/public/

Subsystem Build & Test

Table of Contents 1 Team Vision for Subsystem Level Build & Test Phase 2 Test Plans 3 Test Results Summary 3.1 Power Block 3.2 Voltage Controller and Battery Tests 3.3 Speaker Tests 3.4 LED PCB Test 4 Risk and Problem Tracking 5 Functional Demo Materials 6 ImagineRIT Plans 7 Plans for Next Phase 7.1 Timeline 7.2 3 Week Plan 7.2.1 Brandon Simmons 7.2.2 Danny Saber 7.2.3 Nandakumar Unnikrishnan 7.2.4 Matthew Decker 7.2.5 Aminata Keita 7.2.6 Sylvain Cornelus

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 Plans

The most current version of the test plans can be found here

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

• Check the continuity of all traces on LED PCB.
  • First check the continuity on the bare-board
  • Then check the continuity on the PCB with soldered LEDs
• 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

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

Presentation

ImagineRIT Plans

• Display Martone on table (standard position - Horizontal)
• Provide short background of the project and design
• Demonstrate basic functional aspects (moving legs, playing notes, etc)
• Invite people to interact with Martone (press buttons, try different positions, etc)
• Have Juan present to talk about his vision of the project
• Have a musician friend of Juan's around to play some tunes

Plans for Next Phase

Timeline

3 Week Plan

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.

Matthew Decker

• What did I plan to do?
  • Finish jack insert models. Begin printing inserts and fit testing jacks. Create a set of tests for the jacks (electrical).
• What did I actually do?
  • Finish jack insert models. Tweaking ER’s and Test Plan. Made first printed model of inserts.
• What did I learn?
  • How to print at the Construct (thank you Sylvain) and roughly what the capabilities are. Also that I need to communicate more just for the sake of communication.
• Plans for the next phase:
  • Print the other insert model. Fit test to Martone. Assemble jack circuitry and test for anticipated behavior. Work with Matt S to figure out inserts for his design.

Aminata Keita

• What did I plan to do?
  • Find hooks that we can place on the Martone for the strap. Work on the assembly instructions. Create better planning for the end of the semester. Review the tests plans and ERs. Track any risks that can become a problem.
• What did I actually do?
  • I have created a document for the assembly instructions it is being filled up as we go through the project. I have detected the risks that became problems. I have reviewed the ER and Test plans with Matt to make sure we got them correctly. I have updated the planning based on the risks/problems the team is facing. I also have come up with an idea for hooks we can place on the Martone to hook the strap.
• What did I learn?
  • I have learned that the planning is never accurate, all we can do is adapt. I also have learned to ask the right questions when it comes to writing the ERs and testing plans. In addition I am still learning how to incorporate each other's work into one to make sure we are all on the same page. I also have learned some things about soldering by watching Nandhu do it. Unfortunately I was not able to assist him when he was doing it at the CEMA lab because they only had one station available.
• Plans for the next phase:
  • Plans for the next phase would be pretty much the same as this phase. Keep working on the risks, planning and assembly instructions. Help other team members as much as I can. Try to find the hooks in black instead of gold and order them. Start discussing the project’s paper and poster.

Sylvain Cornelus

• What did I plan to do?
  • Begin CNC and component fabrication
• What did I actually do?
  • Begun CNC and component fabrication
• What did I learn?
  • Wood stock needs to be as close to CAM dimensions as possible or the part will not be made properly. Wood needs to be joined before planning. Rubber cuts well on laser. 3D prints fit well inside the frame. The magnets we ordered are very strong.
• Plans for the next phase:
  • Prepare more accurate wood stock and run CNC operations. Create CAM file for upper frame. Re-dimension and fit to new speakers. Analyze space for new amp. Cut remaining layers for touchscreen layers. Determine proper dimensions for dowel holes. Print touchscreen brackets. Print PCB insert. Assemble HS inserts. Continue to edit assembly instructions. Prepare design page for Edge.

---

Home | Planning & Execution

Problem Definition | Systems Design | Preliminary Detailed Design | Detailed Design

Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Customer Handoff & Final Project Documentation