P18319: Lockheed ATLAS
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Integrated System Build & Test

Table of Contents

Team Vision for Integrated System Build & Test Phase (Kyle)

The Integrated System Build & Test phase is used to demonstrate two key system characteristics: overall system integration, and a system functional demonstration. The teams goal for this phase was to have the X-01 functional testing complete, with a test evaluating the software kinematics, the apparatus's button capability, and substantial progress on the A-01 prototype assembly. The team also wanted to explore other apparatus designs incorporating a NEMA motor providing vertical motion that would be be able to hit the customer's 90 keys-per-minute requirement.

The status of the key objectives this phase will be reviewed, along with ongoing challenges the team has faced, and is currently facing. The test results from this phase will be reviewed, and the revision B of the apparatus will be shown along with test results on the KPM and capacitve touch functionality.

A test rig was built for the display that will enable testing in the 3 targeted orientations (0, 90, and 180 degrees). A power supply enclosure was built to ensure safe operation of the system when powered on.

A Lenovo tablet was purchased for testing the capacitive touch capability of the design. Continued improvement for the X-01 proof of concept has been made via a new electronics mount and frame. The status of the A-01 production model will be reviewed showing manufacturing status.

Resulting from the system integration testing, the risks were updated with the appropriately mitigated concerns following proven effective by testing. An updated bill of materials and current budget status will be discussed.

Lessons learned this phase will be discussed following manufacturing challenges the A-01 prototype presented. The gantt chart was updated moving into the final phase keeping in mind current challenges the team is facing.

Project Recap/Purpose (Kyle)

The team was tasked by Lockheed to design a system that would be used to test multi-function display's to ensure there were no issues with the software and hardware integration.

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The team decided a 2DOF robotic are provided the customer the most flexibility in terms of size, while also adhering to other requirements around weight, and system speed.

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The purpose of this phase is to demonstrate team progress, and to provide the customer an idea on status of system development given the hard deadline of Imagine RIT.

Project Status

Major Mechanical Tasks (Matt)

Task Status
Design and build 180 degree Test Rig 100%
Design and build New X-01 Frame and Electronics Mount 100%
Design and build new Apparatus Design 100%
A-01 Machining/ Assembly 15%
Enclose X-01 power supply for testing 100%

Major Electrical Tasks (Mark)

Task Status
Choose new enclosed power supply for the A-01 prototype. 100%
X-01 Wiring 100%
Protoboard Wiring/Sodering 100%
Integrate Limit Switch Wiring 100%

Major Software Tasks (Sarah)

Task Status
TCP/IP Communication 100%
Calibration Code 100%
TWIN Config File Integration 100%
Full Integration of Subsystem (motors, FSR, switches, etc) 100%

RIT Deliverables

Task Status
Tech Paper 75%
Tech Poster 100%

Test Results Summary (Mike)

TOUCH PRESSING SPEED UPDATED

With the addition of the new NEMA-17 motor system replacing the linear actuator, the pressing speed was once against measured directly on the prototype. No improvements had yet been made to the reinforcement of the NEMA23 arm motor, but the new touching mechanism works sufficiently to conclude test:

public/MSD II/Linear Press Update.png

INTEGRATED DEMONSTRATION STATUS

Currently, the Integrated Demonstration testing process is near completion (expected by the end of this week, due to previous setbacks). Button pressing works as intended, and arm movement speed is sufficient. The kinematics are currently being tuned.

REQUIREMENTS TABLE UPDATED

Below is an updated table of the requirements, with matching color to each status:

public/MSD II/RequirementTablePhase7.png

Apparatus Rev B (Kyle)

The new apparatus design incorporates a NEMA 17 motor and a lead screw to perform the button actuation.

public/Photo Gallery/Prototype Apparatus one.JPG public/Photo Gallery/Prototype Apparatus two.JPG

Capacative Touch

The capacitive touch point operates with a grounded wire and the rubber tip.
public/Photo Gallery/Prototype Apparatus Printed.jpg public/Photo Gallery/Capacitive Touch.jpg

Button Press Speed

Unloaded Speed Test Loaded Speed Test
public/Photo Gallery/Prototype Apparatus Speed 2.gif public/Photo Gallery/GIF-180326_181300.gif

The actuation speed of the motor is around 135 kpm, compared to the 50 kpm from the previous design using the L16 linear actuator, the current design well exceeding the customers 90 kpm requirement.

Testing Rig (Kyle)

A testing rig was designed and built to enable the team to perform testing in orientations ranging from 0 - 180 degrees.

Actual Assembly Solidworks Rendering
public/Photo Gallery/Testing Rig one.jpg public/Photo Gallery/Full MFD Mount.JPG
public/Photo Gallery/Testing Rig three.jpg public/Photo Gallery/Full MFD Mount With X01 Level.JPG
public/Photo Gallery/Testing Rig two.jpg public/Photo Gallery/Full MFD Mount Inverted.JPG

Power Supply and Electronics Enclosure (Harvick)

To address the concerns for testing safety and shock hazards, plastic enclosure boxes for the ATLAS X-01 power supply and A-01 electronic components were designed and manufactured. The A-01 will use a UL listed power supply with no exposed metal components.

