P10225 Detailed Design Review - EDGEedge.rit.edu/content/P10225/public/P10225 Detailed Design...

RIT MULTI-DISCIPLINARY SENIOR DESIGN

P10225 Detailed Design

Review

11/6/2009

Concepts

A B C

(Reference)

Selection Criteria Buy (New) Buy (Used) Build

Size - must be 7'x4'x5' (LxWxH) , must be able to attach

wheels and casters0

- +

Shape - ability to add flow diverters and add angles for easy

draining (can be done by 1 person in > 1 hr)0

0 +

Cover - must be able to buy or make a cover that seals in the

water0

0 0

Price - must be ≤ $500 0 + 0

Sides - must seal in water, must have see-through window 0- 0

Material - must be impervious to water, must not rust,

strength must withstand 6.81 psi stagnant water pressure at

1.5 m deep (with factor of 5 for safety and turbulence)

0

- 0

Maneuverability - must be able to move by ≤ 2 people, must

be able to attach wheels and casters0

0 +

Time to procure - must be able to buy and build in ≤ 6 weeks 00 -

Material availability - must be able to acquire with in ≤ 3

weeks0

+ 0

Time to build - must be buildable with tools and knowledge

of team members0

0 -

Sum + 's 0.00 2.00 3.00

Sum 0's 10.00 5.00 5.00

Sum -'s 0 3 2

Net Score 0 -1 1

Rank 2 3 1

Continue? No No Yes

Concepts

A B C D

(Reference) Build frame from steel

Selection Criteria Buy Prebuilt frame and tank and buy sperate tank

Ablility to Surpport (840 gallons of water) 0 0 - 0

Size of Stand (Need to fit a 7'x4'x4' tank) 0 - 0 +

Cost 0 + - +

Ability to move 0 0 0 +

Weight (Baja team can move without problems) 0 0 0 +

Ability to dissasemble 0 + + +

Potential to rip 0 0 0 -

Sum + 's 0 2 1 5

Sum 0's 0 4 4 1

Sum -'s 0 1 2 1

Net Score 0 1 -1 4

Rank 3 2 4 1

Continue? No No No Yes

P10255 Mini-Baja Water Propulsion TeamTank Screening Matrix

Stand Tank/Frame Screening Matrix

Build frame from

steel and make

separate tank

Build a tank and

frame as one

Concepts

A B

Selection Criteria (Reference)

6359K46

Custom Made w/ 7965K65 Bronze

Bushings

Cost 0 ($191.44) + ($65.00)

Ease of Manufacturing 0 -

Corrosion Resistance 0 0

Ability to Support Load 0 0

Ability to Remove Axle Housing 0 -

Servicability 0 -

Ease of Mounting To Frame 0 0

Sum + 's 0.00 1.00

Sum 0's 8.00 3.00

Sum -'s 0.00 3.00

Net Score 0 -2

Rank 2-Because of Cost 1

Continue? yes

Concepts

P10255 Mini-Baja Water Propulsion TeamAxle Housing Bracket Screening Matrix

P10255 Mini-Baja Water Propulsion TeamLinear Motion Screening Matrix

A B C

(Reference)

Selection Criteria Corrosion Resistant Open Linear Bearing

(9104T110 w/ 6557K23 runner) Skateboard Bearings

Open Linear Bearing (9338T15 w/

59585K89 runner)

Cost 0 ($692.97) + ($90.00) + ($360.57)

Ease of Manufacturing 0 - 0

Corrosion Resistance 0 - -

Ability to Support Load 0 Requires Further Investigation 0

Minimum Resistance to Linear Motion 0 0 0

Replacement Costs 0 + +

Ability to Constrain Frame in Vertical and Horizontal

Directions0

0 0

Ability to Mount to Frame 0 0 0

Sum + 's 0.00 2.00 2.00

Sum 0's 8.00 3.00 5.00

Sum -'s 0.00 2.00 1.00

Net Score 0 0 1

Rank 3-Because of Cost 2 1

Continue?

Concepts

A B C D E E

(Reference)

Selection Criteria Chain Drive V-belt Drive Notched-Belt Drive

Cost- must be less the $250 0 0 0

Corrosion resistant-must be able to perform in water and

not rust0

+ +

Performance- must be able to perform in water and not slip 0- 0

Clean-must not containminate the water 0 + +

Durability-must be able to peroform on a daily basis and be

stored for many months with loosing quaility0 0 0

Time to aquire-must be able to order and receive within 2

weeks0 0 0

Safety- must be able to operate safely 0 + +

Time to build - must be buildable with tools and knowledge

of team members0 + +

Sum + 's 0.00 4.00 4.00

Sum 0's 10.00 3.00 4.00

Sum -'s 0 1 0

Net Score 0 3 4

Rank 3 2 1

Continue?

Motors

A B C D E

Reliance 3hp, 1800

rpm, 180 Vdc

Reliance 3hp, 2500 rpm,

150 Vdc

GE 3hp, 3500 rpm,

180 Vdc

Reliance 5hp, 1800

rpm, 150 Vdc

Reliance 5hp, 2500

rpm, 180 Vdc

Selection Criteria

Horsepower - 1.5-4 hp estimated for single wheel* 0 0 0 - -

rpm - 1750 shaft design rpm 0 - - 0 -

Torque* - Baja engine: 14ft-lbs (168 in-lbs) 0 0 0 + +

Price - Lower is better 0 0 0 - -

Performance at reduced rpm* 0 + + 0 +

Sum + 's 0 1 1 1 3

Sum 0's 5 3 3 2 0

Sum -'s 0 1 1 2 2

Net Score 0 0 0 -1 -2

Rank 1 (tie) 1 (tie) 1 (tie) 2 3

Continue?

No No

Yes, best

performance at

target rpm

No No

Notes: Briggs and Stratton engine, 10hp, approx. 14ft-lbs (168 in-lbs) @ 3800 rpm

Based on Baja team estimate of 3-7 hp at wheels

DC motors provide approx. 35 in-lbs per motor hp

DC motor max torque @ approx. 1/2 speed

P10255 Mini-Baja Water Propulsion TeamDrive System Screening Matrix

Motor Screening Matrix

Concepts

A B C

(Reference)

Selection Criteria PCI Card USB Serial

Interfacing - does it use some sort of standard interface (like

RS232), can it be used on a laptop?0

+ -

Programing - difficulty of programing 0 + +

Support - Is there good software/firmware support? Is there a

community dedicated to provide examples and technical

support?

