test Plan

Acceptance Test Plan

Acceptance Test Plan

Acceptance Test Plan


Home | Imagine RIT

Problem Definition | Systems Design | Preliminary Detailed Design | Detailed Design

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

Admin Mechanical Design Electrical Design Assembly/Integration Documentation

Requirements

Planning

Costing

Risk Analysis

Feedback

Feasibility Analysis

Design & Validation

3D Model

Hardware

Prints

Feasibility Analysis

Design & Validation

Hardware

Software

Machining

Mechanical Integration

Electrical Integration

Test Plans

Final Live Documents

Imagine Poster

User Manual