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Subsystem Build & Test

Table of Contents 1 Team Vision for Subsystem Level Build & Test Phase 2 Test Results Summary 2.1 Power Block 2.2 Voltage Controller and Battery Tests 2.3 Speaker Tests 2.4 LED PCB Test 2.5 Instructions 2.6 Inputs & Source 2.7 Outputs & Destination 3 Risk and Problem Tracking 4 Functional Demo Materials 5 Plans for next phase 5.1 Daniel Saber 5.2 3 Week Plan 5.2.1 Brandon Simmons 5.2.2 Danny Saber 5.2.3 Nandakumar Unnikrishnan

Team Vision for Subsystem Level Build & Test Phase

In this phase of MSD2, the team worked on implementing test plans developed in previous phases, and troubleshooting any problems with current designs. The test plans were meant to provide a means of confirmation as to whether the new designs were successful.

Phase accomplishments:

• Battery Tests
• Speaker Tests
• Execution of mechanical manufacturing
• Attempts at wood CNC Martone Body
• Testing of rigid PCB
• Soldering of LED boards
• Began assembly procedure for building martone

Test Results Summary

Summarize test results and assess effectiveness of test plans to unambiguously demonstrate satisfaction of the engineering requirements

Power Block

1. The power module needs to be connected to the battery input, or an equivalent voltage from a power supply for testing purposes. This converter is configured based on external component references. Since our LEDs and proximity sensor demand five volts and the microcontrollers can handle that input voltage, the output of the converter needs to be a fixed five volts regardless of input voltage as the battery voltage changes depending on charge level.
2. Connected board to power supply, and the output voltage was not what it should have been. Since the boost converter operates at 2MHz, any small defects in how the board was fabricated can cause subtle errors to be amplified and cause errors.
3. Since we are short on time and budget, a small pre-made module board was used which contains the same converter chip that was used in the schematic. This module can output the correct voltage and will be used for further testing and design work.

Voltage Controller and Battery Tests

• Results and lab procedure outline in Lab report document
• Charge Controller Circuit working as expected through current tests
• See here.. for the full lab report
• Status:Tests are 90% complete

Speaker Tests

• Results and lab procedure outlined in lab report document
• Speakers have improved sound roughly 10 dB, but still do not meet requirement
• Team will elect to use improved speakers in the interest of time
• Status: Testing complete
• See full lab report here

LED PCB Test

• 5V will be applied to the input of the LED PCB and all LED's will be checked to ensure that 5V is present
• Juan's code will be plugged into datain and clkin of LED PCB and all LED's will be checked to see that they light up and oscilloscope will be used to ensure that the time that was coded is the actual time taken for the last LED to light up

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
2. Subsystem fabrication

Outputs & Destination

1. Test Results
2. System integration

Risk and Problem Tracking

Updated Risk Register can be found here

The table below represents the risks that have turned into problems

Functional Demo Materials

Include links to:

• Pre-read
• Presentation and/or handouts
• Notes from review
• Action Items

Plans for next phase

Daniel Saber

• Finalize Battery Tests
• Help with any PCB soldering as needed/other team tasks
• Continue to update BOM/Order parts as needed for team

3 Week Plan

• 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)

Brandon Simmons

• What did I plan to do? Solder and test main pcb for correct output voltages.
• What did I actually do? Tested board and found a problem with the converter. Worked to solve the issue by trying new component-board combinations to isolate a component error. Theorized why error occurred and confirmed through searching on Google.
• What did I learn? Low-cost pcb fabrication means low-cost features like functional testing and impedance control.
• Plans for next phase: Continue to solder components/systems on the board and test as I go.

Danny Saber

• What did I plan to do? Test Battery and Voltage controller circuit, as well as speakers.
• What did I actually do? Tested speakers, got most of the battery/voltage controller testing done.
• What did I learn? How were plans and reality different? The plans were not different than reality. I learned how well the speakers worked and reported the results. I also learned how the voltage controller reacts to different battery charge levels.
• Plans for next phase: Help with soldering, assembly plans, other tasks as needed. Finalize battery tests/voltage controller tests.

Nandakumar Unnikrishnan

• What did I plan to do? To finish soldering the LEDs to the LED PCB
• What did I actually do? Finished soldering all LEDs to the LED PCB
• What did I learn? How were plans and reality different? I learned how to solder a surface mount part to a PCB. I learned that I cannot use a soldering iron to do so and how to use solder paste and a hot air gun in its place. It took more time than I expected due to having to use the SMT lab which was not open during the weekend.
• Plans for next phase: Test all the LEDs in the PCB and help anyone else as needed.

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