0

0 0

Additional Hardware required-Card, Microchip 0 - +

Cost - at most $100. 0 + +

Sum + 's 0.00 3.00 3.00

Sum 0's 5.00 1.00 1.00

Sum -'s 0 1 1

Net Score 0 2 2

Rank 3 1 2

Continue? No Yes No

Concepts

A B C

(Reference)

Selection Criteria Honeywell 4AV16F Vane Sensor Optek OH090U Cherry Electrical GS101205

Temperature resistant - operates between -30 C and 50 C 0+ +

Accuracy 0 0 0

Precision 0 0 0

Cost 0 + 0

Additional Equipment needed (Magnets, Gears,…) 0 - -

Ease of Mounting 0 - 0

Sum + 's 0.00 2.00 1.00

Sum 0's 6.00 2.00 4.00

Sum -'s 0 2 1

Net Score 0 0 0

Rank 1

Continue? Yes No No

P10255 Mini-Baja Water Propulsion TeamComputer Interface Screening Matrix

Hall Sensor Screening Matrix

Component Potential Failure Mode VOC Potential Failure EffectsSEV

Potential CausesOCC

DET

RPN

Actions Recommended Resp.

What is the test stand or project

component involved?

How can the Component fail?

What Customer Needs are affected by this failure?

What is the impact of this failure?

How

Sev

ere

is

the

effe

ct? What causes the Process Step to go

wrong?

How

oft

en

does

Fai

lure

or

Cau

se o

ccu

r ?

How

wel

l can

yo

u d

etec

t th

e C

ause

or

the

Fai

lure

? What are the actions for reducing the occurrence of the cause, or improving

detection?

Who is Responsible for the recommended

action?

Frame Frame breakingCN5, CN8,

CN9

Frame unusable, frame fails while test

is in progress, personal injury, property

damage

9

Running frame into wall, dropping stand,

too much weight applied, design of frame

and stress tests not robust, lack of

communication between subsystem

designs, inaccurate weight calculation of

parts

5 4 180

State in SOP proper way to transport stand,

have multiple stress tests to cover different

situations, load frame slowly the first time,

visually inspect when fully loaded before first

test

Stephanie/Greg

Project costProject cost exceeds

$1500 budgetCN12

Some desired components can't be

purchased, test stand performance

decreases, can't meet some customer

needs

7

Lack of communication between

subsystem designs, not enough time

spent researching part or process options,

budget is too low

7 3 147

Each subsystem updates current and

expected expenditures weekly, discuss

updated budget weekly

Everyone

Tarp to frame

attachment

Tarp does not maintain

shape, slips off frame

CN2, CN3,

CN5, CN8,

CN10

Excessive time to fill tank, loss of

water, personal injury, property

damage

4Inadequate frame design to contain tarp,

weak eyeholes that attach tarp to frame9 4 144

Reinforce eyeholes and ensure secure

attachment to frame, add extra pieces to

frame and bottom tray to maintain shape,

check strength of eyeholes, test fill tank

before using with wheel

Stephanie/Greg

Motor Drive

Controller

Controller becomes

damaged due to improper

use. Electronics fail.

CN2,CN3 Motor will not work. 9

Missuse of device. Overheating, power

surges from mains. Not properly

moisture/water proofed.

4 4 144

Include preventative measures like fuses,

surge protection. Include proper use of

controller in SOP.

Henny/Ticiano

Motor

Motor can't generate

required wheel speed,

forward propulsion is less

than real life

CN2, CN3

Inaccurate data if used, motor can't be

used, project is delayed, cost is

increased

7

Not enough money for appropriate

motor, choice of motor isn't robust

enough, not enough knowledge of motor

capabilities

5 4 140

Research motor capabilities prior to purchase,

discuss assumptions and needs with

professors before purchase, determine

importance of data accuracy, allocate more

money to motor if necessary

Blaine/Eric

Motor buffering

Lots of vibration

transferred from motor to

stand

CN2, CN3,

CN5, CN8,

CN10

Frame bending/breaking, damage to

electronics, inaccurate data, personal

injury, property damage

8

Motor causes excessive vibration, not

enough buffering between motor and

frame, lack of consideration of motor

running process

4 4 128

Research motor running specs to determine

likely vibration force, design sufficient

buffering/spacers into frame, write procedure

for identifying unsafe running conditions and

stopping process into SOP

Blaine/Eric

Cover over tarpDoes not seal, difficult to

put on and remove

CN2, CN3,

CN5, CN8,

CN10

Leaking of water, increased assembly

time, personal injury, property damage3

Tightly toleranced track, poorly

constructed top6 6 108

Measure track distances and ensure level

welding, double check all measurements and

test before delivering to customer

Stephanie/Greg

Waterproof

protection

Protection wears and

allows water to enter

CN5, CN7,

CN8

Frame rusts, frame strength decreases,

frame breaks, electronics break,

personal injury, property damage

9

No waterproofing, not enough

waterproofing, waterproofing isn't

durable enough

3 2 54

Check waterproof rating of electronics prior

to purchase, paint all metal on frame with

rust-proof paint, install waterproof seals on

tank cover

Stephanie/Greg,

Henny/Ticiano

DAQ Board

No transfer of data. Not

compatible with certain

operating systems.

CN2, CN3,

CN10No data acquisition 8

Not enough testing of the board on

different operating systems. Electronics

fail (overheating, overvoltage, etc.)

2 3 48

Testing of the DAQ board on different

operating systems. Test run with safe settings

to make sure data acquisition work properly.

Include test run in SOP.

Henny/Ticiano

LabView knowledgeEE Team does not know

LabView well

CN2, CN3,

CN10

Programming can't be completed,

project is delayed, some needs/specs

can't be met

5 No prior learning/experience 9 1 45

Test LabView to learn software. Ask

professors for guidance. Have initial programs

checked by professors.

Henny/Ticiano

Bearings Seizure, deformation,

fracture of bearingsCN2, CN3

Power cannot be transmitted through

shaft8

Water in bearings, excessive/unbalanced

loads, misalignment2 2 32

Stress analysis, overdesign, use sealed

bearings, adequate support/number of

bearings, precise alignment

Blaine/Eric

Tarp to tarp

attachment

Does not seal correctly,

rips or tears

CN2, CN3,

CN5, CN8,

CN10

Leaking of water, not able to run test,

personal injury, property damage8

Poor construction using sealer, holes

created from poor storage and/or

assembly for testing

1 4 32

Practice using heat sealer before creating

tank, check all seams before filling,

demonstrate assembly proceedure

Stephanie/Greg

Speed SensorDoes not transmit data,

can't sense vane

CN1, CN3,

CN10

No speed data. No feedback control for

motor control.4

False handling of sensor, wrong wiring,

wrong material for vane2 3 24

Implement using appropriate schematics.

Check that vane material is compatible before

assembly. Double check wiring and test vane

before using. Check and test sensor in safe

operating conditions. Include test run in SOP.

Henny/Ticiano

Frame Frame bending/fracturingCN5, CN8,

CN9

Frame unusable, inaccurate data

provided, frame becomes weaker6

Design of frame and stress tests

inaccurate, too much weight on frame,

vibration from test

1 4 24

Have multiple stress test to cover different

situations. Once built visually inspect frame

when it is fully loaded before beginning test.

Start test at low RPM and visually inspect

before running full test.

