Test Plan Template - EDGEedge.rit.edu/edge/P10225/public/TestPlan.pdf · How to test: equipment and materials needed, ... Results from each test are posted in the test plan, ... T9

Revised: 02/18/10 RIT KGCOE MSD Program

RIT KGCOE MSD Program Page 1 Revision:

P10225 Mini-Baja Water Propulsion Team

Test Plans & Test Results

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

2. MSD II: WKS 2-3 FINAL TEST PLAN ...................................................... 7

2.1. Data Collection Plan ..................................................................................................................... 7

2.2. Work Breakdown Structure ..................................................................................................... 17

3. MSD II: WKS 3-10 DESIGN TEST VERIFICATION ........................... 18

3.1. Test Results .................................................................................................................................. 18

3.2. Logistics and Documentation ................................................................................................... 31

3.3. Definition of a Successful Test, Pass / Fail Criteria .............................................................. 31

3.4. Conclusion or Design Summary ............................................................................................... 31

3.5. Function/ Performance Reviews ............................................................................................. 31



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

1.4.1. Product Specifications

Engr. Spec. #

Source Specification (description) Unit of

Measure Marginal

Value Ideal Value

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


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

ES11 CN2, CN3, CN5, CN8 Maximum Buoyancy Force Test Stand can withstand

lb 55 110

ES12 CN2 Maximum Error in Tire Water Depth inches ±0.5 ±0.25

ES13 CN12 Maximum cost to build $ 2500 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



ES25 CN9 Test Stand Width feet 4 4


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 Component (s)

T1 Liner Material Test

Determine whether liner material is durable enough

ES20 Tank Liner

T2 Hall Sensor Test Verify the correct working of the Hall Sensor ES6 Hall Sensor

T3 Motor Control Test using Labview

Verify the ability to control the motor using Labview

ES4, ES5 Power Electronics

T4 Liner Seal Test Ensure that seals attaching liner material will hold water

ES16, ES26 Tank Liner

T5 Labview Data Acquisition Test

Verify data acquisition through Labview ES14 DAQ, Sensors

T6 Rail/Runner Movement Test

Verify that rail/runner system moves smoothly and unimpeded

ES9, ES28 Drive Mechanism

T7 Shaft Alignment Test

Verify that drive shaft and motor are properly aligned

ES28 Drive Mechanism

T8 Frame Loading Test

Initial test to ensure that frame will support the weight of the drive system

ES1, ES15 Frame, Drive Mechanism

T9 Weld Inspection Test

Visually inspect welds for possible areas of concern prior to loading

ES15, ES19 Frame

T10 Lid Placement Test

Verify that lid fits on the frame and is easily attached and removed

ES26, ES28 Frame, Tank

T11 Eyehole Strength Test

Ensure that eyeholes can support weight of the water on the liner if attached with a bolt

ES16, ES20, ES26 Liner

T12 Water Holding Test

Determine whether the frame and liner can hold necessary water

ES15, ES20 Frame, Tank

T13 Lid Seal Test Determine whether the lid will keep water in the tank

ES16, ES26 Tank

T14 Test Stand Assembly Test

Verify that instructions for assembly test stand in SOP are appropriate

ES14, ES28 Frame, Tank, Drive Mechanism, Sliding Structure

T15 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

T16 Linear Bearing Load Test

Verify that bearing loads are balanced, incorporate counterweights if necessary

ES8, ES10, ES28 Drive Mechanism, Tank

T17 Linear Bearing Twist Test

Verify tension cable location and propulsion force within load cell limits

ES8, ES28 Drive Mechanism, Tank

T18 Complete Drive System

Verify that all finished parts are aligned and move unimpeded

ES28 Drive Mechanism, Sliding



Movement Test Mechanism, Tank

T19 Structure Natural Frequency Test

Determine whether oscillating force of unbalanced tire matches natural frequency of structure

