P18280: Hot Wheelz Test Bench
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Systems Design

Table of Contents

Team Vision for System-Level Design Phase

During this phase, the team planned to gain a broad understanding of all of the functions that this test bench will be able to perform and to complete a feasibility analysis to guide further design. The team also planned to gain a better understanding of the hybrid systems that the test bench can accommodate in order to allocate space and set up necessary configurations on the test bench for these systems. Finally, the team planned to brainstorm and select concepts for the major systems and functions of the test bench.

Major concepts were brainstormed using a morphological chart during this phase and decision matrices were utilized to analyze these options. A top choice for each function of the test bench was selected, and the team ensured that these choices could be integrated together.

Functional Decomposition

Functional Decomposition

Functional Decomposition

Functional Decomposition document

Benchmarking and Research

Hold Components

Each option was researched to determine its usefulness and feasibility for our application. Results are summarized in the chart shown below.
Hold Components Benchmarking

Hold Components Benchmarking

Communication Between Devices

Communication Between Devices

Communication Between Devices

Read/Pull Data

Programming Language

Programming Language

Connection To Host

Connection To Host

Connection To Host

Microcontroller

Microcontroller

Microcontroller

Detect Fault

Detect Faults

Detect Faults

Display Fault

Display Faults

Display Faults

Supply Power

Supply Power

Supply Power

Hybrid Components

Below are common hybrid components the bench may need to accommodate for:
Series Hybrid Components

Series Hybrid Components

Parallel Hybrid Components

Parallel Hybrid Components

Morphological Chart

Our functional decomposition generated eight main functions for us to design to. To make our decisions we developed a Morphological Chart and created decision matrices for each.

Morphological Chart

Morphological Chart

Morphological Chart

Feasibility: Prototyping, Analysis, Simulation

Analysis of expected weight requirements for the bench
Component Size and Weight Research

Component Size and Weight Research

Deflection analysis for a quarter inch thick aluminum pegboard mounted as the base of the cart using max component weight approximation. Components will be mounted to the pegboard base using nuts and bolts.

Pegboard Deflection Analysis

Pegboard Deflection Analysis

Design matrix for cart frame material selection

Cart Material Selection

Cart Material Selection

Design matrix for microcontroller selection

uController Selection

uController Selection

Server vs Node to Node Implementation User Flow

Server vs Node to Node Implementation

Server vs Node to Node Implementation

Wiring Standards

Wiring Standards

Wiring Standards

Wiring Standards

Power Estimates

Power Estimates

Power Estimates

Microcontroller Storage

Estimates for Minimum Onboard Storage Required

Estimates for Minimum Onboard Storage Required

Minimum Onboard Storage Calculations

Data Rate Calculation

Estimates for Minimum Data Rate Required

Estimates for Minimum Data Rate Required

Minimum Data Rate Calculations

Software Flow Charts

Flow for editing CAN bus definitions
Editing CAN Definitions

Editing CAN Definitions

Flow for deleting CAN bus definitions

Deleting CAN Definitions

Deleting CAN Definitions

Flow for creating new CAN bus definitions

New CAN Definitions

New CAN Definitions

Where CAN Definition Entry fields consist of:

Flow for displaying data

Displaying Data

Displaying Data

Flow for logging data

Logging Data

Logging Data

Concept Development & Concept Selection

Detect Faults

Detect Faults

Display Faults

Display Faults

Enable Portability

Enable Portability

Hold Components

Hold Components

Provide Power to Devices

Provide Power to Devices

Communicate Between Devices

Communicate Between Devices

Write Data to File

Write Data to File

Connect Transmitter to Host

Connect Transmitter to Host

Based on the outcome of our decision matrices, we used the top candidates to build 5 different concepts to compare against the current test bench system used by the Hot Wheelz team.

Component Selection

Component Selection

Concept Selection

We used the following criteria to compare the concepts against each other using Pugh Charts

Criteria

Criteria

Pugh Chart with Concept 2 as the Datum

Pugh Chart with Concept 2 as the Datum

Pugh Chart with Concept 3 as the Datum

Pugh Chart with Concept 3 as the Datum

Pugh Chart with Concept 6 (The Current Design) as the Datum

Pugh Chart with Concept 6 (The Current Design) as the Datum

Pugh Charts

At this point, we have not found any conflicts between the different concepts that have been selected. As designs are created in more detail, conflicts will be tracked and noted. For the Detailed Design Review, we will ensure that all conflicts have a plan for mitigation.

- Concept 3, 4 and 5 had a more negatives than positives for each of the three datum changes.

-Based on the feasibility analysis it was decided that several power sources and items would not fit on the cart due to space constraints

-Concept 4 was removed due to the extreme un-feasibility of utilizing nuclear power.

-Concept 6 was our do nothing solution and in nearly ever case utilizing some improvement caused the other concepts to score better

-Concept 1 is the strongest because it is the most convenient method in terms of space and power utilization.

Systems Architecture

The image below displays an overall system architecture of the entire project. The second Image displays a more detailed architecture of the electrical system. In the electrical system architecture there are two 12V power sources: one for the bench supply and one from the Hot Wheelz Design. The bench supply will always power sensors and telemetry. There will be a switch with the option to test Hot Wheelz GLV systems with the bench supply or the team designed supply. This allows the team to test their power designs or just use the bench supply for convenience.
System Architecture

System Architecture

Electrical System Architecture

Electrical System Architecture

Designs and Flowcharts

Preliminary Layout

Preliminary Layout

Fault Detection Design

Fault Detection Design

Risk Assessment

Risk Table

Risk Table

A working version of the risk assesment table can be found in the following link: Risk Management

Design Review Materials

Our systems level design presentation can be found here

Plans for next phase

For the next phase, our team plans to continue using feasibility analysis and engineering analysis to complete a preliminary detailed design. This design will include a parts list displayed via a Bill of Materials, software design, and test plans to demonstrate that the Engineering Requirements have been satisfied by our design. By the end of the next phase, a preliminary budget will be outlined with costs for each component.


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