Subsystem Build & Test
Table of Contents
Team Vision for Subsystem Level Build & Test PhasePreliminary 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.
- Built prototype shifter housing
- Ordered mechanical components
- Ordered board components
- Set up force sensor for testing
- Finalized schematic
- Board Layout
Tasks to be accomplished:
- Reorder new mechanical components for shifter
- Force sensor testing
- Machine shifter components
- PCB Population and test
Test Results SummaryDue 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
- 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.
- Evaluate how well the test plan was able to confirm satisfaction of subsystem requirements
- Include snapshot of testing completed to date, and include link to live requirements and testing document
Inputs & Source
- Test Plan
Below is a link to the Live Document of the Test Plans:
Outputs & Destination
- Test Results
- 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.
Below a link to the live document of 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.
Below a link to the live document of Problem Tracking:
Updated Electrical Designs
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.
PrototypesThe 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.
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.
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.
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.
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
- Order updated components for clutch (10/3/19)
- Machine preliminary test prototype for clutch (10/10/19)
- Machine finalized components for clutch and begin assembling (End of October)
- Update SolidWorks model to reflect changes (End of October)
Kevin Ramirez P.
- Collect data in manual car (Aiming to get a majority of it done this saturday 10/5/19)
- Filtering and analyzing the collected data (Goal: End of October)
- Assemble the switches and solenoids in the subsystems (10/17/19)
- Machine and install shifter lockout plates - Week 7
- Integrate limit switches and solenoids with shifter - Week 7
- Work with Steven to complete clutch build - Week 7-8
- Purchase any remaining parts/components Week 6-7
- Build/Test PCB Week 7-8
- Assemble switches and solenoids in subsystems Week 7-8
- PCB Test Plan Week 6
- PCB Build/Test Week 7-8
- Software Drivers Week 7-8
- PCB build/test Week 7-8
- Software and drivers Week 7-8
- Vehicle testing Week 7-8 (Majority taking place on Sat. 10/5)
- Software test suite (binaries) Week 7-8