P18363: Player Piano 2
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Systems Design

Table of Contents

Content linked here can also be found in the Systems Level Design Documents directory.

Team Vision for System-Level Design Phase

Plans for this phase defined 3 weeks ago:

Accomplishments of this Phase:

Functional Decomposition

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Click here to download a pdf of the functional decomposition chart: Functional Decomposition Document

Morphological Chart

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Concept Generation

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Click here to download the Concept Development spreadsheet: Concepts Sheet

Benchmarking

Benchmarking of other products

Benchmarking of other products

Click here to download the benchmarking document: Benchmarking Document

Current Device Testing

Current Solenoid Testing

Our goal for these tests were to characterize the current solenoids to a volume output in the piano. To do this our initial thought was to get a impact force of the solenoid with different gap distances.

Current Solenoid test for differences in PWM & Direct Voltage

Current Solenoid test for differences in PWM & Direct Voltage

Click here to download a image of the Solenoid Test Setup: Solenoid Test Data

Feasibility: Analysis, Simulation

Available Space

These pictures show a 3D model of what we measured to be the available space inside of the piano. This includes an angled part in the back where the wippens are located. When designing our device we can design it with this model as a boundary.

Front Isometric View of Measured Space

Front Isometric View of Measured Space

Click here to download a image of the front measured space: Front Isometric View

Back Isometric View of Measured Space

Back Isometric View of Measured Space

Click here to download a image of the back measured space: Back Isometric View

Piano Testing

For this test we set up a clamped tube with a known mass that we dropped on the keys at different heights. We hoped that this would then translate to a force by bringing that same apparatus and putting a force gauge where the key used to be. The problem was that the force gauges that we used did not have a good enough resolution. To be able to still use this data we plan to do a theoretical energy analysis, as well as an energy test using the solenoid. This will hopefully link the solenoids to our volume outputs. This will then help with picking out a solenoid that will be sufficient for different volume levels. To measure the sound output we used a dB meter on a phone with an existing app. This app showed accurate data. Although the uncertainty of this is currently unknown.

Known Mass Drop Setup

Known Mass Drop Setup

Click here to download a image of the Piano Sound Output Testing Graph: Piano Sound Output Testing Setup

Known Mass Drop Test

Known Mass Drop Test

Click here to download a image of the Piano Sound Output Testing Graph: Piano Sound Output Testing Graph

Simulation

In order to reduce risk and gain a better understanding on how to meet the dynamic customer requirement a simulation model was created for a possible solenoid circuit control option. This simulation was built with already owned hardware and briefly tested with the existing solenoid to produce the PWM plot above. These first steps help support the feasibility of creating a hardware current control loop circuit and reduce the micro-controller PWM requirements.

Simulation Schematic

Simulation Schematic

Simulation Results

Simulation Results

Simulation Results with Fast Comparator Switching

Simulation Results with Fast Comparator Switching

Concept Selection

User Interaction

General Processing

Solenoid PWM control

Pedal Press

Mechanism Support/Mounting

Criteria/Options Direct Push on Wippen Pull Lever Actuates Wippen
Degree of Mechanical Complexity Simple Complex
Force Adjust Fixed Mechanical Force Advantage
Achievable power output Smaller Higher
Response Time Faster Slower
Feasibility More Less

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Updated Requirements

Customer Requirements

Customer Requirements

Engineering Requirements

Engineering Requirements

Systems Architecture

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Plans for Prototyping

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Risk Assessment

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Click here to download the updated Risk Management spreadsheet: Risk Management Spreadsheet

Project Plan

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Plans for next phase


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