P18046: The Overcomer

Subsystem Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

The goal for this phase was to fully assemble and test each of our three subsystems, to be able to present to our customer at the end. A lot of work went into this process, between finalizing designs, the actual fabrication and assembly of the parts, juggling incoming orders, dealing with problems, and performing necessary feasibility analysis. In addition to this work, there are other deliverables in progress, such as our final technical paper, our Imagine RIT exhibit submission, and communication and planning with potential user testing sites.

At the end of this phase, many goals were met, but some are still outstanding. Our Imagine RIT exhibit proposal was submitted and accepted successfully. About 30-40% of our technical paper is complete. Our catch and launch subsystem is 90% assembled, and the only outlying pieces correspond to small parts. Our UI subsystem is 90% assembled as well, and the outlying assembly corresponds to springs. The frame is 90% complete as well, with the remaining steps being final assembly and drilling holes. Initially we had planned to have all of our subsystem testing done in this phase as well, but due to a few setbacks, the timeline has been pushed into the next phase. We do not anticipate this to be a problem, because the full system integration will only take a fraction of the time that the subsystem assemblies did.

Fabrication and Assembly

Our full design is broken down into 3 subsystems, the catch and launch, the UI, and the frame. Detailed assembly drawings have been completed for each, and can be found here. In addition to assembly drawings, assembly instructions for the fabricated parts have been created. The instructions associated with bending the metal for the frame can be seen here, and instructions for the catch and launch device can be seen here.

We've taken several photos throughout the assembly processes. Our photo folder can be found here. Additional photos can be found here.

BOM Updates

An updated version of the BOM can be viewed here. At this point, a few outstanding items need to be printed or bought. However, they are all smaller items that will have short lead times with ordering or printing, so we do not foresee any delays in this regard.

Test Results Summary

Subsystem testing has been delayed due to setbacks we experienced in the design and assembly process. The first week of the next phase will be dedicated to completing all subsystem testing. A complete list of our test plans can be viewed here. A snapshot of one test plan can be seen below:

Test Plan Snapshot

Test Plan Snapshot

Risk and Problem Tracking

We encountered two substantial problems in this phase, which can be seen in our problem tracker below. Each problem was addressed quickly with possible solutions, and the solutions have proved successful thus far.

Problem Tracker

Problem Tracker

The live version of our problem tracker can be viewed here. Going forward, we are aware of a few potential risks that could turn into problems in the next phase. Our updated risk-tracking document can be viewed here.

Risk Tracking

Risk Tracking

User Testing

At this time, we have gained approval to begin scheduling testing with Leary Elementary School in the Rush-Henrietta School District. We've requested to perform testing in the first 2-3 weeks in April. Additionally, we are communicating with a teacher from School #29 in downtown Rochester, who has expressed interest in involving her students in our user testing.

An updated version of our informed consent document can be found here.

Plans for next phase

The next phase of our project includes full-system assembly and testing. As previously mentioned, a portion of this time will also be dedicated to the remaining subassembly testing and data collection. This will be completed within the first 3 class days of the next phase. After that, the rest of the time will be spent assembling each subsystem into a full assembly, and performing system-level tests within the team to collect pertinent data. User testing will continue to be a priority with scheduling. A Cycle 7 plan breakdown can be viewed here to see a detailed schedule of what work will be completed by when.

The technical paper is currently about 40% complete, and can be viewed here.

Each team member has outlined what individual work they plan on completing in the next phase, and that document can be viewed here.

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