ES10, ES15

Drive Mechanism, Sliding Mechanism, Frame

T20 DAQ Operating System Support Test

Confirm DAQ’s compatibility with Windows XP and Vista

ES14 Data Processing

T21 Electronics Wiring Test

Verify that electronics have been properly wired ES14, ES28 Electronics Hardware

T22 Signal Isolation Test

Test input and output isolation and signal amplification of Signal Isolation unit

ES28 Data Gathering

T23 Stand Grounding Test

Verify that the entire test stand structure is properly grounded

ES18, ES28 Electronics Hardware, Frame

1.4.3. Test Equipment available

Clamps

Multimeter

Load cell

Hall sensor

DAQ

USB cable

Computer with Labview

Motor

Motor controller

Level

Protoboard

LM741 (x2)

1k resistors (x2)

1.4.4. Test Equipment needed but not available

Tire balancing machine (T9)

Unbalanced tire (T9)

Grommet-attachment tool (T15)

1.4.5. Phases of Testing

1.4.5.1. Component/ Device

1. Hall Sensor

2. Motor Controller

3. Signal Isolation

4. Liner Material

5. Eyehole Strength

6. DAQ Operating System Support

1.4.5.2. Subsystem

1. Tank Water Holding

2. Rail/Runner Movement



3. Shaft Alignment

4. Lid Seal

5. Liner Seal

6. Weld Inspection

7. Complete Drive System Movement

1.4.5.3. Integration

1. Labview Data Acquisition System

2. Wheel in Water

3. Linear Bearing Load

4. Linear Bearing Twist

5. Structure Natural Frequency

6. Frame Loading

7. Electronics Wiring

8. Lid Placement

9. Stand Grounding

1.4.5.4. Customer Acceptance

1. Test Stand Assembly



2. MSD II: WKS 2-3 FINAL TEST PLAN

Each test is performed according to its individual test plan. The test plan includes the test name, number, and description, equipment and materials needed, test procedure, and pass/fail criteria. In addition, the team member responsible for each test and the date on which it is completed are listed on the test plan. Tests are performed as soon as is feasible given the test stand build process, in accordance

with the Project Plan. Results from each test are posted in the test plan, immediately following the test plan process.

2.1. Data Collection Plan

2.1.1. Data Collection Structure, Arranged by Test Date

Test # Test Name Test Description Test Date Test Result

T1 Liner Material Test Determine whether liner material is durable enough 11/13/2009 Pass

T2 Hall Sensor Test Verify the correct working of the Hall Sensor 12/4/2009 Pass

T3 Motor Control Test using Labview

Verify the ability to control the motor using Labview 12/4/2009 Fail

T4 Liner Seal Test Ensure that seals attaching liner material will hold water 2/17/2010 Pass

T5 Labview Data Acquisition Test

Verify data acquisition through Labview 1/11/2010 Pass

T6 Rail/Runner Movement Test

Verify that rail/runner system moves smoothly and unimpeded

2/8/2010 Pass

T7 Shaft Alignment Test Verify that drive shaft and motor are properly aligned 2/8/2010 Pass

T8 Frame Loading Test Initial test to ensure that frame will support the weight of the drive system

2/8/2010 Pass

T9 Weld Inspection Test Visually inspect welds for possible areas of concern prior to loading

1/8/2010 Pass

T10 Lid Placement Test Verify that lid fits on the frame and is easily attached and removed

1/29/2010 Pass

T11 Eyehole Strength Test Ensure that eyeholes can support weight of the water on the liner if attached with a bolt

1/22/2010 N/A

T12 Tank Water- Holding Test

Determine whether the frame and liner can hold necessary water

2/17/2010 Pass

T13 Lid Seal Test Determine whether the lid will keep water in the tank 2/17/2010 Pass

T14 Test Stand Assembly Test

Verify that instructions for assembly test stand in SOP are appropriate

2/16/2010 Pass

T15 Wheel in Water Test Ensure that water stays in tank and churn is manageable when tank wheel is rotated

