P17341: Harris Near-Zero CTE Test Apparatus
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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.

Breakdown of Phase 1 tasks

Breakdown of Phase 1 tasks

Each team member also completed a summary of personal goals and actual accomplishments. Individual entries can be found here.

Team End State Vision

Required Deliverables:

Bill of Materials:

Detailed Documentation of Design:

User’s Guide for Operation:

Mechanical Design Update

The 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.
Support rod layup

Support rod layup

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.

Final test facility assembly

Final test facility assembly

Clip clamp design

Clip clamp design

Electrical 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.

Block diagram representation of sliding mode controller

Block diagram representation of sliding mode controller

Error Analysis

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.

Error analysis with problem contributors highlighted

Error analysis with problem contributors highlighted

Bill Of Materials Update

The 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.
Snapshot of updated BOM

Snapshot of updated BOM

"Make/Buy" color code explanation

The live document version of the BOM is kept here.

Test Plan Summary

Test 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.
Test plan for ER S1: Magnetic Strength

Test plan for ER S1: Magnetic Strength

Test plan for ERs S2, S3, & S6: Control System

Test plan for ERs S2, S3, & S6: Control System

Test plan flowchart for ERs S2, S3, & S6: Control System

Test plan flowchart for ERs S2, S3, & S6: Control System

Test plan for ER S5: Danger of Shock

Test plan for ER S5: Danger of Shock

Test plan for ER S7: Shroud Heating

Test plan for ER S7: Shroud Heating

Test plan for ER S8: Structure Strength

Test plan for ER S8: Structure Strength

Test plan for ER S9: Clamp Strength

Test plan for ER S9: Clamp Strength

Test plan for ER S10: Support Rod Durability

Test plan for ER S10: Support Rod Durability

All live test plan documents can be found here.

Risk and Problem Tracking

Risk 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.
Risk Management list as of final MSD1 design review

Risk Management list as of final MSD1 design review

Plans for next phase

Continue to work on open goals and action items as shown below.

Weekly Roadmap

Weekly Roadmap


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