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Integrated System Build & Test

Table of Contents 1 Team Vision for Integrated System Build & Test Phase 2 System Build 2.1 Welded Frame 2.2 Machined Mold 2.3 1st Iteration 3 Insulation 4 Test Results Summary 4.1 Test Plan Results 5 Risk and Problem Tracking 5.1 Risk Assessment 5.2 Problem Tracking 6 Functional Demo Materials 7 Plans for next phase

Team Vision for Integrated System Build & Test Phase

During this phase, the team aimed to complete building the structural frame and mold to begin integrating the heating and electrical systems. In addition, finalized design packages for the mold, heating, and electrical systems.

We were able to tack weld the structural frame so that we could verify all components were in the correct position and properly aligned. We found that the alignment for attaching the car jack and mold frame were off. The tubes to attach the car jack only needed to be repositioned but additional holes need to be drilled for the mold attachment. For our heating system, the heaters and insulation were purchased and received. The electrical system has begun to be assembled, however we realized we do not have all the necessary components. Additional wiring, connectors, and thermal paste are needed to finish assembly. We have receive most of the electrical components and begun assembly of the system. We plan to meet with professor Indovina to ensure that everything is connected properly and the electrical system will function as planned.

System Build

The product manufacturing time can be found here.

Welded Frame

Machined Mold

1st Iteration

Insulation

Insulation is needed on the system due to safety and heating efficiency. For insulating the system, we have chosen to wrap and tape ceramic fiber insulation around some of the vertical square tubing and use flat sheets on the top and bottom of the mold. The insulation benchmarking can be found here.

The complete drawings for preparation of the insulation can be found here.

Test Results Summary

Test Plan Results

The majority of our tests for the engineering requirements cannot be completed until more of the system is built and the heating, electrical, and insulation subsystems are integrated.

The engineering requirements that could be tested sufficiently at this point include:

• ERE2 - number of molds accepted
• ERE5 - machine size
• ERE7 - manufacturing time
• ERE11 - # of workers
• ERE13 - mold size accepted

Working Test Plans & Results can be found here.

Risk and Problem Tracking

Risk Assessment

A working Risk Assessment file can be found here.

Problem Tracking

A working Problem Tracking file can be found here.

Functional Demo Materials

• Notes from review & Action Items

Plans for next phase

• As a team, where do you want to be in three weeks at your next demo with your customer (if you haven't already done this)?

Individual 3-week plans

• Pierce Scroggins - Scroggins Three-Week plan

• Adam Santagata - Santagata Three-Week plan

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