Stephanie/Greg

Drive beltBelt snaps, streches, falls

off pulley, slipsCN2, CN3 Power cannot be transmitted to wheel 9

Incorrect distance between pulleys (too

far, too short), misalignment of shafts1 2 18

Precise construction, use grooved timing belt,

design distance between shafts to achieve

correct tension, precise alignment between

shafts

Blaine/Eric

Drive mechanism

structure

Deformation or fracture of

welds or membersCN2, CN3,

CN5, CN8

Shaft breakage, mechanism is not rigid

and does not move as a single piece 8

Torsional force in frame generated by

spinning tire, weight of motor, faulty

welds, resonance in structure

2 1 16

Perform stress analysis, design frame to

withstand forces several times greater (~6x)

than expected

Blaine/Eric

RunnersSeizure, deformation,

fracture of runnersCN2, CN3

Mechanism cannot measure force

generated by wheel8

Water in bearings, excessive/unbalanced

loads2 1 16

Secure lid design, lid to shield drive parts,

design even spacing to balance loads

Blaine/Eric

Secondary shaft and

bearings

Seizure, deformation,

fracture of shaft or

bearings

CN2, CN3 Power cannot be transmitted to wheel 8

Imprecise machining, misalignment in

bearings, water in bearings, excessive

torque/rpm

1 2 16

Precise machining and construction, CNC

machining of custom part, use sealed bearings

Blaine/Eric

Casters Casters breakCN3, CN5,

CN9, CN10

Frame not level and can't move, frame

damage, personal injury, property

damage

5Improper selection of the casters, too

much weight on frame3 1 15

Gathering Detailed information about caster

specs. Once built check condition of casters

before moving or using stand

Stephanie/Greg

Frame welds Welds do not holdCN5, CN8,

CN9, CN10

Frame becomes unusable until fixed,

personal injury, property damage7 Welding process 2 1 14

Check the frame before using it, and test

weldsStephanie/Greg

Motor coupled to

shaft

Shaft misalignment (axial,

parallel, or both)

CN2, CN3,

CN5, CN8,

CN10

Breakage of shaft, coupling, or both,

personal injury, property damage9 Poor construction of drive system 1 1 9

Make shaft alignment top drive system

construction priorityBlaine/Eric

P10225 Mini-Baja Water Propulsion TeamFailure Modes and Effects Analysis

Drive shaft Misalignment in bearings,

bending at pulley

CN2, CN3,

CN5, CN8

Shaft bends or breaks, personal injury,

property damage9

Poor construction of drive system,

inadequate support near pulley, excess

tension in drive belt

1 1 9Make shaft alignment top drive system

construction priority, provide pulley supportBlaine/Eric

Shaft couplingOperation exceeds design

limits

CN2, CN3,

CN5, CN8,

CN10

Coupling breaks, personal injury,

property damage8 Overpowered drive system 1 1 8

Keep operation within torque and rpm limits

of couplingBlaine/Eric

Vinyl or poly tarp Rip or tear

CN2, CN3,

CN5, CN8,

CN10

Leaking of water, will not fill, not able

to run test, personal injury, property

damage

8Inadequate tarp material, careless storage

and/or assembly for testing1 1 8

Order material samples, perform tensile test

on samples before committing to final

material, testing material properties and

warning customer about storage and

construction

Stephanie/Greg

Potential Failure Mode

R

P

N

Actions Recommended Resp. Due Date Plan B

Actions Taken,

Dates of

Completion

Rip or tear 8 Order material samples to test Stephanie/Greg 10/23/2009 Use solid, water-proof tank Samples ordered

on 10/23

Casters break 15 Gather detailed information about caster specs Stephanie/Greg 11/4/2009 Find alternative casters to useDecided not to

use casters

Frame breaking 180 Perform multiple stress tests to cover different situations Stephanie/Greg 11/5/2009 Redesign test standCompleted on

11/03/2009

Frame bending/fracturing 24 Perform multiple stress tests to cover different situations Stephanie/Greg 11/5/2009 Redesign frame structureCompleted on

11/03/2009

Project cost exceeds $1500 budget 147Each subsystem group updates current and expected

expenditures weeklyEveryone 11/20/2009 Ask Dr. Hensel for larger budget

Reviewed budget

twice/week

Project cost exceeds $1500 budget 147 Discuss updated budget weekly Everyone 11/20/2009 Ask Dr. Hensel for larger budgetReviewed budget

twice/week

Motor can't generate required wheel speed,

forward propulsion is less than real life140 Determine importance of data accuracy Blaine/Eric 11/20/2009 Ask Baja if they want accuracy


forward propulsion is less than real life140 Research motor capabilities prior to purchase Blaine/Eric 11/20/2009

Ask Dr. Hensel for larger budget and buy overly-large

motor


forward propulsion is less than real life140 Discuss assumptions and needs with professors before purchase Blaine/Eric 11/20/2009


motor


forward propulsion is less than real life140 Allocate more money to motor if necessary Blaine/Eric 11/20/2009


motor

Deformation or fracture of welds or members 16Design frame to withstand forces several times greater (~6x) than

expectedBlaine/Eric 11/20/2009

Redesign structure with regard to failed element

(loading or resonance)

Completed on

11/05/2009

Deformation or fracture of welds or members 16 Perform stress analysis Blaine/Eric 11/20/2009Redesign structure with regard to failed element

(loading or resonance)

Completed on

11/05/2009

Seizure, deformation, fracture of runners 16 Design secure lid Greg 11/20/2009 Design alternate linear motion mechanism

Seizure, deformation, fracture of runners 16 Attach lid to shield drive parts Blaine/Eric 11/20/2009 Design alternate linear motion mechanism

Seizure, deformation, fracture of runners 16 Design even spacing to balance loads Blaine/Eric 11/20/2009 Design alternate linear motion mechanism

Rip or tear 8Perform tensile test on samples before committing to final

materialStephanie/Greg 12/4/2009 Use solid, water-proof tank

Rip or tear 8 Test material properties before committing to material Stephanie/Greg 12/4/2009 Use solid, water-proof tank

EE Team does not know LabView well 45 Test LabView to learn software Henny/Ticiano 12/11/2009 Use different software to program stand (DaisyLab)

EE Team does not know LabView well 45 Ask professors for guidance Henny/Ticiano 12/11/2009 Use different software to program stand (DaisyLab)

EE Team does not know LabView well 45 Have initial programs checked by professors. Henny/Ticiano 12/11/2009 Use different software to program stand (DaisyLab)

Seizure, deformation, fracture of bearings 32 Perform stress analyssi Blaine/Eric 12/11/2009 Redesign drive system

Seizure, deformation, fracture of bearings 32 Allow for safety factor when designing Blaine/Eric 12/11/2009 Redesign drive system

Seizure, deformation, fracture of bearings 32 Provide adequate support/number of bearings Blaine/Eric 12/11/2009 Redesign drive system

Seizure, deformation, fracture of bearings 32 Test to ensure precise alignment Blaine/Eric 12/11/2009 Redesign drive system

