P19231: Training Wheels
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Subsystem Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

Preliminary prototypes were being built and assembled during this phase. Any problem necessary mitigation was addressed and resolved and a more concrete future plan was established for the remaining design phase.

Tasks accomplished:

  1. Built prototype shifter housing
  2. Ordered mechanical components
  3. Ordered board components
  4. Set up force sensor for testing
  5. Finalized schematic
  6. Board Layout

Tasks to be accomplished:

  1. Reorder new mechanical components for shifter
  2. Force sensor testing
  3. Machine shifter components
  4. PCB Population and test

Test Results Summary

Due to the force sensor calibration process and other higher-priority work, the Chevy Cruze driving tests were pushed back for the next phase.

Maximum force tests were conducted by Steve to determine force loads a human can exert using different muscle motions. The following was determined:

-Two-leg Leg Press: 426lb -Two-arm Chest Press: 220lb -Two-arm Seated Row: 250lb

Instructions

  1. Quantitatively summarize the capabilities, performance, throughput, and robustness of your subsystems as demonstrated by execution of the text plan. Document your testing with photos or videos in addition to test data.
  2. Evaluate how well the test plan was able to confirm satisfaction of subsystem requirements
  3. Include snapshot of testing completed to date, and include link to live requirements and testing document

Inputs & Source

  1. Test Plan

Below is a link to the Live Document of the Test Plans:

P19231 Test Plans

Outputs & Destination

  1. Test Results
  2. System integration

Risk and Problem Tracking

As seen on the Risk Management, the team is falling behind in the testing area. The three risks which likelihood has been increased are all sectioned in the resource section. The data and testing has not been completed, so the likelihood has been increased to 9. The likelihood or Risk 15 was increased to 3 due to issues in ordering components; making them arrive later than desired and thus, setting the team back. For the next weeks, we are shifting out attention to completing these test during the next weeks while awaiting certain components to arrive.

Risk Assessment 1

Risk Assessment 1

Risk Assessment 2

Risk Assessment 2

Risk Assessment 3

Risk Assessment 3

Below a link to the live document of Risk Assessment:

P19231 Risk Assessment

On the problem tracking, we have to main problem we are tracking so far. This are the only two problems we have identified so far due to being behind on the testing. Once testing, validation & verification of the subsystems and different test, this list would most probably have more entries.

Problem Tracking List

Problem Tracking List

Problem Tracking CMO Chart

Problem Tracking CMO Chart

Below a link to the live document of Problem Tracking:

P19231 Problem Tracking

Updated Electrical Designs

Power Supplies

Power Supplies

Common MCU

Common MCU

Display Board

Display Board

Shifter Board

Shifter Board

Board Layout

Board Layout

Software

Power Supplies

Power Supplies

The software architecture, as previously mentioned, is layered from bottom to top in increasing levels of abstraction. Currently the IO layer is being worked on and should be completed by the end of week 7. Drivers include CAN, QuadSPI, SDIO, GPIO, USART and timers. After that, task scheduling, the DEV and APP layers will be worked on in parallel in the coming weeks (week 8 and later).

As each feature is completed, a test program will be written to validate the feature. This will aid in validation and regression testing in the event of inevitable hardware issues.

In its current state, the RaspberryPi data logger will be set to do vehicle testing this weekend (10/5) according to the drafted plans.

Prototypes

The process of machining the clutch pedal components began in this phase. The sheet metal that would provide stability to the clutch system was machined and holes were placed in the proper locations.
Sheet Metal Plate Progress

Sheet Metal Plate Progress

Sheet Metal Plate Progress

Sheet Metal Plate Progress

The clutch rods were also machined to their defined lengths. However, the weight was determined to be heavier than anticipated, and aluminum stock was chosen to be ordered in place to ensure the pneumatic piston could easily move the system. Screw sizes were also questionably too small for the system and larger, sturdier screws were selected to be ordered so that sheer stresses would not be uncertain.

Machined Clutch Beams

Machined Clutch Beams

The force sensor was programmed for future testing. The software was edited and modified to collect data. However, the fluctuations in the force sensor were very small so an amplifier was determined necessary for data collection.

Force Sensor Setup

Force Sensor Setup

The piston ordered was incorrect due to oversights on the direction of the "standard" movement of the pneumatic piston and inability to modify the cylinders. So, a new piston was ordered and verified to be the correct one we needed. Bimba was chosen as the vendor and we called them on the phone to speak about the component we were ordering.

Piston Problem

Piston Problem

Piston Problem Mitigation

Piston Problem Mitigation

The shifter subsystem prototype opened

The shifter subsystem prototype opened

The shifter subsystem prototype

The shifter subsystem prototype

A mechanical prototype was built for the shifter subsystem. The housing with the shifter knob and rod were completed. The subsystem will next require limit switches and the solenoid-driven lockout plates.

Testing will begin on the shifter subsystem shortly.

Plans for next phase

Updated Project Timeline

Updated Project Timeline

Steven Keil

Kevin Ramirez P.

Tyler Smith

Kevin Gates

Matt Wagner

John Jenco


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