2/17/2010 Pass

T16 Linear Bearing Load Test

Verify that bearing loads are balanced, incorporate counterweights if necessary

2/17/2010 Pass

T17 Linear Bearing Twist Test

Verify tension cable location and propulsion force within load cell limits

2/17/2010 Pass

T18 Complete Drive System Movement Test

Verify that all finished parts are aligned and move unimpeded

2/6/2010 Pass

T19 Structure Natural Frequency Test

Determine whether oscillating force of unbalanced tire matches natural frequency of structure

2/8/2010 Pass

T20 DAQ Operating System Support Test

Confirm DAQ’s compatibility with Windows XP and Vista 2/12/2010 Pass

T21 Electronics Wiring Verify that electronics have been properly wired 2/12/2010 Pass



Test

T22 Signal Isolation Test Test input and output isolation and signal amplification of Signal Isolation unit

12/4/2009 Pass

T23 Stand Grounding Test Verify that the entire test stand structure is properly grounded

2/12/2010 Pass

2.1.2. Test Plans, Arranged by Phases of Testing

2.1.2.1. Component

1. Hall Sensor 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.

Equipment Needed: 1. Multimeter 2. Hall Sensor 3. Power Supply 4. Motor

Testing Procedure: 1. 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.

2. To test that the Hall Sensor is outputting the correct RPM the Hall Sensor will be hooked up to the Data Acquisition System (DAQ, Computer) and the motor is set to a known speed (full speed). The rpm output of the Hall Sensor will be compared to the known speed.

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 and if the known RPM and the hall sensor output are the same. If nothing happens or the RPM measurements don’t agree, the test fails.

2. Motor Controller Description: 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.

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

Testing Procedure: 1. 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.

3. Signal Isolation 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.

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

Testing Procedure: 1. 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.

4. Liner Material 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.

Equipment Needed: 1. Tensile Test Machine

Testing Procedure: 1. 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

5. Eyehole Strength Description: Eye-holes are being put into the tank material so it can be attached securely to the frame. These eyeholes must to support the weight of the water and support being attached to the frame with bolts.

Equipment Needed: 1. Material being used to create the tank 2. Eye-hole material (grommets)



Testing Procedure: 1. Create an eye-hole in a piece of tank material 2. Put equal equivalent force on eye-hole to simulate weight of water

Pass/Fail Criteria: Pass: Eye-hole holds strong while force is being applied, doesn’t pull out or rip the tank material. Fail: Eye-hole rips out of tank material, or rips tank material.

6. DAQ Operating System Support Description: This test is designed to confirm the DAQ’s (UBS-1208LS) compatibility with Windows XP, and Windows Vista. Also, the program will be tested to confirm its compatibility with different versions of LabVIEW.

Equipment Needed: 1. USB-1208LS 2. USB Cable A to B connector

Testing Procedure: 1. IntaCal provides the device drivers to the operating system. Therefore, InstaCal will be

installed on a computer with Windows XP, one with Windows Vista. 2. The USB-1208LS will then be plugged in to each computer, checked if InstaCal has recognized

the device properly, and the test and calibration procedure will be run as an extra confirmation.

3. Finally, the test program will be run on different versions of LabVIEW, including 8.4, 8.5, 8.6, and 8.9, to confirm its compatibility.

Pass/Fail Criteria: *There will be a Pass/Fail rating associated with each version of the program that is tested. Pass: DAQ is supported by at least one of the three operating systems, ideally both. Fail: Does not meet pass criteria.

2.1.2.2. Subsystem

1. Tank Water Holding Description: The purpose of this test is to determine whether the frame and liner for the tank can hold the water needed for the test stand.

Equipment Needed: 1. Test stand frame 2. Liner for tank 3. Hardware used to attach liner to frame

Testing Procedure: 1. Set up the test stand and attach liner according to the SOP 2. Visually inspect all liner seals prior to filling tank 3. Start filling the tank with water, starting with 6 inches deep of water 4. Wait 10 minutes and make sure frame and liner are holding up to water 5. 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 the liner is able to hold the water without leaking



Fail: Water leaks out of liner or the frame bends, buckles or breaks

2. Rail/Runner Movement Description: Verify that the rail/runner system supporting the drive mechanism moves smoothly and unimpeded.

