P17521: Kodak Dry Ink Station Coupling Test Bed
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Integrated System Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

According to the following project plan, the main goals for this phase were to complete ordering and manufacturing of all parts, both mechanical and electrical, such that they could be tested for individual functionality and assembled into the final test fixture. Any time left post-assembly before the gate review was to be spent on preliminary analysis of the fixture, especially concerning system validation testing.

Currently, the team is running slightly behind schedule, with action items in effect to catch back up to speed. Mechanical assembly aims to be completed by Thursday, 11/9, with full integration of electrical subsystem the next day, Tuesday 11/7. Partial integration of the electrical and mechanical systems will take place tomorrow, 11/3. such that preliminary encoder data can be collected and analyzed.

Fall Project Plan

Fall Project Plan

Below is the up-to-date tracking of all project expenditures. Currently, P17521 has used 43% of its budget.

Expenditure Tracking Spreadsheet

Project Status

Mechanical

Mechanical Subassembly

Mechanical Subassembly

We ran into a few issues within this phase; initially when rendering a copy of the slide, it was assumed the hole pattern was consistent but upon building, the centermost hole does not exist as originally assumed. Due to this, we have to increase the length of the shaft in order to utilize the next set of tapped holes. Another issue encountered is the slight misalignment of the curved slot on the rotational base plate. We will temporarily rectify this by “borrowing” two of the 4 slide toggle clamps while we put a new base plate through the shop. The only mechanical component that needs to be reworked is the solid coupling for fixing the rod to the motor shaft. Currently, one inner diameter is slightly too small to fit securely on the motor shaft. This will be a relatively simple fix.

Manufacturing Method Quantity Complete Notes
Machining – Previous Gate Review 24 24 All Original Parts Complete
Machining – Additional Parts 2 1 Lengthened shaft will be complete by Friday, 10/3/17. Temporary shim spaces have been cut from stock for the time being, new machined shims are in the works.
3d Printing – Previous Gate Review 6 6 The mounting pieces for the spring in the micrometer set up are being printed this week.
3D Printing – Additional Parts 2 0 Temporary toggle mounts for the rotational base are set to print Friday, 11/3/17. The spacer for the hysteresis break is set to print Friday, 11/3/17.
Modifications 1 0 The rotational base requires a modification for the clamps, we are going to begin rectifying the situation using toggle clamps for a short term solution.

Part Drawings

Toggle Clamp Riser Carriage Track Block End Shaft Support Motor Mount Base Motor Mount Upright Carriage Track Block Slide Adapter, side 1 Slide Adapter, side 2 Rear Slide Block Right Rear Slide Adapter Right Front Slide Adapter Left Front Slide Adapter Left Rear Slide Adapter Turntable Adapter Motor Mount Coupling Spacer Motor Mount Angular Calibration Block Micrometer Mount Base Micrometer Mount Receiver

Electrical

A wiring diagram was drafted to solidify electrical design, below:

Electrical Design

Electrical Design

Electrical Design

Wiring Diagram Table

Wiring Diagram Table

All electrical components were tested individually for functionality, and all were confirmed to function properly. Very rough testing data was collected by hand-fixing the motor to one of the encoders. Data was later collected by utilizing coupling components from a disassembled DIS. This setup and data collected is shown below:

Data Collection by hand

Data Collection by hand

Data from isolated setup

Data from isolated setup

This data will be used as dummy data for the analysis outlined in the following section until more accurate data is available. A more detailed description of the work put into the completed electrical subsystem build can be found in the following document: Electrical Design

Analysis

Data analysis will be conducted differently via different software programs. A DSP analysis will be carried out by Matlab (using the included dsp toolbox), while more general control charts (X-bar/R, etc.) and other statistical analyses will be carried out by Minitab. The essential analysis will be determining the differences between the input and output encoder values without a coupling inserted into the system. These differences will define the error due to the fixture.

Risk and Problem Tracking

All risks tracked remained unchanged throughout this phase:

Post-Summer Risk Management Update

Post-Summer Risk Management Update

The one unanticipated issue faced was the risk of an order not being approved at a certain step in the process. A purchase order was requested by the team, and left to the purchasing process. The order was not approved at the guide approval step, for whatever reason that was not a request rejection. Lessons learned, here, are that the project manager (Ryan) and/or purchaser (Adam) need to keep track (daily, every other day, etc.) of each order to ensure none get stuck at one particular step. Any orders stuck at one particular step shall be followed up on by one of the two persons.

Plans for next phase

Fall Project Plan

Fall Project Plan

As noted in the project plan above, the next steps for the upcoming phase are to finalize assembly of the overall fixture system, as well as completing system validation testing. There is time allocated to improving the test fixture, whether the system validation testing passes or fails (hopefully passes). Concurrently with the system validation testing, efforts will need to be placed on coupling research & purchasing to ensure coupling testing can be carried out as soon as system validation testing has passed. Another pass needs to be taken at the project expenditures list, as one or two more things have been ordered in the past few days that need to be added.


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