Subsystem Build & Test
Table of Contents
Team Vision for Subsystem Level Build & Test Phase
During this phase our team set out to order the remainder of materials that would be required for our initial prototype build. This included all hardware, and the parts required to build the hydraulics system for the seat.
Additionally, the team planned to begin writing the technical paper and mapping our our vision for imagine RIT. Our goal during this phase was to complete the outline, and begin adding content to the technical paper in order to make the 75% completion goal attainable by the end of week 11.
A third goal of the team during this phase was to work to complete the cutting and forming of all of the raw materials required for the build so that we could begin the construction of the system base and present it for our week 7 review.
The team planned to accomplish these goals by adhering to the schedule pictured below:
During this phase, our team was able to make a good amount of progress towards these goals, while experiencing a few challenges along the way. We were able to successfully order all of the materials required for the current build plan of the prototype. We have successfully obtained all of the material for the hydraulics system, the hardware for the system, and have successfully outlined, and begun the technical paper.
However during this phase, our team had to make minor changes to the system design to support the build plan, delaying our start build time. As a result of this delay, the team was unable to complete the build of the system base and seat plate. However, we have successfully started both of these projects and are scheduled to have them completed by the first week of Phase 3.
The team has established that at this time, there are no critical risks to the success of the project, and anticipate completion of the build according to schedule.
Summary of Progress
As the project came into the manufacturing phase, the team consulted with Gary Houdienus as a welding SME to understand the welding process. The primary feedback that Gary offered was to reconsider welding to sheet metal as the heat from welding would result in a very warped plate. As a result, the design was changed to replace welded joints with bolted joints for all sheet metal components. This led to several waterjet components needing to be remade. Fortunately, we were able to resubmit the the work request and receive the components in a timely fashion. Other work that was completed was the machining and drilling of the seat plate components and getting stock prepared for the hydraulic components.
As shown in the photo, drilling and milling operations were completed for the seat reinforcement structure. The steel tube in the photo will be welded together to form the seat structure; note that the angles have not been cut as this will be done using the metal chop saw immediately before welding. Once the structure is welded, we will be able to assemble the sheet metal plates to the structure using countersunk flat head screws.
Bill of MaterialsDuring this phase, we were able to successfully order and receive more of the required parts from the Bill of Materials spreadsheet.
Throughout the duration of MSD 1 Phase 4 and the previous MSD 2 phase, we purchased all of our steel tubing and sheet metal. However, we still needed to look into buying any remaining hardware and the different components for the hydraulic sub system. We were able to accomplish this with ease. Our hardware (ball bearings, shoulder bolts, cotter pins, etc.) and hydraulic parts (PVC piping, o-rings, etc.) were purchased from McMaster Carr and had a collective cost of $206.75 (not counting any shipping costs).
Purchasing these parts brought our current expenditures to $318.57, which gives us a remaining budget of $181.43. As of right now, we do not believe that any additional purchases will need to be made but if at some point we do need to look into buying something, we will have the necessary funds to do so.
The live document for the bill of materials list can be viewed here.
Risk and Problem TrackingDuring this phase, we were able to successfully come up with a few more risks to add to our list. This brings our risk total to 30 for MSD 2. The live risk document can be seen by clicking here.
In addition to finding new risks, we were also able to continue any risks that manifested into problems. Since the previous phase, only 2 risks manifested into problems. However, these problems are considered to be ordinary and will not impact the production of the group in the long run. To view the live problem tracking spreadsheet, click here.
Functional Demo MaterialsInclude links to:
- Presentation and/or handouts
- Notes from review
- Action Items
Plans for next phase
Moving forward, our team will begin the build of the major system components and begin to test their integrity according to the test plans. All fabricated and formed parts will be assembled to create a complete prototype which will then be tested for structural integrity and functionality.
At the next demo, the team plans to have all parts assembled and plans to be working to fine tune all components requiring adjustment to ensure the finalized system works as intended.
To accomplish these goals the team plans to adhere to accomplish the following tasks.
In order to accomplish all of these tasks, we will follow the schedule shown below
Four Week Plans
To accomplish all of the goals stated above each of the team members have established 4-week plans that can be found below.