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Preliminary Detailed Design

Table of Contents 1 Team Vision for Preliminary Detailed Design Phase 2 Feasibility: Prototyping, Analysis, Simulation 3 Drawings, Schematics, and Flowcharts 4 Bill of Material (BOM) and Design for Manufacturing and Assembly (DFMA) 5 Test Plans 6 Updated Design and Flowcharts 7 Risk Assessment 8 Design Review Materials 9 Plans for next phase

Team Vision for Preliminary Detailed Design Phase

TEAM PLANS:

• Develop safety testing plan
• Troubleshoot and document software code
• Troubleshoot and document teensy code
• Troubleshoot motor controller
• Develop a motor simulation
• Complete all Preliminary Detailed Design modules
• Start a BOM
• Create a more detailed crash test simulation
• Update risk assessment

ACCOMPLISHMENTS:

• Developed safety testing plan
• Began troubleshooting and documenting software code
• Began troubleshooting and documenting teensy code
• Began troubleshooting motor controller
• Completed all Preliminary Detailed Design modules
• Started a BOM
• Created a more detailed crash test simulation
• Updated risk assessment

Feasibility: Prototyping, Analysis, Simulation

Link to charge control feasibility analysis: https://docs.google.com/document/d/1tHbUyb3gxsgpWx-lM5S8grxJ6HY5RqTztgwY8NGHAvA/edit?usp=drive_web&ouid=105759191677059871389

Link to motor controller alternatives analysis: https://drive.google.com/drive/u/0/folders/1lIcMrcBGKS6OCWaZLcGFXm56TkXYW3OC?ogsrc=32

Link to Bluetooth replacement feasibility: https://docs.google.com/document/d/1xknp51uJouha6EHSk1yjfMX3n6b-RJbXB09XJhv6YEI/edit

Link to updated crash test simulation: https://docs.google.com/document/d/1HtKTCd_U2dBP0uVGRGmKBvV7CSt6_2izfrwi0Se2BjA/edit?usp=drive_web&ouid=105759191677059871389

Drawings, Schematics, and Flowcharts

Next Steps for Troubleshooting:

• Implement Hall Sensors in Code
• Refer to Motorware Project “proj_lab10d” (Controlling 2 3-Phase Motors from 1 Microcontroller)
• Verify Hardware can interface with Hall Sensor Connectors
• Contact Subject Matter Expert
• Verify Hardware Implementation is Correct
• Implement Other Sensors & Develop Algorithm

If Next Steps Don’t Resolve Issues:

• Transition to Motor Controller Alternative (TBA)
• Rev Control Board to accommodate new Motor Controllers or New Motors

Link to Motion Controller Architecture: https://docs.google.com/document/d/1S9sN656IWgaqp4TzmUQTmAv2GEX9jjQLft2oCWbbl2w/edit

Link to Teensy Architecture: https://docs.google.com/document/d/1RN04T3sgNmc5skXu0pVDLBYyZ_3ojdjqY1T0HojvrfU/edit?usp=drive_web&ouid=105759191677059871389

Link to Legacy Hardware: https://drive.google.com/drive/u/0/folders/1V6ETsTMFWzWMK5wNQ5VCNBdubydyDa1s?ogsrc=32

Hardware Changes:

• One box for all electronics and battery
• Feasible if we switch to Li-ion Battery and management system
• Add a small box to hold I/O board at the top for wiring simplicity
• New Bumper/Cover to make bumper more aesthetically pleasing
• New IR sensor mount

Link to CAD files for updated Hardware: https://drive.google.com/drive/u/0/folders/1bvHEuJ_vJtiiXlEcKqsq0otVUXMleTGn?ogsrc=32

Bill of Material (BOM) and Design for Manufacturing and Assembly (DFMA)

Test Plans

Link to test plan: https://docs.google.com/spreadsheets/d/1AmBFFO4dmnHYG12WO0Zh-YeA2Rgk4Er3uYxAVvUBOC0/edit#gid=1376671776

Updated Design and Flowcharts

Updates to CR, ER, and HOQ include:

• Removing word patient from requirements as per customers request
• Updating HOQ include updated customer and engineering requirements

Risk Assessment

Link to live risk assessment document: https://docs.google.com/spreadsheets/d/1IUBApUwGq3AFYyOMnU-ayqfGaxz9dV2a5lK9rZC-yuU/edit?usp=drive_web&ouid=105759191677059871389

Design Review Materials

Link to design review presentation: https://docs.google.com/presentation/d/1gpqw3_MEnI4sRN4wTBJYA5uiuqL8ahWcRjhefgPcUWU/edit#slide=id.p

Plans for next phase

Link to project plan: https://drive.google.com/file/d/1bh3N9mrzuckO9NYruhA12CVBaeKGeMdk/view

Key things to accomplish in the next phase:

• Finish Mechanical Designs
• Finalize Orders for Battery & Bluetooth Module
• Implement Hall Sensor integration/ fix to Controller
• Write Sensor Code
• Meet with Subject Matter expert about BLDC
• Plan for motor controller replacement if risk remains to end of semester

Link to Team's 3-week plans: https://drive.google.com/drive/u/0/folders/1kqlke4MjNi_C-YojENZg1x6K7m6pCKas?ogsrc=32

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