Equipment Needed: 1. Finished Stand 2. Level

Testing Procedure: 1. 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: The test passes if the rails move smoothly. If the rails bind, the test fails.

3. Shaft Alignment Description: This test is designed to verify that the drive shaft and motor are aligned.

Equipment Needed: 1. Finished drive mechanism

Testing Procedure: 1. Turn shaft inside completed assembly with fingers to make sure motion is smooth and does

not bind. 2. Attach motor and turn coupled shaft with fingers. 3. Start motor at lowest possible rpm, increase 5% until assembly becomes unstable or target

rpm is reached. Pass/Fail Criteria: The test passes if the shaft spins freely. If the shaft binds, the test fails.

4. Lid Seal Description: This test is designed to determine the ability of the lid to keep the water in the tank, and prevent water from getting to the electronics.

Equipment Needed: 1. Assembled frame 2. Lid attached to frame

Testing Procedure: 1. Set up tank per SOP and fill tank with water to operating level 2. Put lid on tank according to the SOP 3. Simulate the splashing of water that will be caused by the wheel turning

Pass/Fail Criteria: Pass: If no water escapes though the lid. Fail: If water reaches the areas of the tank where the electronics will be located.



5. Liner Seal Description: This test is designed to ensure that the seals holding the tank material together will be able to hold in the water without leaking.

Equipment Needed: 1. Material being used to create the tank 2. Equipment to test seal strength

Testing Procedure: 1. Seal several pieces of the tank material together 2. Fill with water 3. Inspect that no water is leaking out from seals

Pass/Fail Criteria: Pass: If water stays in sealed pieces of tank material without leaking out. Fail: If any small amount of water comes though the seams of the tank material

6. Weld Inspection Description: This test is designed to visually inspect the welds for possible areas of concern prior to loading.

Equipment Needed: 1. Welded sections of frame 2. Assembled frame 3. Set of eyes

Testing Procedure: 1. Visually inspect the welds of all the pieces of the frame before and after it is assembled to

make sure they were welded correctly and will be able to hold. 2. Re-weld areas that don’t pass, and re-inspect.

Pass/Fail Criteria: Pass if all welds fully penetrate the metal and the welds are not porous.

7. Complete Drive System Movement Description: The purpose of this test is to verify that all parts are aligned and move unimpeded in finished form.

Equipment Needed: 1. Finished test stand

Testing Procedure: 1. With drive system completed and mounted (motor, coupling, belt), slowly turn wheel by

hand.

Pass/Fail Criteria: The test passes if all of the parts spin freely. It fails if binding is detected in the system.



2.1.2.3. Integration

1. Labview Data Acquisition System Description: 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.

Equipment Needed: 1. Sensors (Load Cell, Hall Sensor) 2. (2) DAQs 3. (2) USB Cables

Testing Procedure: 1. The sensors used need to be attached to the DAQ (one sensor to each DAQ). 2. The DAQs needs to be connected to the computer using the USB cables. 3. The sensors and the DAQs need to be tested separately before the data acquisition test can

be started. 4. Once the correct workings of all the sensors and the DAQs are verified, this test can be

started. 5. 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.

2. 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.

Equipment Needed: 1. Completed test stand

Testing Procedure: 1. Fill tank to operating level. 2. Start motor turning at lowest possible rpm. 3. Increase speed 5% at a time until water action becomes unacceptable, belt skips, or

maximum wheel speed is reached.

Pass/Fail Criteria: Pass: Water churn is manageable and belt does not skip Fail: Water churn is not manageable or belt skips

3. Linear Bearing Load Description: This test is designed to verify that unbalanced bearing loads do not impede linear motion of drive system and determine counterweights required to allow free linear motion.