Seizure, deformation, fracture of bearings 32 Use sealed bearings Blaine/Eric 12/11/2009 Redesign drive system

Does not seal correctly, rips or tears 32 Practice using heat sealer before creating tank Stephanie/Greg 12/14/2009 Use solid, water-proof tank

Does not transmit data, can't sense vane 24 Check that vane material is compatible before assembly Henny/Ticiano 12/18/2009 Seek alternative methods like back EMF

Does not transmit data, can't sense vane 24 Check and test sensor in safe operating conditions Henny/Ticiano 12/18/2009 Seek alternative methods like back EMF

Belt snaps, streches, falls off pulley, slips 18 Test to ensure precise construction Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)

Belt snaps, streches, falls off pulley, slips 18 Use grooved timing belt Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)

Belt snaps, streches, falls off pulley, slips 18 Design distance between shafts to achieve correct tension Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)

Belt snaps, streches, falls off pulley, slips 18 Test to ensure precise alignment between shafts Blaine/Eric 12/18/2009 Use alternate drive mechanism (geared shafts)

Seizure, deformation, fracture of shaft or

bearings16 CNC machine customer part to ensure precision Blaine/Eric 12/18/2009 Redesign machined part and/or use stock parts

Seizure, deformation, fracture of shaft or

bearings16 Use sealed bearings Blaine/Eric 12/18/2009 Redesign machined part and/or use stock parts

Welds do not hold 14 Test weld strength before using stand Stephanie/Greg 12/18/2009 Send stand out to be wielded by licensed company

Shaft misalignment (axial, parallel, or both) 9 Make shaft alignment top drive system construction priority Blaine/Eric 12/18/2009 Redesign drive mechanism to allow for misalignment

Misalignment in bearings, bending at pulley 9 Provide support for pulley in design Blaine/Eric 12/18/2009 Redesign drive mechanism to allow for misalignment

Misalignment in bearings, bending at pulley 9 Make shaft alignment top drive system construction priority Blaine/Eric 12/18/2009 Redesign drive mechanism to allow for misalignment

Operation exceeds design limits 8 Keep operation within torque and rpm limits of coupling Blaine/Eric 12/18/2009 Order/fabricate more robust part

Frame breaking 180 Load frame slowly the first time Stephanie/Greg 1/8/2010 Rebuild frame

Frame breaking 180 Visually inspect when fully loaded before first test Stephanie/Greg 1/8/2010 Fix any issues that do not pass visual test

Tarp does not maintain shape, slips off frame 144 Test fill tank before using with wheel Stephanie/Greg 1/8/2010 Use solid, water-proof tank

Controller becomes damaged due to improper

use. Electronics fail.144 Include fuses and surge protection in design Henny/Ticiano 1/8/2010

Needs to be resolved. Failure in implementing

preventative measures can be harzardous to health.

Controller becomes damaged due to improper 144 Include proper use of controller in SOP Henny/Ticiano 1/8/2010 Needs to be resolved. Failure in implementing

Lots of vibration transferred from motor to stand 128 Research motor running specs to determine likely vibration force Blaine/Eric 1/8/2010 Separate motor and frame into separate structures

P10225 Mini-Baja Water Propulsion TeamRisk Mitigation Plan

Lots of vibration transferred from motor to stand 128 Design sufficient buffering and spacers into frame Blaine/Eric 1/8/2010 Separate motor and frame into separate structures

Lots of vibration transferred from motor to stand 128Write procedure for identifying unsafe running conditions and

stopping process into SOPBlaine/Eric 1/8/2010 Separate motor and frame into separate structures

Does not seal, difficult to put on and remove 108 Measure track distances and ensure level welding Stephanie/Greg 1/8/2010 Rework design so it is easier to assemble and seal

Does not seal, difficult to put on and remove 108Double check all measurements and test before delivering to

customerStephanie/Greg 1/8/2010 Rework design so it is easier to assemble and seal

No transfer of data. Not compatible with certain

operating systems.48 Include test run in SOP. Henny/Ticiano 1/8/2010

Begin testing other provided DAQ board. Arduino

Duemilenove is another cheap alternative.

Does not seal correctly, rips or tears 32 Demonstrate assembly proceedure Stephanie/Greg 1/8/2010 Use solid, water-proof tank

Does not transmit data, can't sense vane 24 Implement using appropriate schematics Henny/Ticiano 1/8/2010 Seek alternative methods like back EMF

Does not transmit data, can't sense vane 24 Include test run in SOP. Henny/Ticiano 1/8/2010 Seek alternative methods like back EMF

Frame bending/fracturing 24Once built, visually inspect frame when it is fully loaded before

beginning testStephanie/Greg 1/8/2010 Test stand weight capacity befor running experiment

Frame bending/fracturing 24 Start test at low RPM and visually inspect before running full test. Stephanie/Greg 1/8/2010Start test several times at increasingly higher RPMs

before running full test

Casters break 15Once built, check condition of casters before moving or using

standStephanie/Greg 1/8/2010 Replace casters if broken

Welds do not hold 14 Check frame visually before using it Stephanie/Greg 1/8/2010 Fix any welds that don't pass visual inspection

Does not seal correctly, rips or tears 32 Check all seams before filling tank Stephanie/Greg 1/11/2010 Use solid, water-proof tank

Tarp does not maintain shape, slips off frame 144 Reinforce eyeholes and ensure secure attachment to frame Stephanie/Greg 1/13/2010 Use solid, water-proof tank

Tarp does not maintain shape, slips off frame 144 Add extra pieces to frame and bottom tray to maintain shape Stephanie/Greg 1/13/2010 Use solid, water-proof tank

Tarp does not maintain shape, slips off frame 144 Check strength of eyeholes Stephanie/Greg 1/13/2010 Use solid, water-proof tank

Frame breaking 180 State in SOP proper way to transport stand Stephanie/Greg 1/25/2010 Develop better way to transport stand

Rip or tear 8 Warn customer about storage and construction Stephanie/Greg 1/25/2010 Use solid, water-proof tank

Protection wears and allows water to enter 54 Check waterproof rating of electronics prior to purchase Henny/Ticiano 1/29/2010 Paint all metal and install seals NOW

Protection wears and allows water to enter 54 Paint all metal on frame with rust-proof paint Stephanie/Greg 1/29/2010 Paint all metal and install seals NOW

Protection wears and allows water to enter 54 Install waterproof seals on tank cover Stephanie/Greg 1/29/2010 Paint all metal and install seals NOW


operating systems.48 Test DAQ board on different operating systems Henny/Ticiano 1/29/2010




operating systems.48

Perform test run with safe settings to make sure data acquisition

works properlyHenny/Ticiano 1/29/2010



Does not transmit data, can't sense vane 24 Double check wiring and test vane before using Henny/Ticiano 1/29/2010 Seek alternative methods like back EMF

Subassy Component Name

Number

Needed Specs Product Name Seller Price Resp. Reasons for Choosing

Arm Structure_Drive Axle

Housing1

Low carbon steel, 36" x 3/8" wall

thickness, 1.5" outside diameter#7767T533 Round Tubing McMaster-Carr $ 40.97 Eric

Needed to be large enough in Diameter to House 3/4" Drive Shaft

and Also had to have think enough walls to accomidate Ball

Bearings.

