Build & Test Prep
Table of Contents
Team Vision for Build & Test Prep Phase
In this phase of MSD2, the team worked on finalizing unfinished designs from MSD1 and transitioning to the testing phase of MSD2. From MSD1, there were some unfinished mechanical designs that have been completed during this phase. Additionally, almost all parts needed for testing in phase 6 have been ordered and/or have already been recieved.
- Completion and validation of the Martone's design by the customer and guide.
- Establishment of the test plans needed based on the ERs.
- Meeting with Juan and Matt to update project status
- Ordered all critical parts/materials to start testing and building.
- Soldering of Rigid PCB and testing of speakers underway
- Preliminary printing of 3D inserts
- Successful testing with heat set insert installation
Mechanical Design FinalizationDue to the large workload of the mechanical design work, the continuous requests for more systems by the customer, and the single ME on the project, the detailed mechanical design of the Martone has only just been finalized. Below are various views of the Martone Assembly showing form, fit, and function:
Eventually a separate Edge page will be dedicated to describing the mechanical design philosophy/assumptions/process/features and dimensioned drawings. Although this should ideally have been done this phase for MSD, it does not hold back testing and assembly. The most important models/drawings(touchscreen related) are finalized and ready for lasercutting; 3D models do not need drawings to be printed; and CNC step files are made and ready for a run.
Updated DocumentsAn updated version of the Customer Requirements and Engineering Requirements can be found here.
Test Plan Summary
The test plans can be found here.
- All components have been ordered and received
- The PCBs have passed continuity tests
- Components for the 5-volt boost converter circuit have been soldered
- Testing is progressing
Power Block Testing and Speaker Testing
- Power Block testing will take place following the the completion of the main PCB soldering
- This test plan aims to confirm the functionality of the battery, and the charging circuit for the battery
- Speaker Testing has been completed--speakers do not satisfy engineering requirement of 75 db-85db. This requirement may not be attainable due to the limited output of the audio shield.
- Make sure the LED Layer works as expected.
- All the LED’s should have 5V power.
- The data connection should go through to all LED’s.
- The speed of connection should be almost 1ms.
Risk and Problem Tracking
Open RisksThe table below represents the risks that the team has to deal with through out the life of this project. The risk register can be found here
The picture below represents the risk waterfall until the end of the semester. Much has not change if we compare it to the one in phase 4. The only element that has increased is the likelihood of Phase 5 down because we have added new risk items.
Closed RisksAs the project goes on, some of the risks have been closed because they did not apply anymore to the project.
Cabling DiagramThis is an image of the first page of the cabling diagram: here
LED PCBThe LED PCB from the previous phase has been changed due to cost constraints. The design itself remains the same, however the PCB has been cut in half, making the new PCB much cheaper to fit the budget. Two different PCB's have been made for the left side and the right side which will be put together as shown in the cabling diagram. The schematic and layout files can be found here.
Plans for next phase
High Level PlanThe planning below is a high level one with the important milestones that the team has to go through to make the building a success.
Low Level Plans
- Investigate discovered issue of high input current when switch is activated
- Continue testing and soldering portions of rigid PCB
- Moniter closely the risks and make sure to take actions if triggered
- Update the planning if needed
- Finish Assembly Instructions
- Keep looking on where to place the hooks for the Strap
- Once the LEDs arrive, solder all LEDs to the LED PCB
- Test the LED PCB according to the test plans
- Select replacement potentiometer and model it.
- Assign placements for jacks/pot for Sylvain/Matt S. designs.
- Model insert(s) to hold them in place. Have them 3D-printed.
- Trial-and-error testing to get the inserts right.
- Work on testing the jacks to make sure they operate together as anticipated.
- Sand down sides of LED PCB's
- Help solder LED PCB's as needed
- Test Battery/Charge Controller Circuit to confirm functionality
- Continue to update BOM/Order parts as needed for team
- Run a CNC operation to create an upper frame and if possible a lower frame as well
- Practice cutting TS layers with laser cutter and tweak dimensions as needed
- Continue 3D printing inserts and testing fits
- Order any parts that have not been yet ordered
- Identify source for old speakers to use for grill
- Design grill press 3d prints to shape to ellipse
- Identify source for old speakers to use for grill
- Begin drafting assembly instructions with Aminata
- Create final part drawings as they are validated and
dimensions are locked in
- Begin updating and filling out a final design summary of Martone Edge page