Equipment Needed: 1. Completed test stand

Testing Procedure: 1. With stand completed, tank filled, and tension cable in place, start motor turning at lowest

possible rpm. 2. Increase speed 5% at a time until binding is detected in linear motion of drive system or 100%



speed is reached. 3. If binding is detected, add counterweights to drive structure in 10lb increments to counteract

twisting and repeat until no twisting occurs. Do not exceed 700lb total load on bearings.

Pass/Fail Criteria: Pass if drive mechanism does not bind. Fail if drive mechanism binds and cannot be remedied with counterweights.

4. Linear Bearing Twist Description: This test is designed to verify that the tension cable is in the correct location along the drive frame to keep the linear motion bearings from twisting, and to verify that the propulsion force is within the load cell limits.

Equipment Needed: 1. Completed test stand 2. Tension cable 3. Mechanical strain gauge

Testing Procedure: 4. With stand completed and tank filled, clamp tension cable to drive frame and connect to

mechanical strain gauge attached to frame in place of load cell. 5. Start motor turning at lowest possible rpm. 6. Increase speed 5% at a time until drive structure twist causes bearings to bind, forces become

too great for strain gauge, or 100% speed is reached. 7. If twist is detected, reposition tension cable on drive structure and repeat until no twisting is

occurs.

Pass/Fail Criteria: Pass if drive mechanism does not bind and propulsion forces are in range of the load cell. Fail if drive mechanism binds or propulsion forces are beyond range of load cell.

5. Structure Natural Frequency Description: This test is designed to determine if an unbalanced tire will create an oscillating force that will match the natural frequency of the entire structure.

Equipment Needed: 1. Test stand 2. Clamps to lock sliding frame in place 3. Unbalanced tire (1.5 ounces out of balance at rim radius) 4. 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.



6. Frame Loading Description: The purpose of this test is to trial the frame for the first time to make sure it will support the weight of the drive system.

Equipment Needed: 1. Assembled frame 2. Drive system

Testing Procedure: 1. Slowly add weight to the assembled frame 2. After each addition of weight, visually inspect the frame to make sure it is holding. 3. Once the frame has proven to support the drive system with no issues, test its ability to hold

the weight at different rpms. 4. Continue to increase the weight and the rpms while inspecting the rigidity of the frame until

equivalent weight of total drive system with wheel and fender is reached at maximum speed.

Pass/Fail Criteria: Pass: If the frame stays standing, and doesn’t show signs of buckling or areas that may break. Fail: If frame doesn’t stay standing, or and area starts to shear or bend.

7. Electronics Wiring Description: This test is designed to verify that the electronics have been properly wired.

Equipment Needed: 1. DC Motor 2. KBCC225 (Motor Controller) 3. Signal Isolation Unit 4. PD-2515 (Power Supply) 5. LSB300 (Load Cell) 6. CSG110 (Load Cell Voltage Conditioner) 7. USB-1208LS (DAQ) 8. 10Awg Cable 9. L6-20P (Power Plug) 10. RSC081206 (Electronic Enclosure)

Testing Procedure: The wiring of the electronics will be qualitatively checked to make sure that there are no improperly wired wires and that they are not loose: 1. Power cables will be checked that their connections are secure and insulated to prevent a

person from touching it accidentally. 2. Signal cables and wires will be checked that they are secure. 3. Wires and cables will be checked for appropriate gauge. Power wires should all be 10Awg,

signal wires should be 22-28Awg. 4. Wires and cables will be checked that the insulation is not damaged. If damaged, they will be

replaced or patched. 5. Wires and cables will be checked that they are connected to the appropriate terminals

according to schematics. 6. In addition, twists and loops will be checked for the appropriate radii.

Pass/Fail Criteria: Pass: Wires are secure and electronics are properly wired. Twists and loops have enough radii to not damage the wires. Power connections are sealed properly. Damaged insulation is patched or



the wire is replaced. Fail: Does not meet the pass criteria.

8. Lid Placement Description: This test is designed to visually inspect whether the lid slides onto and off of the frame easily, and fits correctly on the frame.