Arm Structure_Swing Arm 1Low carbon steel, 36" x .12" wall

thickness, 1.5" outside diameter#7767T43 Round Tubing McMaster-Carr $ 30.65 Eric Chose large material for base stress calculations.

Arm Structure_Restraint 2 Share Material With Axle Carrier $ - Eric Need to constrain Linear Motion of Axle Housing

Arm Structure_Handle 1Low carbon steel, 36" x .12" wall

thickness, 1.5" outside diameter#7767T43 Round Tubing McMaster-Carr $ - Eric

Will share material with arm structure_Swing Arm. This member

will not see large amount of force and a lighter tubing could be

substituted if available.

Custom Arm Structure

Mounts_Body2 3.25"x4.5"x1.125" Low Carbon Steel #8910K853 Material McMaster-Carr $ 42.22 Eric See Axle Housing Screening Matrix

Custom Arm Structure

Mounts_Bushing2 Bronze Bushing #6381K574 Bronze Bushing McMaster-Carr $ 14.02 Eric See Axle Housing Screening Matrix

Custom Arm

Structure_Nuts and Bolts8

Grade 8 Zinc Plated Bolts and Nuts

Self Locking Nuts

#91286A391

#97135A255McMaster-Carr $ 15.00 Eric See Axle Housing Screening Matrix

Bearings_Linear Motion 12Corrosion Resistant Skateboard

Bearing608ZZ10-1 VXB Bearing $ 7.08 Eric See Linear Motion Screening Matrix

Bolts_Linear Motion 12 Shoulder Bolt 92981A202 McMaster-Carr $ 14.04 Eric See Linear Motion Screening Matrix

Angle_Linear Motion 2 Low Carbon Steel Angle 1/4" Thick Rochester-Steel $ 6.56 Eric See Linear Motion Screening Matrix

Spacers_Linear Motion 48 Steel Spacer 1mm Thick #98055A115 McMaster-Carr $ 8.39 Eric Provides Correct Spacing For Design

Square Tubing_Linear

Motion1 Low Carbon Square Tubing 1"x1" 14 Gauge Rochester-Steel $ 140.00 Eric Adequate Material for Frame

C-Channel_Linear Motion 2 Square U-Channel Rochester-Steel $ 25.00 Eric Required For Design

Position Locking Pin 2 Low Carbon Steel Round Stock .75" Round Stock Material Rochester-Steel 2.00$ Eric Low Cost

Drive Shaft Support

Bearing1 Mounted Ball Bearing 6244K530 McMaster-Carr $ 35.79 Eric

Cost is Cheaper than Stainless Steel; Meets RPM and Load

Requirements

Cross Member for Drive

Shaft Support Bearing

1 Low Carbon Steel Rectangle Bar 10"x1 1/4 3/8" Thick Rochester-Steel $ 1.50 Eric Required to get Drive Shaft Bearing to correct height

Spacer Material 1 Low Carbon Steel1.5" OD 3/8" Wall Thickness Round

TubingRochester-Steel $ 1.00 Eric Spacer Required to Apply Pressure to Tapered Roller Bearings

Drive Axle Housing Bearing 2Hardened Carbon Steel

Sleeves_Flanged_Double Sealed#6384K365 Sealed Ball Bearing McMaster-Carr 19.32$ Eric Bearings Meet Size, Load, and RPM requirements

Seal 1 Shaft Seal #8910K815 MSC $ 4.87 Eric Will protect Bearings From Debris; correct size

Gussets and Tabs 1 1/4" Low Carbon Steel 1/4" Low Carbon Steel Rochester-Steel $ 3.00 Eric Increase Rigidity of Structure

Shaft Material 1 Al 6061 1.5" OD x 1ft length R3112 Metals Depot $ 11.25 Eric Wheel Axle Shaft

Hub 1 Mini Baja Hub Mini Baja Hub Mini Baja $ - Eric Provided by Mini Baja; Stress Calculations already Complete

Axle Carrier 13" OD .5" Wall thickness Low Carbon

SteelRound Tubing Rochester-Steel $ 5.00 Eric

Required To get Wheel Away From Swingarm and to Carry

bearings

Inboard Tapered Roller

Bearing1 Steel 55mm OD 30mm ID #6677K58 Tapered Roller Bearing Mini-Baja $ - Eric Provided by Mini Baja; Meet RPM and Load Requirements

Outboard Tapered Roller

Bearing1 Steel 72mm OD 35mm ID #6677K62 Tapered Roller Bearing Mini-Baja $ - Eric Provided by Mini Baja; Meet RPM and Load Requirements

Driven Pulley 1 Timing Belt Pulley H-Pattern - Steel Goodyear 48H150SK Cross Brothers $ 110.42 Eric See Drive System Screening Matrix

Driven Pulley Hub 1 Timing Belt Pulley Hub Goodyear SK Cross Brothers $ 14.00 Eric See Drive System Screening Matrix

Driver Pulley 1 Timing Belt Pulley H-Pattern - Steel Goodyear 18H150SH Cross Brothers $ 39.66 Eric See Drive System Screening Matrix

Driver Pulley Hub 1 Timing Belt Pulley Hub Goodyear SH Cross Brothers $ 9.00 Eric See Drive System Screening Matrix

Timing Belt 1 Heavy Series Timing Belt Goodyear 780H150 Cross Brothers $ 39.80 Eric See Drive System Screening Matrix

Motor 13 HP DC, max 3500 rpm, 180 volt, 54

lbs3 HP DC Power Equipment Co 400.00$ Blaine Price (low), Power (high)

Wire (For Motor Drive and

Motor)1 12 AWG 12 AWG Steph Malinowski -$ Ticiano Appropriate gauge

Shaft and Coupling 1 72" long, 5/8" dia., full keyway Keyed Shaft and Set Screw Coupling McMaster-Carr 77.00$ Blaine High Strength, matches diameter of motor

Tank Tank Bladder 5 7' L x 4' W x 4' H Poly Tarp tarpsplus.com 90.00$ Greg Bladder to hold water, tear resistant

Frame 1 95' x 1"sq x 11 gauge Square Tube Stock Steel and Surplus 135.00$ Steph Can handle stress, reasonably priced, not too heavy

Liner Structure 3 4'W x 8'L x 3/8"thick Plywood Home Depot 43.35$ Greg Added support for tarp bladder

Window 2 2'W x 4'L x 1/4" thick Acrylic Plexiglass estreetplastics.com 77.98$ GregAbility to see the movement of the water while supporting

bladder

Welding Supplies 1 Spool of filler wire ER70S-6 .030" dia x 2lb spool Mahany Welding 7.00$ Steph Mahany gives discounts to RIT students

Bolts 20 1/2" - 13 x 2 1/4" Stainless Steel Bolts x10 www.fastenal.com 18.00$ Steph Cheap, readily available, will handle possible stresses

Corrosion Protection 6 Spray can paint Rust-o-leum paint Home Depot 24.99$ Steph

Fixtures 8 1-1/4" x 1-1/4" x 1/8" x 1' Angle Iron Steel and Surplus 1.00$ Steph Can handle stress, reasonably priced, not too heavy

Micro-controller (DAQ) 1

Two 10-bit analog outputs, One 32-bit

counter, External trigger input, 12-bit

(DI), 11-bit (SE) resolution, 8 SE or 4 DI

analog inputs, 16 digital I/O lines

MiniLab 1008 USB-1208LS Mr. Wellin -$ Ticiano Free. Capable of required data acquisition.

