Integrated System Build & Test
Team Vision for Integrated System Build & Test PhaseDuring this phase, the team has the low range goal of completing the mechanical assembly of the Crew-Lock and testing rig, a medium range goal of electrical and mechanical integration, and a reach goal of testing completion and confirmation. Due to budgetary and parts order delays, as well as manufacturing delays, the team is approximately 1.5 weeks behind schedule, making the completion of testing and confirmation a reach goal. With this in mind, the team is willing to put in a lot of work during this 3 week period in order to get as many deliverables complete by the end of the phase.
ISS Model below courtesy of Sebastian Hernandez
Risk, Change, and Problem TrackingThe Change Management, Risk Management, and Problem Tracking workbooks can be downloaded in the Design Review Materials Section at the bottom of this page.
BOM and Finance Trackinghe BOM workbook and Expense Tracking can be downloaded the Design Review Materials Section at the bottom of this page.
CNC and MachiningBelow are images of the CAM and CNC process performed on the MDF in the RIT Construct. Major proponents of this process include Michael Buffalin IV and the assistants at the RIT Construct.
Below is the Spindle RPM controller for the ShopSabre CNC machine. The RPM used varied depending on the tool used and operation performed on the MDF.
Below is the CAM program used in fabrication. The speeds and feeds used varied depending on the tool used and operation performed on the MDF.
Metallic handles were added as ergonomic aides on the EVA bulkhead.
Bulkhead Maintenance HatchThe maintenance hatch has an attached air-tight zipper for the maintenance of the sensor PCB. The air-tight zipper is sandwiched between two layers of air-tight Vinyl. The Vinyl is glued using a Vinyl glue that is solvent based and air-tight.
Bulkhead PaintingBulkhead painting was done to create an aesthetic and functional finish. The paint serves as a sealant for the wood and as a finished touch for the Crew-Lock.
Vacuum Barrier & PanelsThe Vacuum Barrier Includes the Vinyl layer in the bulkheads, and the habitable volume created by the TPU coated Nylon layer surrounding the Crew-Lock.
Bolted Flange Manufacturing
Electrical & Programming
Motor Control Board
Test Results SummaryThe Test Results Summary can be downloaded in the Design Review Materials Section at the bottom of this page.
Functional Crew-Lock VideoBelow is a functional testing video of the Crew-Lock during Brandon's Industrial Design Senior Capstone presentation.
Phase Final Products
- Machined & Painted MDF
- Vinyl-TPU coated Nylon Sandwich
- Holes & Attachment Points
- Vacuum Barrier
- TPU-coated Nylon layers x2
- Sandwiching and Airtight Sealing
- Attachment to Bulkheads
- Metallic - Bulkheads
- Soft - Vacuum Barrier
- Soft - Panels
- LED Attachment
- AA Battery Powering Pack
- Testing Rig
- Stationary IV-side
- Cart EV-side
- Deployment System
- Stepper Motors
- Motor Controller Boards
- Arduino Micro-controller
- Sensor Board
- Proximity Sensor
- Pressure Sensor
- Threaded Rods
- Flange Bearing & Bearing Tables
- Car Batteries x2
- Pressure System
- Vacuum Pump
- Air Compressor
- Tubing & Valve Work
Integrated System Build & Test Phase Review Notes
|Starting Date||Ending Date||Meeting Notes|
|March 2019||April 2019||Design Review Notes - Integrated System Build and Test|
Conclusions for this PhaseThis phase, the team worked hard to assemble the Crew-Lock. The team accomplished many goals after hours of hard work. The Crew-Lock is mechanically and electrically functional. The problems now consist of completion of the sensor board (errors in soldering or PCB design) and making final touches for robustness of the Crew-Lock's electro-mechanical systems. The bulkheads, deployment system, ergonomic aids, air system, and testing rig are as good as the team can get them. The power system still needs touching up, as the two car batteries the team owns will be in desperate need of charging before Imagine RIT. Justin was able to contact the RIT Electrical Vehicle Team and have them charge the batteries for the team. The bearings still need a better fixing method besides duct tape. The use of a set screw method will be implemented to create a more aesthetically pleasing and mechanically clean stopping mechanism.
Documentation-wise, the Technical Paper and the Lightning Slide Talk have been started, and the Imagine RIT poster is complete. Paragraphs from each subsystem area, pictures, and sources/acknowledgements have been done by each team member. Moving into the final phase, our team must focus on finishing touches to the Crew-Lock and completing Imagine RIT and hand-off documentation.
Plans for next phaseIn the next phase, Customer Handoff & Final Project Documentation, the team will be focusing on the following:
- Completing testing using pressure and proximity sensor board
- Troubleshooting any problems during testing
- Lightning Talk presentation slide/video
- 10-page technical paper
- Materials, tools, and work-space organization
- Imagine RIT display setup
The Detailed Gantt Chart and Schedule can be downloaded the Design Review Materials Section at the bottom of this page.
Design Review Materials
- Final Crew-Lock BOM
- Change Management System Sheet
- Problem Tracking
- Risk Management
- Master Schedule
- Testing Results Matrix
- All Testing Plans Excel Workbooks