Equipment Needed: 1. Assembled test stand 2. Lid for test stand

Testing Procedure: 1. Set up the test stand 2. Slide lid onto the test stand 3. Check to make sure all dimensions of the lid are correct, especially gap of track to top

Pass/Fail Criteria: Pass: If the lid slides onto the test stand easily, and everything that needs to be covered by the lid is covered by the lid. Fail: Lid is not the correct size and doesn’t properly fit because it is too big or too small.

9. Stand Grounding Description: This test is designed to verify that the whole test stand structure is properly grounded to reduce the risk of personal injury or equipment damage.

Equipment Needed: 1. Fluke multimeter 2. Assembled test stand

Testing Procedure: 1. Set up the Fluke multimeter in short circuit mode 2. Check that all metal parts of the test stand are short circuited together (i.e. there is a good

electrical connection) 4. Perform this test on every separable section of the stand

Pass/Fail Criteria: Pass: All metal sections of the test stand show a good connection. Fail: Any part of the stand does not show a good connection. If this test fails, any part that does not show a good connection will be bridged with a wire that will ensure a good connection.

2.1.2.4. Customer Acceptance


Description: An assembly procedure will be provided in the SOP giving step by step instructions for putting the test stand together. The purpose of this procedure is to have someone outside the group check over the steps to make sure they are understandable and no steps were missed.

Equipment Needed: 1. All parts of the pieces to the test stand 2. All hardware needed to assemble stand 3. Written section of the SOP explaining how to set up stand



Testing Procedure: 1. Have all the parts needed and SOP out and ready. 2. Give the SOP to the outsiders setting up the stand. 3. Watch them set up the stand and see if there is confusion that needs to be clarified in the

SOP.

Pass/Fail Criteria: Pass: If the stand gets set up correctly Fail: If the stand does not get set up correctly or damage is done to the stand.

2.2. Work Breakdown Structure

2.2.1. Mechanical Tests:

2.2.1.1. Stephanie Malinowski and Greg Wall are responsible for performing all tests related to the tank frame, liner, and lid. These include the following tests:

Liner Material Test

Liner Seal Test

Lid Seal Test

Weld Inspection Test

Frame Loading Test

Lid Placement Test

Tank Water-Holding Test

2.2.1.2. Blaine Byers and Eric Hodgkinson are responsible for performing all tests related to the test stand sliding structure and drive mechanism. These include the following tests:

Rail and Runner Movement Test

Shaft Alignment Test

Wheel in Water Test

Bearing Load Test

Bearing Twist Test

Structure Natural Frequency Test

2.2.2. Electrical Tests:

2.2.2.1. Henriette Bullmer is responsible for performing all tests related to the test stand software. This includes the following tests:

LabVIEW Data Acquisition Test

2.2.2.2. Ticiano Torres Peralta is responsible for performing all tests related to the test stand sensors and hardware. These include the following tests:

Hall Sensor Test

Motor Control Unit Test

Signal Isolation Test

Electronics Wiring Test

Data Acquisition Operating System Support Test



Stand Grounding Test

2.2.3. Integration Tests:

2.2.3.1. The entire Mechanical Engineering team, Blaine Byers, Eric Hodgkinson, Stephanie Malinowski, and Greg Wall, will perform the following test stand integration tests:

Test Stand Assembly Test

Complete Mechanical System Movement Test

3. MSD II: WKS 3-10 DESIGN TEST VERIFICATION

3.1. Test Results

3.1.1. Component

1. Hall Sensor Results: Pass Voltage response was detected at the multi-meter confirming that the sensor is working. Voltage spikes were around the expected 0.4 volts. DAQ counter has strict voltage input requirements, 4 – 5 volts. Hall Sensor voltage will have to be amplified with an operational amplifier with gain of about 10V. Amplification circuit was completed. A gain of 10 V/V was not enough. Thus the gain was increased to a final gain of 17 V/V.

2. Motor Controller Initial Results: Fail Motor control works as expected but the electronic interface will not be possible. Actions Taken: To combat this failure, a mechanical knob will be used to physically control the motor.

