P19127: XHab Deployable Crew Lock Structure
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Integrated System Build & Test

Table of Contents

Team Vision for Integrated System Build & Test Phase

During 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

Concept Rendering from Integrated System Build (Closed)

Concept Rendering from Integrated System Build (Closed)

Concept Rendering from Integrated System Build (Open)

Concept Rendering from Integrated System Build (Open)

Risk, Change, and Problem Tracking

The Change Management, Risk Management, and Problem Tracking workbooks can be downloaded in the Design Review Materials Section at the bottom of this page.
Problem Tracking - Phase 7

Problem Tracking - Phase 7

Change Management - Phase 7

Change Management - Phase 7

Risk Management - Phase 7

Risk Management - Phase 7

BOM and Finance Tracking

he BOM workbook and Expense Tracking can be downloaded the Design Review Materials Section at the bottom of this page.
Crew-Lock Final BOM - Phase 7

Crew-Lock Final BOM - Phase 7

Fabrication Updates

Bulkheads

CNC and Machining

Below 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.

Spindle RPM Controller for the ShopSabre CNC

Spindle RPM Controller for the ShopSabre CNC

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.

CAM Program Speeds, Feeds, Trajectory, and Coding

CAM Program Speeds, Feeds, Trajectory, and Coding

ShopSabre 4860 CNC Machine

ShopSabre 4860 CNC Machine

Bulkhead Ergonomics

Metallic handles were added as ergonomic aides on the EVA bulkhead.

Metal Handles Attached to EVA Bulkhead

Metal Handles Attached to EVA Bulkhead

Bulkhead Maintenance Hatch

The 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.
Maintenance Hatch on IV Bulkhead using Airtight Zipper

Maintenance Hatch on IV Bulkhead using Airtight Zipper

Bulkhead Painting

Bulkhead 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.
Bulkheads Set-up for Painting in Ethan's Garage

Bulkheads Set-up for Painting in Ethan's Garage

Painted Bulkhead with Air-tight Sandwich Ring

Painted Bulkhead with Air-tight Sandwich Ring

Vacuum Barrier & Panels

The Vacuum Barrier Includes the Vinyl layer in the bulkheads, and the habitable volume created by the TPU coated Nylon layer surrounding the Crew-Lock.

Vacuum Layers

Heat Sealing Vacuum Barrier Layer and Handles layer

Heat Sealing Vacuum Barrier Layer and Handles layer

Test forming of Vacuum Barrier Layer and Handles layer

Test forming of Vacuum Barrier Layer and Handles layer

Vinyl Sandwich

Preparation of Vinyl layers prior to Heat Sealing and Bulkhead Sandwiching

Preparation of Vinyl layers prior to Heat Sealing and Bulkhead Sandwiching

Preparation of Heat Sealing Interfaces

Preparation of Heat Sealing Interfaces

Heat Sealing Process

Heat Sealing Process

Heat Gun Settings

Heat Gun Settings

Testing Rig

Testing Rig - Wood Machined and Set for Securing

Testing Rig - Wood Machined and Set for Securing

Testing Rig with Bulkhead

Testing Rig with Bulkhead

Deployment System

Bolted Flange Manufacturing

Manufacturing Plan for Bolted Flanges

Manufacturing Plan for Bolted Flanges

Bolted Flange Table Manufacturing

Bolted Flange Table Manufacturing

Completed Bolted Flange

Completed Bolted Flange

Motor, Threaded Rod, and Control Board Function Testing

Motor, Threaded Rod, and Control Board Function Testing

Electrical & Programming

Arduino Microcontroller

Arduino Microcontroller

Sensor Board

Completed Sensor Board

Completed Sensor Board

Motor Control Board

Motor Control Board Elements Diagram

Motor Control Board Elements Diagram

Motor Control Boards and Arduino in Breadboard Set-up

Motor Control Boards and Arduino in Breadboard Set-up

Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Arduino Micro-controller Programming

Test Results Summary

The Test Results Summary can be downloaded in the Design Review Materials Section at the bottom of this page.
Test Results Summary - Phase 7

Test Results Summary - Phase 7

Functional Crew-Lock Video

Below is a functional testing video of the Crew-Lock during Brandon's Industrial Design Senior Capstone presentation.

Crew-Lock Functional Testing Video

Phase Final Products

Crew-Lock from Integrated System Build

Crew-Lock from Integrated System Build

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 Phase

This 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.

P19127 Imagine RIT Poster

P19127 Imagine RIT Poster

Plans for next phase

In the next phase, Customer Handoff & Final Project Documentation, the team will be focusing on the following:

The Detailed Gantt Chart and Schedule can be downloaded the Design Review Materials Section at the bottom of this page.

Condensed Gantt Chart - Phase 8

Condensed Gantt Chart - Phase 8

Design Review Materials


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