USB Cable 1 1', B to A connection N/A Mr. Wellin -$ HennyAlready available. Required by DAQ. Standard Computer

Interface.

Testing Software 1 N/A TracerDAQ www.mccdaq.com -$ Ticiano Free. Usefull for initial testing of DAQ's outputs.

Calibration Software 1 N/A InstaCal www.mccdaq.com -$ Ticiano Free. Required by the DAQ.

Data Processing Software 1 Labview Universal Libraries LabView Already on computers -$ HennyOn most computers at RIT, no extra cost for licensing, fairly easy

to program

Hall Sensor 1 handles 2000 rpm Honeywell 4AV16F Vane Sensor www.newark.com 25.12$ Henny Cheaper and less susceptible to dirt

Vane 1 ferrous vane, max 1.02 mm thickness Low-carbon, cold-rolled steel N/A -$ Blaine

Circuit Board 1 4" x 4", epoxy glass Vector Electronics Circuit Board www.alliedelec.com 7.09$ Henny Simple circuit board with sufficient size

Wire 1 28 awg, basic insulation, 100' coil Alphawire #2856/1 WH005 www.alliedelec.com -$ Henny Wire used that is already available at no cost

Load Cell 1 50 lbs, 150% Overprotection. FUTEK LSB300 Mr. Wellin -$ Ticiano Free. In range with estimated requirements (45lb).

Load Cell Voltage

Conditioner1 2mV/V Input, 5/10V Output FUTEK CSG110 Mr. Wellin -$ Ticiano Required by the load cell. Only one model available. Free.

Safety

MeasuresKill Switch Button 1

Fits 7/8in. and 1in. frame or handle

bars. 36in. shielded lead wire with

spade end.

Kill Button Switch www.northerntool.com 10.99$ Ticiano Flashy red button. Looks durable.

Motor Drive Controller 1 3HP, 230VAC in, 180 VDC out, 1PH KBCC-225 www.kbelectronics.com 203.00$ Ticiano Lowest price among DC motor controllers. Adequate specs.

Motor Drive Controller

Accessory1

05V input, 0-10V output, Voltage

Follower isolationSignal Isolation Unit Ticiano Torres -$ Ticiano Free.

Power Supply 1 96-264VAC to 24VDC PSAA15W-240 www.trcelectronics.com 21.00$ Ticiano Required to power the Signal Isolation Unit

Power Supply 1110/120VAC to 220/230VAC

@50/60Hz, 3000Watts

VOD 3000 2 WAY - STEP UP/DOWN

TRANSFORMER

www.voltage-converter-

transformers.com89.99$

Henny,

TicianoAdequate power rating. Relatively inexpensive.

Total

Total + shipping

Sliding

Structure

P10225 Mini-Baja Water Propulsion TeamBill of Materials

1,872.05$

2,021.81$

Data Gathering

Power

Electronics

Drive

Mechanism

Frame

Data Processing

Revised: 11/06/09 RIT KGCOE MSD Program

RIT KGCOE MSD Program Page 1

P10225 Mini-Baja Water Propulsion Team

Test Plans & Test Results

By: Henriette Bullmer, Blaine Byers, Eric Hodgkinson, Stephanie Malinowski, Ticiano Torres Peralta,

Erika Soltis, Greg Wall

Table of Contents

1. MSD I: WKS 8-10 PRELIMINARY TEST PLAN ................................... 2

1.1. Introduction, Overview, Summary, Purpose, History ............................................................ 2

1.2. Project Description, Sub-Systems/ Critical Components Being Tested ............................. 2

1.3. Approval; Guide, Sponsor............................................................................................................ 3

1.4. Test Strategy .................................................................................................................................. 3

1.5. Definitions; Important Terminology; Key Words .................................................................. 6

1.6. References ...................................................................................................................................... 6



P10225 Mini-Baja Water Propulsion Team

Test Plans & Test Results

1. MSD I: WKS 8-10 PRELIMINARY TEST PLAN

1.1. Introduction, Overview, Summary, Purpose, History

1.1.1. Every year, RIT’s Baja SAE club designs a water-land vehicle to compete in

competitions around the world. The goal of this project is to help the Mini-Baja

team create the optimal water propulsion system for powering their vehicle during

the water portions of the competition. The first portion of the project will be to

design and build a testing device to measure the force of the propulsion system.

This will aid in the second part of the project, which will focus on designing and

testing a successful system that can be implemented on the Mini-Baja vehicle.

1.2. Project Description, Sub-Systems/ Critical Components Being Tested

1.2.1. The primary objective of this project is to provide the Mini-Baja team with a

recommendation for the best water propulsion option available within their

constraints. The team will also provide documentation supporting this

recommendation and testing results. To do this, a test stand will be created for

analyzing different water propulsion alternatives.

Water Propulsion Project Subsystem Diagram



1.3. Approval; Guide, Sponsor

Approved by:

Team Members – Henriette Bullmer, Blaine Byers, Eric Hodgkinson, Stephanie Malinowski,

Ticiano Torres Peralta, Erika Soltis, Greg Wall Guide – Professor Chris DeMinco

Sponsor – RIT Mini-Baja Team

1.4. Test Strategy

1. What to test: test number, name, and description

2. How to test: equipment and materials needed, test configurations and procedures, pass/fail

criteria

3. Responsibilities and the approval process

4. Risks and contingencies

1.4.1. Product Specifications

Engr.

