MSD I: Readiness to move to Build & Test
Team Shared Visions
Week 6 Progress Demonstration Shared Vision
- Entire system will be assembled and ready for testing
- Test bench/setups will be ready for use
- All test plans will be finalized and ready to be put in to action
- Most electrical testing will be completed
Final Project Review Shared Visions
- Assemble cylinder completely at RIT
- Perform all testing at RIT that is currently planned
- Send Eric Prototype on October 29
- Receive all test results within 2 weeks of sending cylinder
- Analyze results and make design suggestions before end of semester
- Assemble cylinder at RIT
- Perform some testing on cylinder at RIT but may not have time for all tests currently planned
- Send Eric prototype near end of semester
- May receive some testing results from Eric
- Will not have time to analyze or make design suggestions
- Cylinder is either fully assembled or partially assembled
- Are not able to send cylinder to Eric before end of semester
- Receive no testing feedback
- Document all work for passing along to future project or for hand off to ACM
Draft of Overall Plan for MSDII
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The full pdf can be downloaded for viewing here.
Draft of Test Plans
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The full pdf can be downloaded for viewing here.
Draft of Problem Tracking
Post Mortem & Peer EvaluationsNeeds Improvement:
- Timeliness to meetings
- Firm deadlines that are actually deadlines
- Both for action items and EDGE, presentation
- Strictness with Eric
- Discuss with Eric
- Put together communication document
- Need group bonding
What We Learned:
- Set more realistic goals
- Include buffer time
- Should upload progress on EDGE throughout phase
What We Did Well:
- Didn't really storm
- Collaborated well
- It was difficult to get stuff done when Robert and
Mike went on so many trips
- Develop better plans when team members are absent
- Good that we started shifting more of the planning responsibility to John- continue doing that next semester
- Keep presentations more concise and be more confident
- Practicing beforehand will help
- Stay focused during meetings- no scrolling fb responding to lots of messages unless very urgent
- Robb and John communicate on assignments
- If outside of abilities let Robert know
Our team self critique spreadsheet can be downloaded here.
MSD II: Project close-out
Current State of the Project
Actual Performance vs. RequirementsThe spreadsheet below shows the performance of our final project versus the initial design requirements. Unfortunately we did not get to test many of the things we originally wanted to.
How robust is your final design?
While our final design does have some flaws, it is quite a robust project and should be able to stand up to normal operating conditions. In some senses it is actually too robust as it weighs a lot more than we indented due to the thickness of a lot of the steel components.
Did you meet your project budget?
We did not meet the budget we were given, but we knew that would potentially be the case going in. We were only given the $500 starting from the Senior Design Program and $500 from an ASTM Grant. Our customer did not provide any more funds directly, however they did help a ton with acquiring components and machining of components.
Was customer satisfied?
Our customer was very satisfied with our work. I think we exceeded expectations in some ways and the things we missed the mark on are fairly easy fixes.
Comparison of current and original project plan/schedule
Our scope of our project changed a bit in MSD I but was fairly consistent with MSD II. We mainly limited some testing and removed a few small things (like filtration) from our system. Our schedule was constantly changing during MSD II. This was due to a variety of issues encountered with dealing with vendors, obtaining things from our customer, general inability to communicate with our customer at times, personal life setbacks to the group, and more. I think a big thing we learned as a group was to work in parallel instead of series. If we had an issue with getting a part from our customer we should have found an alternative and when looking to obtain a component, reach out to several vendors simultaneously instead of picking just one to start with.
Review Individual Team Member StatusFor the most part all team members contributed to the project and got their responsibilities done. We did run into a few issues throughout the semester but nothing that we were physically unable to work through. Our MSD II plan may have been a bit too optimistic. Our time scale was very off as we planned to begin drawings and production week 1 while in reality this did not start until the half way point in the semester.
Risk Assessment and Problem Solving Status
Our most important risks were either mitigated/solved, we have a plan in place to have them fixed in a future design, or they ended up outside the scope of our final deliverable. There were some design issues that we did not anticipate but we already know how these could be fixed.
Lessons learnedMost of the lessons learned from this project were covered above. While on the one hand it is good to have an optimistic schedule (as when you inevitably fall behind you are at least not in too bad of a shape), sometimes it is tough to always feel behind when you set an unrealistic schedule for yourself. As mentioned above, be self dependent and when you run into a road block think on your feet and find a way around it. Working in parallel and exploring as many options as possible at once is the most efficient way to arrive at an answer the quickest. Communication with your team is key as well as everyone taking on an equal amount of work. I think the biggest challenge we faced in MSD II was having some members putting in overtime while others were unable to work for various reasons.
Future Modifications - Mechanical
- Reduce weight
- Thinner barrel walls, reduce overall size, smaller ball screw system
- Redesign method for keeping ball nut from spinning
- Add flats on rod to allow for easier assembly/disassembly
- Modify ball screw to properly be secured by end
- Currently only fixed in one direction axially
- Causes pulley to contact rear cover during movement
- Seal groove between inner barrel and insert
improperly sized for -035 O-Ring.
- Currently using -034 O-Rings
- Modify part geometry to properly fit o-ring
- Redesign sealing surfaces to make assembly easier
- Passing ball screw through insert seals was especially difficult
- Resulted in many torn seals
Future Modifications - Electrical
- Add encoder or find a motor with an encoder IO to track position and prevent hitting mechanical stops
- Find SMD/SMT type components, would reduce size of
- Build an overall PCB that consists of Controller, H-Bridge, Buck Converter, *Isolation circuit and fuses.
- Design a compartment to store entire electrical system
- Program with improved motor feedback
- Implement more design around the force sensor, where to place.
- Design an efficient buck converter
- Hall effect sensor to control the position of the piston (another option for tracking distance)
- Hall effect sensor to measure feedback of piston
- Make minor design updates to drawings based on
- More in-depth design changes required later to reduce weight
- Finishing documentation of work
- Need to determine how hand off will work since Eric does not have access to EDGE
- Update paper for ASTM submission
- Need review by Don and Eric
- Determine plan for shipping
- Planning to ship on 12/14
- Teardown, final testing, cleaning on 12/14
- MSD wanted to show video on Facebook page
Advice to Future Teams
- In general, just set realistic goals. Better to have a few key things to hit on and to deliver on those goals (and maybe add as you go) than to set unrealistic expectations and come up short.
- Have team bonding events. No need to go crazy but our team said we were going to hang out a bunch and never did. Something I regret not doing.
- COMMUNICATE! And be honest with your team. An excuse for not getting your work done works once or twice, but if it becomes chronic it will disrupt team chemistry. Also communicate well with your guide. They will become your friend throughout the MSD project.
- Have fun! This is the first and only time you will get to take on a project and really call it your own of this magnitude in your entire college career. Yes it is a lot of hard work, but don't do it for the grade.
- In regards to the point above, I highly recommend finding a project in the field you are passionate about. This project was proposed by Robert Cybulski (in conjunction with Mike Troise) as both members are heavily involved with the amusement industry. This made the long nights spent on this project so much more worth it.
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