Power Supply Enclosure Electronics Enclosure
public/Photo Gallery/Enclosed Power Supply Photo.png public/Photo Gallery/Electronics Enclosure.png
public/Photo Gallery/Enclosed Power Supply.JPG public/Photo Gallery/Electronics Enclosure.JPG

Touch Screen Tablet for X-01 (Harvick)

The Lenovo Tab 4 was chosen for touch screen testing, it is expensive at $176 and fit the display of the MFD almost perfectly.
Lenovo Tab 4 for Prototype X-01
public/Photo Gallery/Lenovo Tab 4 for Prototype X-01.JPG

New Electronics Mount and MFD Frame (Matt)

A new electronics mount is going to be cut out of aluminum to help solve the deformation issue with the plastic mount. It also was cut to be as light weight as possible. A new MFD frame was also cut to help reduce weight of the X-01 prototype.

public/Photo Gallery/Updated Frame x01.JPG

Manufacturing Status A-01 (Matt)

The A-01 order was hit with setbacks regarding a waterjet order, and insert machining because of machine shop and outside team member commitments.

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Carbon Fiber Arms (Matt)

The telescopic carbon fiber arms were delivered and came out great. The button clip and the collet are both needed to provide quick adjustments and still make the arm rigid.
public/Photo Gallery/Telescoping CF Arm.jpg

Waterjet Order (Matt)

The following waterjet order was submitted, but was not processed on time. The Waterjet had shifted the aluminum plate during cutting, and caused some minimal loss of material.

public/Photo Gallery/Waterjet Submission 2.JPG
public/Photo Gallery/Waterjet2.jpg

TWIN - ATLAS Communication Interface (Sarah)

A custom communication standard was created in order to interface with ATLAS over TCP/IP from TWIN for the purpose of: Follow this link to view the full first revision of the ATLAS Communication Standard.

An example message format accepted by ATLAS can be seen below:

public/Photo Gallery/comm_standard_example.PNG

This might look like this as a string:

"0024 0002 0008 250.00 200.00"

This tells us...:

Calibration Sequence (Sarah)

ATLAS X-01 Calibration Test (Vertical)
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ATLAS X-01 Calibration Test (Upright)
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ATLAS Code

View the current revision of integrated ATLAS code here.

There is a new file called "test_tcpip.py" which is a python script that uses TCP/IP to interact with ATLAS exactly as TWIN will.

ATLAS main code now runs on a loop which reads in commands from the Python test code in order to operate.

A-01 Power Supply Selection (Mark)

The power supply chosen for the ATLAS A-01 is a UL Listed Mean Well 2226505 221W 24V 9.2A Power Supply.

Mean Well 221W 24V 9.2A Power Supply 4 Pin DIN Jack
public/Photo Gallery/2226505.jpg public/Photo Gallery/A27C_1_201706162070140911.jpg

Bill of Materials (Mark)

public/MSD II/BOM_Final_Phase7.png

public/MSD II/BudgetPhase7.png

Risk and Problem Tracking (Mike)

Safety Risks and Touching Speed have been successfully mitigated, but due to production delays, several risks remained open that were expected closed, and 1 risk is now reopened for need for action.

public/MSD II/Risk Management Chart Phase 7.png public/MSD II/Risk Remaining Phase 7.png public/MSD II/Risk Expectation Chart Phase 7.png

ATLAS Subsystem and Technology Dependency (Harvick)

To ensure the team is working toward the most critical tasks required for integrated system test in this phase, subsystems readiness were tracked based on subfunctions and task owners in the chart below.

public/Photo Gallery/ATLAS Technology Dependency.PNG

RIT Deliverables

Technical Paper (Mark)

The technical paper was started can be found here.

The current status of the paper is 75% complete. After tweeking a few things, test results will be filled in, and final conclusions.

Poster (Harvick)

public/Photo Gallery/ATLAS Poster.png

This poster will be on display during Imagine RIT, and possibly at some points during the next academic year.

Phase III Summary and Closeout (Harvick)

• Major delay in schedule (4 weeks) for A-01 completion due to aluminum waterjet work order delays.

• 3/6 team members were sick after spring break, forcing more collaboration and workload sharing to prevent further schedule slips.

ATLAS MSD II Phase 3 Closeout
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Plans for next phase (Harvick)

ATLAS MSD II Phase 4 Integrated Master Schedule
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Lessons Learned (Harvick)

• Put more clearance on 3D printed parts to account for thermal expansion and surface irregularities.

• Identify manufacturing risks and alternatives processes early in project to prevent schedule slips.

• Establish a "Day Zero" and allocate resource for outsourcing manufacturing tasks. During this phase the machine shop was not able to waterjet the order in a reasonable amount of time. The order was consistently pushed back, through spring break, and then even further back due to a priority order.

• Recognize there is a point where we cannot push the schedule back any further. Accepting delays is not a contingency plan, it is letting someone outside the team drive the schedule of the project.

Peer Review Feedback

Team Member Peer Review Action Feedback
Harvick Tang Send official notice for Sunday meetings and communicate with guide more closely. Sent out email with date, time, location, and tasks expected to be done during Sunday meetings. Communicated with guide more on scheduling and team progress.
Sarah Bentzley Be more vocal about when I need help with things or am feeling overwhelmed. Asked for help from other teammates regarding test requirements (Mike), inverse kinematics (Harvick), programming the new touch apparatus design (Kyle), and regarding wiring (Mark).
Matt Craven Communicate more around team meetings, and if you will be able to attend. Communicated more using the messenger app, the team was more aware around team meeting.
Mark Min Put in electrical safety measures to prevent accidential injury. Chose new power supply, and created a safe enclosure for the current supply.
Mike Kelly Be assertive about drawing conclusions for test results. Confusion about project test status was cleared up.
Kyle McAlinn Refer specific system questions to system lead to make sure the team member contributions remain evident to those outside the team. The team was more dynamic when it came to discussing and solving problems and questions.

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