P18392: Remote Control Bicycle Braking System
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Build & Test Prep

Table of Contents

Team Vision for Build & Test Prep Phase

Phase Goals

Phase Accomplishments

Test Plans

Test Overview

Test #1: Rider Out Of Range

Test Description: System turns off and stops rider when out of range of remote

ER(s): E3

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Student A will ride the modified tricycle as student B handles the Remote. To simulate out of range the remote can be turned off and the radio communication. The effect of the braking system will be observed when the radio communication is ended.

Test #2: Maximum Wireless Range

Test Description: Determine the maximum usable range of system

ER(s): E6

Ideal Value(units): 250 Meters (m)

Test Procedure:

  1. Power on Brake System and Remote.
  2. Confirm that connection has been established.
  3. Move the remote 50 m away from the brake system, maintaining line of sight.
  4. Confirm that no connection error is reported on the remote after one minute.
  5. Increase the distance between Brake System and Remote by 50 m, repeating step 4 at each increase until the system is tested at the 250 m.

Test #3: Multi-surface Stopping Capability

Test Description: Confirm that the system is able to wirelessly stop a rider on pavement & gravel

ER(s): E9 E10

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Bring bike up to considerable speed on pavement (~15mph)
  2. Remotely apply brake to initiate full stop
  3. Confirm tricycle has come to full stop
  4. Repeat on lehigh valley trail 1-3

Test #4: Mechanical Failure Notification

Test Description: Confirm remote notifies guardian when mechanical failure is injected into system.

ER(s): E11

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Disconnect brake actuator
  2. Confirm that "Mechanical Error" notification LED illuminates and buzzer sounds to inform user
    • If LED is not illuminated and buzzer does not sound the test has failed

Test #5: Electrical Failure Notification

Test Description: Confirm remote notifies guardian when electrical failure is injected into system

ER(s): E12

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Disconnect fuse in bicycle side enclosure.
  2. Confirm that "Electrical Error" notification LED illuminates and buzzer sounds to inform user
    • If LED is not illuminated and buzzer does not sound the test has failed

Test #6: Communication Failure Notification

Test Description: Confirm remote notifies guardian when system is not able to properly communicate

ER(s): E13

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Disconnect remote antenna
  2. Confirm that "Communication Error" notification LED illuminates and buzzer sounds to inform user
    • If LED is not illuminated and buzzer does not sound the test has failed

Test #7: IP Rating (Weather Protection)

Test Description: Confirm no water ingress when electronics enclosure is subjected to IP65 conditions

ER(s): E17

Ideal Value(units): Pass (Pass/Fail)

Water Test Procedure:

  1. Submerge box in water
  2. Leave box submerged for 3 minutes
  3. Throughout the duration of the 3 minute test observe the box watching for any escaping air bubbles.
    • If air bubbles are observed while the box is submerged the test has failed.

Dust Test Procedure:

  1. Burry box in sand
  2. Leave box buried for a minimum of 1 hour
  3. Unburry box
  4. Open box and examine contents for any dust
    • If dust is found within the interior of the box the test has failed.

Test #8: User Fatigue (Weight)

Test Description: Confirm remote is not fatiguing to carry on person

ER(s): E20

Ideal Value(units): 300 (g)

Test Procedure:

  1. Place completed remote on digital scale
  2. Read weight and compare to target

Test #9: User Fatigue (Size)

Test Description: Confirm remote is not fatiguing to carry on person

ER(s): E21

Ideal Value(units): 10x5x4 (cm)

Test Procedure:

  1. Measure completed remote external dimensions
  2. Confirm dimensions satisfy ideal value
  3. Confirm with customer that they are happy with the ergonomics of the remote

Test #10: Standby Battery Life

Test Description: Determine standby time of system with no actuations

ER(s): E26

Ideal Value(units): 4 (hours)

Test Procedure:

  1. Brute Force:
    • Fully charge batteries
    • Create program to continually update file with a timer value
    • Leave batteries loaded with systems on standby until power is lost
    • Read files with respective timer values to determine time to full discharge while system is on standby
  2. OR Measure real-world baseline current draws:
    • Remote: Teensy LC on standby, display, LEDs
    • Bike : Teensy LC on standby, LEDs
    • Mathematically derive standby time using measured current draws and battery capacities

Test #11: Variable User Commanded Brake Force

Test Description: Confirm adequate variability in user commanded brake force

ER(s): E27

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Power on Brake System and Remote.
  2. Confirm that connection has been established and brake is not engaged.
  3. Actuate brake using braking force slider on Remote.
  4. Confirm corresponding movement of the actuator.

