P18280: Hot Wheelz Test Bench
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

Progress Report

Pre-DDR Status Report

Dynamometer Requirements

The KGCOE dynamometer is equipped with a platform to mount the devices to be tested along with the appropriate ventilation to remove engine exhaust.

The following items will be collected from previous Hot Wheelz dynamometer tests and will be used during testing of our own project:

Cart Design

Revision B: 3D Model

The figures below show Rev B of the cart from the PDDR

Revision B of Test Cart-Iso view

Revision B of Test Cart-Iso view

Feasibility testing and updates

1. Balance of Weight- Front to Back

-Center of Mass in x and y calculated from ground and handle (origin). With values below and calculations shown, a critical angle for tipping and a critical force to lift cart was found.

Tipping Point Calculations

Tipping Point Calculations

2. Reduce number of peg holes

Pegboard

Pegboard

3. Motor shelf brake

-McMaster clasp found

McMaster Clasp

McMaster Clasp

4. Engine airflow

-Pattern of slots created to increase airflow ability.

Engine Airflow

Engine Airflow

5. New shelf attachment method

-Wall mount shelving chosen

Shelf Attatchment

Shelf Attatchment

FEA testing Results:

Test Bench item to be tested Results Important Values
Motor Shelf Apply engine mass at center of plate and have mounting at from and rear side as if held by hand or table on one side and cart on other The engine is the heaviest component which will need to move. Most of the weight will be supported by the dyno table but FEA will test for the transition
Main Base Pegboard Unnecessary now; cart will be supporting the weight of everything now instead of the pegboard. Load capacity 2000 lbs.
Main supporting walls Weights are supported by new shelf supports Weight capacity 220 lbs per shelf*

Shelf Support Feasibility

Concern: Shelf runner pulling itself off of center divider

Solution:

-Divider is ½” thick and screws being used have a tensile strength of 170,000 psi

-Calculated pullout strength is 320lbs at the screw using ¼-20

Pullout Strength

Pullout Strength

Revision C: 3D model

-After making the model changes described above Cart Rev C was made.
Revision C of Test Cart-Side view

Revision C of Test Cart-Side view

Revision C of Test Cart-Top view

Revision C of Test Cart-Top view

Revision C of Test Cart-Isometric view

Revision C of Test Cart-Isometric view

Revision D: 3D model modifications

Material choices:

Original- 1/2" thick aluminum

Analysis- Simulation completed on largest shelf with Balsa wood characteristics (similar to particle board) FOS of 4

Shelf material analysis

Shelf material analysis

New- 1/4" Particle board shelves
Revision D of Test Cart-Isometric view

Revision D of Test Cart-Isometric view

Next Steps

To be completed by start of next semester:

1. Confirm drawing package is up to date

2. Order/ purchase material for manufacturing

3. Order cart to begin build

Drawings, Schematics, Flow Charts, Simulations

Mechanical Drawing Package

Working Drawing Package can be found here

Cart Manufacturing Plans

Test Bench Electrical System

Finished GUI Models

For additional GUI mockups, see the PDDR page.

The Flask microframework is being used in conjunction with the SQLalchemy database. All the GUI pages have been linked to each other in Flask. The database has beeen filled with dummy data. Information gathered from the HTML pages when the user hits submit can be used to add new CAN entries, edit entries, and delete them as well as modifying other data.

Raw CAN Table HTML Template

Raw CAN Table HTML Template

Dynamic CAN Table HTML Page

Dynamic CAN Table HTML Page

Dynamic Edit CAN Entry Page

Dynamic Edit CAN Entry Page

Dynamic Edit CAN Entry Page

Dynamic Edit CAN Entry Page

Overall Schematic

Schematic Page 1: Shutdown and Test Circuitry Interfacing

Schematic Page 1: Shutdown and Test Circuitry Interfacing

Schematic Page 2: Sensor Interfacing page 1

Schematic Page 2: Sensor Interfacing page 1

Schematic Page 3: Sensor Interfacing Cont.

Schematic Page 3: Sensor Interfacing Cont.

Schematic Page 4: Raspberry Pi Interface

Schematic Page 4: Raspberry Pi Interface

Power Consumption

Bench Power Consumption

Bench Power Consumption

Next Steps

Prototyping Plans

Prototyping plans for the sensor interfacing can be found here

Calibration Plans

Calibration Plans for the complete sensor system can be found here

Bill of Materials (BOM)

Bill of Materials

Bill of Materials

The full bill of materials can be found here. The team's budget can be found here. The biggest changes to the budget this phase were the addition of extra components to help secure the motor shelf, shelf runners and arms, and a cart purchased rather than fully fabricated ourselves.

Test Plans

Our test plan tracking document can be accessed here

Test plan S1: Distance from system for successful retrieval of data via wireless telemetry has been completed and passed. During testing it was also confirmed that the wireless system will operate through the dynamometer walls.

Risk Assessment

Our updated risk assessment can be accessed here
Detailed Design Risk Assessment

Detailed Design Risk Assessment

Projected Risk Importance

Projected Risk Importance

Plans for next phase

Our team plans to make any necessary changes to design following the Detailed Design Review and then continue purchasing components to allow for build tasks to be started in January at the beginning of MSD II. We plan to build the different components of the cart (walls, shelves, etc.) and begin prototyping electrical circuits. Additionally, we plan to continue programming the raspberry pi, implement the GUI, and write a program for the CANbus to transmit information to the GUI. See below for a detailed schedule for MSD II.

MSD II Schedule

MSD II Schedule