Build & Test Prep
Table of Contents
Team Vision for Build & Test Prep Phase
The first planned goal of the team was to come back up to speed as a group following the 3-month intermission since the end of MSD1. This included a review of work already completed and deliverables still required. The final necessary components for the full-scale model were identified to allow purchase as soon as possible, minimizing the effect of lead time. Test plans were drafted that will verify completion of the identified engineering requirements, which will be refined and carried out as the necessary purchased components arrive.
Each team member also completed a summary of personal goals and actual accomplishments. Individual entries can be found here.
Team End State Vision
- The best case scenario is that we have a working prototype that successfully measures the coefficient of thermal expansion of test coupons. If this is not completed with full functionality, then we will provide a system with partial functionality. In this situation, explanations and proposed design changes will be provided. Our worst case scenario will be presenting a final prototype with functioning pieces, but not having a fully functional integrated system.
Bill of Materials:
- We will include a Bill of Materials (BOM) that will list all of the materials included in the final prototype.
- We will also include a BOM that will take our current material components and show recommended upgrades that were out of our budget, but would provide significant enhancements to a fully functional CTE tester.
Detailed Documentation of Design:
- Our prototype will display the capabilities of
magnetic levitation and through component research and
testing, a detailed document will be provided to
recommend upgraded components for purchase.
- With a limited budget, more affordable components were implemented to ensure a proof of concept was provided.
- Documentation will include recommended upgrade of
components with technical documentation.
- Each upgrade will also be run through our error analysis to highlight the improvement in our error budget.
- All technical documentation we have utilized throughout senior design will be provided.
- All test documentation supporting our engineering requirements will be provided. This will include successful and failed tests.
- Our full error budget with current prototype design and recommended design with component upgrades will be provided.
User’s Guide for Operation:
- An in depth, step by step instructional guide of
operation will be provided.
- Mechanical operation
- Thermal shroud
- Clamping system
- Coupon fastening
- Electrical operation
- Control system
- Magnetic levitation detail
- Connections and plug ins
- Mechanical operation
Mechanical Design UpdateThe composite support rods for the CTE tester were fabricated over the summer at the Harris facility. The structure was laid out in order to minimize axial CTE, and thus minimize the contribution to the total error. The support rods are currently undergoing the final CTE testing before they will be incorporated into the final prototype.
The bulk of the mechanical design is unchanged from the end of MSD1. Fabrication will be carried out according to the previously finalized design, with minor modifications to the clamp design.
The electrical subsystem design remains unchanged from the end of MSD1. The subsystem still consists of a MOSFET-biased electromagnet controlled by an Arduino, utilizing the sliding-mode control scheme.
Before proceeding with the error analysis, the error contributors that would be most difficult for the team to quantify were identified. These are the temperature error effect due to the heat given off by the magnet, the electrical noise in the wires, and all environmental effects. Note that the current values for these are estimates only. In the coming weeks, the team will meet with subject matter experts in order to determine how to quantify these sources of error.
Bill Of Materials UpdateThe bill of materials was updated to reflect components that have been purchased for the final prototype and highlight any materials still needed. A color coding scheme was applied to quickly identify components on hand, in transit/fabrication, and awaiting purchase/construction.
The live document version of the BOM is kept here.
Test Plan SummaryTest plans were drafted to verify that our final design will meet the engineering requirements laid out during the Problem Definition phase. Testing will begin when the necessary assembly & test fixture components are purchased and arrive in the following weeks.
All live test plan documents can be found here.
Risk and Problem TrackingRisk management is unchanged at this time. Risk management form was filled out with regards to the prototype device and not necessarily the final concept. New risks will be evaluated going forward with the final build as they reveal themselves.
Plans for next phase
Continue to work on open goals and action items as shown below.