Test #12: Low Battery Notification

Test Description: Confirm user is notified when battery drops below given state of charge

ER(s): E31

Ideal Value(units): < 30 (%)

Test Procedure:

  1. Charge both batteries above low battery threshold (>30%)
  2. Monitor state of charge of both batteries while loaded
  3. Determine if low battery notifications are tripped at proper threshold

Test #13: Remote Survivability

Test Description: Determine robustness of remote design subject to drop from chest height

ER(s): E34

Ideal Value(units): 1 (m)

Test Procedure:

  1. The assembled remote will be held 1 meter above the ground and dropped. The surface that the remote will be dropped on will vary from grass, gravel, to pavement. The remote will be examined after each drop to check for damage and functionality.

Test #14: Actuator Maximum Force

Test Description: Characterize maximum force provided by actuator

ER(s): E38 E39

Ideal Value(units): 250 (N)

Test Procedure:

  1. Securely mount actuator to table
  2. Securely anchor spring scale to wall or other fixed surface
  3. Connect spring scale to actuator using cable or rope
  4. Connect power and control to actuator
  5. Begin recording video of spring scale dial and logging of current draw
  6. Actuate actuator and continue until maximum working current draw is reached
  7. Release force on spring scale
  8. Stop video and replay to record maximum force reached

Test #15: Maximum Brake Actuator Time

Test Description: Determine time to engage brake with actuator.

ER(s): E35

Ideal Value(units): 0.5 (s)

Test Procedure:

  1. Power on Brake System and Remote.
  2. Confirm that connection has been established and brake is not engaged.
  3. Ride tricycle forward at a speed under 5 mph.
  4. Press emergency brake button on remote.
    • Time to be evaluated is the time from the button being pressed to resistance in tricycle movement being felt.

Test #16: Actuator Stroke Limit

Test Description: Find stroke limits of actuator when installed

ER(s): E42 E35

Ideal Value(units): 2 (in)

Test Procedure:

  1. Initially before installation the actuator stroke will be tested. Using the motor diver the actuator will fully extended. The length of the actuator will be measured, the actuator will be fully retracted and then measured again. Using the two measurements the stroke will be extrapolated. Once the actuator is mounted on the tricycle the measurement process will be repeated.

Test #17: Actuator Stall Current

Test Description: Determine maximum stall current draw of actuator

ER(s): E40

Ideal Value(units): 4 (A)

Test Procedure:

  1. Determine stall conditions of actuator
  2. Establish current monitoring of actuator
  3. Measure current draw of actuator under stall

Test #18: System Intrusion

Test Description: Confirm original function of tricycle is unaffected by system

ER(s): E1

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Student A will mechanically disconnect the braking system and attempt to ride the tricycle.
  2. The Student will observe the rideability of the tricycle.

Test #19: Actuations Per System Charge

Test Description: Determine # of full actuations possible on single charge.

ER(s): E43

Ideal Value(units): 240 (#)

Test Procedure:

  1. Determine conditions required for full actuation
  2. Brute force: Create program to repeatedly fully actuate system
    • Track and count number of actuations until power is lost from full charge
  3. OR Establish current monitoring of actuator
    • Measure current draw under full actuation
    • Mathematically derive number of actuations possible using battery capacity

Test #20: Manual Disengage

Test Description: System is able to be manually disengaged

ER(s): E25

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Power on Brake System and Remote.
  2. Confirm that connection has been established and brake is fully engaged.
  3. Toggle manual disengage switch near the actuator.
  4. Confirm that the tricycle’s movement is unrestrained.

Test #21: Alert Cluster

Test Description: Alert cluster is visible & audible in all outdoor conditions

ER(s): E15 E16

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Once the Alert cluster is assembled the cluster will be brought into several different environments. In the direct sunlight student A will activate the cluster and record visibility. In high wind conditions (riding the tricycle) the cluster will be activated and the noise level will be observed. Also in low light conditions the cluster will be tested to ensure the light is not excessively bright and blinding to the rider.

Test #22: Over Speed Protection

Test Description: System activates when rider above set maximum speed

ER(s): E33

Ideal Value(units): Pass (Pass/Fail)

Test Procedure:

  1. Power on Brake System and Remote.
  2. Confirm that connection has been established and brake is disengaged.
  3. Set maximum speed on remote to 10 mph.
  4. Attempt to ride bike at 15 mph.
  5. Confirm that brake automatically is applied.

Risk and Problem Tracking

public/MSD2/BuildPrep/Risk.png

Budget

Budget Breakdown

Budget Breakdown

BikeBudget Breakdown

BikeBudget Breakdown

For a more detailed expense list see:

Justin_Kon/BOM-Purchased.pdf

Plans for next phase

Phase 1 Gantt Chart

Phase 1 Gantt Chart

Phase 2,3,4 Gantt Chart

Phase 2,3,4 Gantt Chart

Team Plan

Individual Plans

Functional Demos


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