Spec. # Source Specification (description)

Unit of

Measure

Marginal

Value

Ideal

Value Comments/Status

ES1 CN5, CN8, CN9 Test Stand Mass (No Water, No Tire) kg 100 70

ES2 CN2, CN3, CN5,

CN6, CN8

Minimum Temperature Test Stand

can withstand C -10 -30

ES3 CN2, CN3, CN5,

CN6, CN8

Maximum Temperature Test Stand

can withstand C 40 50

ES4 CN3 Minimum Wheel Speed RPM 100 50

ES5 CN3, CN5, CN8 Maximum Wheel Speed RPM 600 700

ES6 CN2, CN3 Maximum Error in Wheel Speed

Sensor % 2 1

ES7 CN2, CN3 Minimum Forward Propulsion Force

from Rotating Tire lb 1.1 0.4

ES8 CN2, CN3, CN5,

CN8

Maximum Forward Propulsion Force

from Rotating Tire lb 13.5 15.7

ES9 CN2, CN3 Maximum Acceptable Error in Force

Sensor lb 2 1

ES10 CN2, CN3, CN5,

CN8

Maximum Oscillating Force Test

Stand can withstand lb

From Unbalanced

Tire

ES11 CN2, CN3, CN5,

CN8

Maximum Buoyancy Force Test

Stand can withstand lb 55 110

ES12 Maximum Error in Tire Water Depth inches ±0.79 ±0.59

ES13 CN12 Cost to build $ 1000 1500

ES14 CN1, CN4, CN5,

CN10 Documentation to Baja # pieces 5 5

ES15 CN5, CN6, CN8 Frame Material Strength Factor of

safety 2 3

ES16 CN5, CN7, CN8 Corrosion Resistant years 3 5

ES18 CN4, CN5, CN10 Kill Switch # switches 1 4

ES19 CN5, CN9, CN10 Smooth Edges on Frame # edges 4 8



ES20 CN5, CN7, CN10 Maximum Water Force Tank can

enclose psi 6.81

ES21 CN4, CN5, CN10 Warning Signs # signs 1 5

ES22 CN5, CN10 Button Size in² 0.62 1

ES23 CN6, CN7, CN9,

CN10 Wheels and Casters on Tank # wheels 4 6

ES24 CN6, CN7, CN9,

CN10 Wheels and Casters on Frame # wheels 4 6

ES25 CN9 Test Stand Width feet 4 4

ES26 CN2, CN3, CN5,

CN7, CN8 Water Resistance of Electronics

Resistant

to rain

water

yes yes

ES27 CN4, CN9 Disassemble-able Frame # separate

parts 2 4

ES28 CN2, CN3, CN4 Repeatability # equal

repetitions 5 10

ES29 CN2, CN3, CN4 Maximum sensor calibration error % 2 1

1.4.2. Tests to be Performed

Test # Test Name Test Description Source Subassembly(s)

T1 Hall Sensor Test Verify the correct working of the Hall Sensor ES6 Data Gathering

T2 Labview Data

Acquisition Test

Verify data acquisition through Labview ES14 Data Processing

T3 Motor Control Test

using Labview

Verify the ability to control the motor using Labview ES4, ES5 Power Electronics

T4 Water Holding Test Determine whether the frame and tarp can hold

necessary water

ES20 Frame, Tank

T5 Rail/Runner

Movement Test

Verify that rail/runner system moves smoothly and

unimpeded

ES9, ES28 Drive Mechanism

T6 Shaft Alignment

Test

Verify that drive shaft and motor are properly aligned ES28 Drive Mechanism

T7 Wheel in Water

Test

Ensure that water stays in tank and churn is

manageable when tank wheel is rotated

ES16, S20,

ES26

Drive Mechanism,

Tank

T8 Complete System

Movement Test

Verify that all finished parts are aligned and move

unimpeded

ES28 Drive Mechanism,

Swing Arm, Tank

T9 Structure Natural

Frequency Test

Determine whether oscillating force of unbalanced

tire matches natural frequency of structure

ES10,

ES15

Drive Mechanism,

Swing Arm, Frame

T10 Signal Isolation

Test

Test input and output isolation and signal

amplification of Signal Isolation unit

ES28 Data Gathering

T11 Liner Material Test Determine whether liner material is durable enough ES20 Tank

1.4.3. Test Equipment available

• Clamps (T9)

• Multimeter (T1)

• Load cell (T2)

• Hall sensor (T1,T2, T3)

• DAQ (T2, T3)

• USB cable (T2, T3)



• Computer with Labview (T2,

T3)

• Motor (T3)

• Motor controller (T3)

• Level (T5)

• Protoboard (T10)

• LM741 (x2) (T10)

• 1k resistors (x2) (T10)

•

1.4.4. Test Equipment needed but not available

• Tire balancing machine (T9)

• Unbalanced tire (T9)

1.4.5. Phases of Testing

1.4.5.1. Component/ Device (wks 2-12)

1. Hall Sensor

2. Motor Controller

3. Signal Isolation

1.4.5.2. Subsystem (wks 6-13)

1. Tank Water Holding

2. Rail/Runner Movement

3. Shaft Alignment

1.4.5.3. Integration (wks 11-15)

1. Labview Data Acquisition System

2. Wheel in Water

3. Complete System Movement

4. Structure Natural Frequency

1.4.5.4. Reliability (wks 15-20)

Note: If there is a specification, such as a drop test, out of range voltage or some other form of potentially destructive testing, discuss this with your Guide and Sponsor. As an example, this specification maybe waived depending upon the specific customer needs. • Reliability is the most important characteristic • You can improve reliability by design. • However you may need special test procedure to characterize reliability. • Reliability test procedures are expensive. • Basically reliability test are conducted at elevated stress (electrical, tolerances, temperature ..) levels. Sometimes they are invasive and destructive.

1.4.5.5. Customer Acceptance (wks 20-21) Finally you have to demonstrate the functionality and performance of the System to the customer. You have to develop a Test Plan to demonstrate the critical functional in a step-by-step fashion to prove that it satisfies customer (functional) specifications.

P10225 Water Propulsion System for Mini-Baja

1

Test 1: Hall Sensor Test

Description: This test is designed to verify the correct working of the hall sensor. The hall sensor is

used to detect the rpm of the motor. It consists of a hall sensor attached to a magnet. A ferrous vane, which is attached to the drive shaft of the motor, passes through the opening between the hall sensor and the magnet. This changes the magnetic field, which is detected by the hall sensor and a pulse is sent to the DAQ. The rpm can be calculated by tracking the time between pulses. Start Date: TBD Finish Date: TBD Equipment Needed:

1. Multimeter 2. Hall Sensor 3. Power Supply

Resources Needed:

1. Room Testing Procedure: To test the correct working of the hall sensor, it will be connected according to the wiring diagram and to a multimeter. A ferrous vane will be put in between the sensor and the magnet. Pass/Fail Criteria: The test passes if the voltage read-out on the multimeter changes when the ferrous vane is put in between the sensor and the magnet. If nothing happens, the test fails.

