Build & Test Prep
Table of Contents
Your website should document your journey through MSD, so include work-in-progress as well as latest results. Use pdf's for display whenever possible so that information is easily viewable without the need to download files and open applications. (Your EDGE file repository should still contain original editable files).
All template text must be removed prior to your Build & Test Prep Review
Team Vision for Build & Test Prep PhaseSummarize:
- What did your team plan to do during this phase?
- What did your team actually accomplish during this phase?
Test Plan SummaryOur vacuum former has three main subsystems that must be tested separately before the entire project can be assembled.
- Build outer frame
- Full scale 80/20 build
- Ensure plastic can be properly clamped and held
- Cannot have interference from clamps
- Cannot slip out from between the frames
- Test the ability of the plastic holder to slide up
and down on the frame
- No binding
- Cannot fall out of track
Vacuum System Test PlanBefore construction of the full system, we plan to perform testing on the vacuum subsystem. This will help find any design problems in the subsystem and correct them before testing the system as a whole. We plan to test the following:
- Time to draw vacuum on one tank
- Time to release vacuum on tank
- Time to release vacuum through piping system
- Leak testing
- Vacuum force drawn on mold/plastic (Qualitative)
- Full system testing
- Obtain permission for testing in welding area
- Simulate frame system
- Suspend heater in welding area (Must be facing down)
- Test switch assembly
- Determine max and min output
- Adjust output using pressure adjustment screw
- Ensure safety
- Check for any possible leaks
- Make sure switch is working properly
- Suspend plastic under heater at max distance (approx.
- Use both 1/8" and 1/4"
- Use timer to find time to heat
- Move plastic incrementally closer to the heater to
find the minimum safe heating distance
- Record max temp and time to heat for each distance and plastic thickness
- Before testing make sure:
- Your ventilation source is a minimum of 400 cfm for the SG-10L heater
- The propane tank is 6 to 8ft away from the vacuum former
- Smell the area for propane including the near the floor. Propane gas is heavier than air. If you smell gas don’t light the heater.
- Someone to take video of the testing
- Someone is by the shut-off valve to quickly close the propane tank.
- Have a soap and water solution.
- Verify there are no leaks
- Put a soap and water solution on the connection points including the outlet pressure boss on the manifold (Image 1) and hose of the propane system
- Turn on the ventilation
- Open propane tank and verify that there are no bubbles forming.
- If bubbles form there is a leak. Add more Teflon tape or buy a new part.
- Clean off the water soap mixture
- Test the heater
- open the shut-off valve and propane tank's valve, and then turn on the heater
- If there is black soot build up on the heater turn it off and close the tank. There is a problem with the propane burning
- If there is ice build up on the propane tank turn
the heater off and close the tank.
- The liquid propane evaporating is cooling the tank too much and will affect the heater's performance.
- Another propane tank or a larger tank needs to be added to the system.
Use your test plan to summarize test results and assess effectiveness of test plans to unambiguously demonstrate satisfaction of the engineering requirements
- Osha.gov. (2019). 1926.153 - Liquefied petroleum gas (LP-Gas). | Occupational Safety and Health Administration. [online] Available at: https://www.osha.gov/laws-regs/regulations/standardnumber/1926/1926.153 [Accessed 21 Feb. 2019].
- SunStar Heater Instructions
- Ensure team has space and equipment necessary to begin building and testing
Risk and Problem Tracking
- Update your Risk Management
- If you have risks that have manifested themselves as problems, begin problem tracking.
Design Review MaterialsInclude links to:
- Presentation and/or handouts
- Notes from review
- Action Items
Plans for next phase
- As a team, where do you want to be in three weeks at your next review?
- As an individual on the team, what are you doing to help your team achieve these goals? (Use the individual 3-week plan template for this)