Subsystem Build & Test
Table of Contents
Team Vision for Subsystem Level Build & Test PhaseDuring this phase, our team starting building the physical system. Necessary items were purchased and the Bill of Materials was updated as part needs and naming conventions changed. A demo was conducted to cover most of the test plans from the Build & Test Prep phase. Results are documented here, as well as discussion of importance and next steps moving forward.
By the end of this phase, we built and tested our system, and discovered what worked in our design, and what needed to be changed. Specifically, we found out that we needed connectors of a different material, since the plastic ones we were using ended up melting during our test burn. Additionally, we got temperature data from the test burn to use to validate the model.
Test Results Summary
Analysis: Temperature DataFor our subsystems build demo, our team tested the capabilities of the system with the reservoir and platform that were built. Our team completed a fourth burn trial to collect temperature data with thermocouples for the reservoir water temperature. The details of the testing conditions are outlined in the timeline below:
The schematic and actual setup images below show the
placement of the thermocouples and the newly constructed
platform and reservoir used to complete this test:
The final results from the test are summarized below:
|Starting water temperature||15.8 °C||60.44 °F|
|Increase||+8.1 °C||+14.58 °F|
|Ending water temperature||23.9 °C||75.02 °F|
|Amount of water heated||12.3 gallons|
|Time elapsed||1 hour|
|Ambient temperature||13.89 °C||57 °F|
The trial did not reach the target temperature of
35°C, which was due to the choice of burn material
used during the trial and windy conditions. Some of the
feedstock was wet, while others did not burn well in
general. Some leakage occurred, which was mitigated by
duct tape, and formally addressed in post-analysis.
Additionally, there was not enough material for a full
two hour burn, so the results were not truly
representative of use conditions. Based on the linear
trend of the average water temperature, which is labelled
"cold water" in the figure below, if the burn lasted
another hour, the target temperature could have been
Our team has completed 4 burn trials thus far testing the capability of the heat recovery system. Three of the trials are summarized on the chart below; trial 1 was neglected since water temperature data was not taken:
This proves that there is capability with heating the water by the system. Burn technique will be more closely documented in the training manual as well, since Trial 3 noticed an improved temperature increase due to proper feedstock.
Test Plans Status
A screenshot of an overview of our test plans has been
included below, and a link to a PDF for the test plan
results can be seen here.
Risk and Problem Tracking
The live problem management document can be found here.
Updated Engineering RequirementsAs of the end of this phase, we have also updated our engineering requirements to better match the reality of our project. This was due to a lack of information on our part when we were originally specifying engineering requirements. A screenshot of the current iteration of the engineering requirements can be see below, and a link to the live document can be found here.
Functional Demo MaterialsInclude links to:
- Presentation and/or handouts
- Notes from review
- Action Items
Plans for next phaseAs a team, where do you want to be in three weeks at your next demo?
- The next investigation is to find ways to eliminate excess materials to make the system more affordable for the users. Ideally, our team would like to eliminate some of the reservoir components by extending rubber piping from the coils and feeding them over any open reservoir. Also, our team would like to simulate models for different coil materials, such as aluminum, to predict time and temperatures that can be achieved.