3. Signal Isolation Results: Pass

Before Null Offset Adjustment

Signal Voltage In (V) Output Voltage (V)

0 0.100

1.005 2.149

1.990 4.093

3.000 6.104

4.000 8.103

5.000 10.096



After Null Offset Adjustment

Signal Voltage In (V) Output Voltage (V)

0 0.010

1.000 2.020

2.000 4.011

3.000 5.995

4.000 8.013

5.000 10.011

Noise was present but not significant.

4. Liner Material Results: Pass

Clear Vinyl Material Test Results:

Number Inputs: Ambient Temperature 20.3

Number Inputs: Relative Humidity 38.4

Area (cm^2)

Modulus (MPa)

Maximum Load (N)

Tensile stress at Maximum

Load (MPa)

Tensile stress at Break (MPa)

Extension at

Maximum Load (mm)

Extension at Break (Cursor) (mm)

1 0.12903 18.883 232.200 17.996 17.853 225.403 226.319

2 0.12903 21.684 209.691 16.251 15.027 158.072 161.070

3 0.12903 22.565 232.068 17.985 17.302 174.405 177.073

Mean 0.12903 21.044 224.653 17.411 16.727 185.960 188.154

Median 0.12903 21.684 232.068 17.985 17.302 174.405 177.073

Maximum 0.12903 22.565 232.200 17.996 17.853 225.403 226.319

Minimum 0.12903 18.883 209.691 16.251 15.027 158.072 161.070

Standard Deviation

0.00000 1.92263 12.95785 1.00424 1.49801 35.12137 34.00665



Vinyl with Nylon Mesh Material Test Results:

Number Inputs: Ambient Temperature 20.3

Number Inputs: Relative Humidity 38.4

Area (cm^2)

Modulus (MPa)

Maximum Load (N)

Tensile stress at Maximum

Load (MPa)

Tensile stress at Break (MPa)

Extension at

Maximum Load (mm)

Extension at Break (Cursor) (mm)

1 0.07742 66.073 76.215 9.844 3.435 54.152 236.229

2 0.07742 70.322 73.451 9.487 3.537 143.318 272.650

3 0.07742 70.531 83.587 10.797 3.571 351.820 376.901

Mean 0.07742 68.975 77.751 10.043 3.514 183.096 295.260

Median 0.07742 70.322 76.215 9.844 3.537 143.318 272.650

Maximum 0.07742 70.531 83.587 10.797 3.571 351.820 376.901

Minimum 0.07742 66.073 73.451 9.487 3.435 54.152 236.229

Standard

Deviation

0.00000 2.51550 5.23943 0.67676 0.07078 152.76918 73.01068

5. Eyehole Strength

Results: N/A After a liner redesign, it was determined that eyeholes would not be used to attach the liner to the frame. This test was thus unnecessary.

6. DAQ Operating System Support Results: Pass with respect to certain versions, see table below.

OPERATING SYSTEM RESULTS

Windows XP Pass

Windows Vista Pass

Windows 7 Fail

Initially, the test failed for Windows Vista. It was later discovered that this was because .Net Framework was not installed. With this program installed the program functions on Vista.



LABVIEW VERSION RESULTS

LabVIEW Version Pass or Fail Comment

8.4 Fail Program failed to execute

8.5 Pass

8.6 Pass

8.7 Fail Program loaded but gave errors when run.



Instructions were included in the SOP that the program is only run on these versions of LabVIEW. The Baja computer to be used has been checked for compatibility with these versions.

3.1.2. Subsystem

1. Tank Water Holding Results: Pass The tank was filled to ¾ of the way full and was inspected periodically during the fill time. The fill inside of the liner is shown during the fill process in Figure 1, below. The frame was structurally sound during the entire fill process and the liner did not tear or get any holes due to the weight of the water. More than enough water was put into the tank to run the test, and the tank was able to take the force of the water moving during the test.

Figure 1: Liner and Supports with Tank Half Full

2. Rail/Runner Movement Results: Pass Bearing movement was smooth, but bearings on the motor side of the carriage were indenting the aluminum rails.



