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Subsystem Build & Test

Table of Contents 1 Team Vision for Subsystem Level Build & Test Phase 1.1 Planned To Accomplish 1.2 Accomplished 2 Test Results Summary 2.1 Mechanical 2.1.1 Initial Tests 2.1.2 Testing Rigs 2.1.3 Controller Casing 2.2 Software 2.2.1 Raspberry Pi Application 2.2.2 Database Structure 2.2.3 Web Application 2.3 Electrical 2.3.1 PCB Assembly 2.3.2 Battery Source Test 2.3.3 Troubleshooting 3 Risk and Problem Tracking 4 Functional Demo Materials 5 Plans for next phase 5.1 Individual Four Week Plans 5.1.1 Brittany 5.1.2 Robbie 5.1.3 Max 5.1.4 Josh 5.1.5 Jimmy 5.1.6 Isaac 5.2 Timelines 5.2.1 Mechanical and Electrical 5.2.2 Software

Team Vision for Subsystem Level Build & Test Phase

Planned To Accomplish

• Begin Design of testing rig
• Perform preliminary tests
• Connect web application to database
• Be able to pull data from database
• Assemble the power management PCB and test for the desired functionality.

Accomplished

• Tests were performed at packaging science lab
• Web application can connect to database and pull data
• Assembly of the PCB was finished. Found possible design issues.
• Testing Rig in Progress. Waiting on final materials

Test Results Summary

Mechanical

Initial Tests

• Whilst our testing rig was being designed, some tests were still to be run to verify our approach
• Results from the testing session can be seen below
  • Packaging Drop Test Pictures and Videos
  • Packaging Drop Test Data

Testing Rigs

• Our rig to be designed was first laid out in CAD to plan its functionality and the minor details about it
  • Red shows updates to CAD model previously not included to help improve initial design

• With parts we had come in, we were able to construct the majority of the rig
  • Final part additions are to be added on the 19th, due to the final parts coming in over the weekend

• To drop the helmet, a quick release mechanism is to be used in order to ensure the helmet drops properly

Controller Casing

• Current model is broken at the pegs
• Possible Solutions
  • Switch to wood and screws
  • Reprint with stronger density
  • Use screws instead of pegs

Software

Raspberry Pi Application

• Finalized the application that interprets the UDP packets from the collector
• Was able to make the application multi-threaded so that when a new packet is received the time that it is blocking the application is minimal
• In the threaded application after the data is interpreted, it is then sent to the database using the procedure that inserts the data into both the recent G force table and History Table

Database Structure

• Worked on stress testing database with high CPU usage and did not see any drop in preformance when an estimated load of 10 users was put on the DB
  • We will continue testing the DB under higher loads to find the limit of this database set up.
• Finalized Database Structure
• This database structure reduces redundancy as well as reduces insertion/update because of the reduced redundancy
• Procedures created
  • Procedure to get the most recent G Force and Battery Data
  • Procedure to insert data when new data is available into the recent G Force table and the History table

Web Application

• Created initial screen that allows users to enter the sensor ID that they would like to view data for
• Added back end code to connect to database and run important queries
• After entering the sensor ID, the web application will then return the most recent data for requested sensor ID
• Determined there will be three types of users that will need to be determined when creating an account
  • Player account : needs to have a sensor ID when creating the account and can only view information about their player
  • Coach account: has the ability to create teams with players so he can view all of the players together
  • Observer account: has the ability to view individual player data or team data but cannot modify teams

Electrical

PCB Assembly

• The PCB was assembled with the exception of the micro-usb connector, which will be attached after a session of troubleshooting an issue that is addressed below.

Battery Source Test

• A single cell lithium-polymer battery measured with a voltage of 3.75V was connected to the input of the PCB (white JST terminal).
• A problem was encountered when no voltage output was found across the output pins. Expected approximately 3.6V
• Suspecting a possible issue with the power plane after measuring the voltage supplied to the ICs from the battery were found to be measuring at 0V as well.

Troubleshooting

• Found that the input GND pin for the the battery power supply wasn't properly grounded. Grounding this fixed the issue with not voltage flowing through the power plane.
• No output from the linear regulator. Possible cause can be that the two input pins and two output pins must be utilized for a fully functional design. Currently using one of each.

Risk and Problem Tracking

• Like all other phases of the project, the risks involved are always changing and the list of them is being updated. A link to our most recent risk assessment can be found here.

• For our latest problem tracking document, click here.

Functional Demo Materials

A pre-read document for the review can be located here

Plans for next phase

Individual Four Week Plans

Brittany

• Complete Testing Rig
  • All but hockey puck and quick release parts should be in by Review
• Assist Packaging Science with controlled drop to confirm maximum height
• Attach electronics to helmet
• Begin outline for Final Paper
• Review Potential Design Challenges for submission

Robbie

• Implement Methods to determine if the sensor has been inactive for 2 minimal
• Finish implementing buffer on Raspberry Pi to store data if database connection is down
• Continue working on sensor Code to only send data when there is a high impact felt
• Continue Creating database functionality to make web development smoother
• Continue assisting teammates with Web application and Battery Board application

Max

• Finish apparatus
• Run preliminary test to ensure we will get high enough forces.
• Adjust as necessary.
• Run systematic drop tests at required angles.
• Run Temperature stress tests.

Josh

• Update visual aesthetic of recent impact page
• Incorporate login page
• Add functionality difference between coach and player
• Test data pull for multiple sensors at once
• Keep edge up to date

Jimmy

• Finish Test Rig
• Continue communicating with Packing Science
• Run systematic drop tests at required angles
• Determine final location for helmet components.

Isaac

• Troubleshoot PCB to find the design flaw. Possibly bring it to a functional state for system integration testing.
• Complete the redesign of the PCB if necessary.
• Assist mechanical team with battery placement and wiring.

Timelines

Mechanical and Electrical

Software

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