Engineer set-up experiment: Henriette Bullmer Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 3: Motor Control Test using Labview

This test is designed to verify the ability to control the motor using Labview. The motor needs to be able to be adjusted precisely to make the test stand useful. If the rpm are off, the data acquired will be useless. Start Date: TBD Finish Date: TBD Equipment Needed:

1. Motor Control 2. Motor 3. Hall Sensor 4. DAQ 5. USB Cable

Resources Needed:

1. Computer with Labview Testing Procedure: For this test, the motor control will be connected to the DAQ, which will be connected to the computer. The DAQ needs to be tested before this test can be performed. A program will be written in Labview to connect to the motor control, which will control the motor. The test program will involve an on/off button and a ramp-up/ramp-down function. It will also include a dial, which will control the speed of the motor manually. Pass/Fail Criteria: For this test to be successful, the motor needs to respond to the program. A hall sensor will be connected to Labview as well to verify the rpm at the motor. If the controls of the program agree with the output of the hall sensor, this test passes. Engineer set-up experiment: Henriette Bullmer Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 11: Liner Material Validation

Description: Determine whether the material chosen for the liner will be durable enough to withstand

multiple uses as well as the force of the water pulling on it. Start Date: 11/30/09 Finish Date: 12/4/09 Equipment Needed:

1. Tensile Tester

Resources Needed: 1. Liner samples

Testing Procedure: There will be 6 of each sample cut into “dog bones” according to the standard specification. Three of the six will have a small holes placed in the center. All six samples will be pulled using the tensile tester and the data collected will be averaged. Pass/Fail Criteria: If tensile strength is less than 1.73 psi then the sample fails If tensile strength with hole in it is less than 0.86 psi then sample fails

Engineer Performing Experiment: Greg Wall Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 10: Signal Isolation Test

Description: Both simulations and hardware tests of the Signal Isolation unit will be performed. The

goal is to test for input and output isolation and also to test that the signal amplification works correctly. Start Date: 10/30/2009 Finish Date: 11/21/2009 Equipment Needed:

1. Protoboard 2. LM741 x 2 3. 1k resistors x 2 4. 24v Power supply

Resources Needed:

1. Cadence OrCAD & PSPISE Testing Procedure: Amplification will be tested by spanning the whole range of input signals (0 – 5V) and checking for the appropriate output voltage (0 – 10V). Signal isolation will be tested by placing a high voltage source on the output and checking that it does not travel back to the input. Pass/Fail Criteria: Pass: Input signal range of 0 – 5V is linearly amplified to and output range of 0 – 10V. The high voltage of the output test source does not propagate to the input.

Fail: Does not meet the pass criteria. Engineer Performing Experiment: Ticiano Are there any visual defects before testing: Yes No If yes then Explain:

• Test 4: Initial Water Holding Test

Description: Determine that the frame and tarp for the tank can hold the water needed for the test stand

Start Date: 1/11/2010 Finish Date: 1/15/2010 Equipment Needed:

1. Test stand frame 2. Tarp for tank 3. Hardware used to attach tarp to frame

Resources Needed:

1. Source of water 2. Space to perform test in, preferably outside

Testing Procedure: 1. Set up the test stand and attach tarp according to the SOP 2. Start filling the tank with water starting with 6in 3. Wait 10minutes and make sure frame and tarp are holding up to water 4. Repeat steps 2 and 3 until tank is completely full with water Pass/Fail Criteria:

Pass: If the frame is able to withstand the force of the water pushing out on it, and if the tarp is able to hold the water without leaking. Fail: Water leaks out of tarp, or the frame bends, buckles or breaks

Engineer Performing Experiment: Greg Wall and Stephanie Malinowski Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 5: Rail/Runner Movement Test

Description: Verify that the rail/runner system supporting the drive mechanism moves smoothly and

unimpeded.

Start Date: Week 4-5? (with finished stand) Finish Date: Equipment Needed:

1. Finished Stand 2. Level

Resources Needed:

1. Project engineers Testing Procedure: With stand leveled, grab hold of completed and mounted drive mechanism. Move back and forth as long as no binding is detected. Pass/Fail Criteria: Rails move smoothly/rails bind

Engineer Performing Experiment: Blaine Byers Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 6: Shaft Alignment Test

Description: Verify drive shaft and motor are aligned.


1. Finished drive mechanism Resources Needed:

1. Team Engineers Testing Procedure: Turn shaft inside completed assembly with fingers to make sure motion is smooth and does not bind. Attach motor and turn coupled shaft with fingers. Start motor at lowest possible rpm, increase 5% until assembly becomes unstable or target rpm is reached. Pass/Fail Criteria: Shaft spins freely/shaft binds

Engineer Performing Experiment: Blaine Byers Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 2: Labview Data Acquisition Test

This test is designed to verify the data acquisition through Labview. To make the test stand usable for the Baja team, data should be output in graphs using Labview. Start Date: TBD Finish Date: TBD Equipment Needed:

1. Sensors (Load Cell, Hall Sensor) 2. DAQ 3. USB Cable

Resources Needed:

1. Computer with Labview Testing Procedure: The sensors used need to be attached to the DAQ. The DAQ needs to be connected to the computer using the USB cable. The sensors and the DAQ need to be tested separately before the data acquisition test can be started. Once the correct workings of all the sensors and the DAQ are verified, this test can be started. A small program for data acquisition will be written in Labview to get data from the sensors. The data will be output in simple graphs to make sure everything is working correctly. Pass/Fail Criteria: This test fails if the graphs do not display any data. This means the program needs to be modified and the test needs to be rerun. Engineer set-up experiment: Henriette Bullmer Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 7: Wheel in Water

Description: With stand completed and tank filled, observe churn of water and make sure water stays in tank and flow is manageable. Start Date: Week 4-5? (with finished stand) Finish Date: Equipment Needed:

1. Finished Stand Resources Needed:

1. Team engineers Testing Procedure: Fill tank to operating level, start motor turning at lowest possible rpm, increase speed 5% at a time until water action becomes unacceptable or 100% is reached. Pass/Fail Criteria:

Water churn is manageable/is not manageable Engineer Performing Experiment: Blaine Byers Are there any visual defects before testing: Yes No If yes then Explain:_


1

Test 9: Structure Natural Frequency Test

Description: This test is to determine if an unbalanced tire will create an oscillating force that will match the natural frequency of the entire structure. Start Date: Week 4-5 Finish Date: TBD Equipment Needed:

1. Test Stand Structure 2. Clamps to Lock Sliding Frame in Place 3. Unbalanced Tire (1.5 ounces out of balance at rim radius)

Resources Needed:

1. Tire Balancing Machine Testing Procedure:

1. Assemble Stand (Do Not Fill Tank with Water) 2. Put unbalanced Tire on Stand 3. Incrementally increase speed from 0-50 mph. 4. Observe the structure for extreme vibration while going through wheel speed range. 5. If extreme vibration occurs quickly slow the speed of the wheel.

Pass/Fail Criteria: Extreme vibration at a particular wheel speed constitutes failure. Minimum Vibration across entire wheel speed range constitutes passing.

Engineer Performing Experiment: Eric Hodgkinson Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________


1

Test 8: Complete System Movement

Description: Verify that all parts are aligned and move unimpeded in finished form.


1. Finished test stand Resources Needed:

1. Team Engineers Testing Procedure: With drive system completed and mounted (motor, coupling, belt), slowly turn wheel with hand. Pass/Fail Criteria:

All parts spin freely/binding is detected in system Engineer Performing Experiment: Blaine Byers Are there any visual defects before testing: Yes No If yes then Explain:________________________________________________________ ________________________________________________________________________

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