Actions Taken: More bearings were placed under the motor to allow for more even weight distribution, and a stainless steel plate was added to protect the aluminum from indentation, shown in Figure 2, below.

Figure 2: Stainless Steel Support Plate

3. Shaft Alignment Results: Pass Shaft spins freely by hand as well as by motor.

4. Lid Seal Results: Pass The lid was placed on the test stand while the tire was spinning at a high rate of speed in water. No water escaped from the sides of the tank and the electronics were not in danger of getting wet. The pulley belt sprayed some water onto the top of the lid but this did not endanger the motor or other electronics in any way. Possible Future Steps: Add a shield around the pulley top or remove the lid and let the water fall back into the tank. (The lid was removed during testing and no water splashed out of the tank or towards the electronics).

5. Liner Seal Results: Pass The liner was filled with water until the tank was about ¾ of the way full, as shown in Figure 3, below. The liner was effectively able to hold all the water and none of it leaked out.



Figure 3: Tank Liner Filled with Water

The wheel was then run in the water and the liner was able to contain the water while the test was running. This is illustrated in Figure 4, below.

Figure 4: Tank Liner Containing Water with Wheel Running

6. Weld Inspection Results: Pass All welds were ground smooth, and checked for good penetration and porosity. Two of the welds were porous. They were ground down and re-welded. Welds all passed. Figure 5, below, shows two examples of welds that passed the inspection.



Figure 5: Examples of weld are circled in red

7. Complete Drive System Movement Results: Pass Complete mechanical system moves smoothly and without binding. The complete system is shown in Figures 6 and 7, below.

Figure 6: Wheel Arm (Raised Position)



Figure 7: Motor Coupled to Shaft

3.1.3. Integration

1. Labview Data Acquisition System Results: Pass The load cell graph displayed data which means the data acquisition portion of the test passed. The hall sensor did not display any data but no error has occurred, which can be seen in the ErrMsg box in Figure 8 (circled in red). This means that the hall sensor needs to be tested separately from the data acquisition test again to make sure it functions correctly.

Figure 8: Screen Shot of LabVIEW Window with Data Acquisition Running



2. Wheel in Water Results: Pass Water churn was contained by tank with very little disturbance near the edges. Belt did not skip at any speed for any reason.

Figure 9: Wheel Running in Water

3. Linear Bearing Load Results: Pass Drive mechanism moved smoothly and was unaffected by weight imbalance due to motor.

4. Linear Bearing Twist Results: Pass Drive mechanism movement was smooth and did not bind or twist due to force generated by tire. Force generated by tire did not approach limits of load cell.

5. Structure Natural Frequency Results: Pass The structure exhibited some vibration, likely due to a bent shaft that caused motor movement, not from an unbalanced tire. At lowest speeds, mechanism moves smoothly with little vibration. At around 25% motor power, structure exhibits moderate low frequency vibration. At around 50% motor power (approximate testing speed) vibrations diminish and mechanism exhibits vibration similar to low-speed operation. After several minutes of running at 50% power, the shaft key securing the driver pulley fell out of place. This was likely caused by a slightly bent shaft, causing alternating high/low stress on that



side of the pulley. The shaft was delivered with a slight bend, possibly exacerbated by motor movement, and thus could not be avoided. The vibration issues were remedied by the addition of structural support under the motor.

6. Frame Loading Results: Pass The top cross piece was placed on the frame, as shown below, and the frame proved able to hold the weight.

Figure 10: Weight of Cross Piece on Frame

Then the top cross piece with the drive assembly piece was placed on the frame and it held these pieces without any difficulty, as shown in the figure below.

Figure 11: Weight of Cross Piece and Drive System on Frame

Finally, the top cross piece, drive assembly piece, and motor with wheel were placed on the frame, below, and it was able to support the weight without any visual signs of problems. The wheel was spun at different rpms and the frame was able to handle the vibrations of the motor spinning the tire. Throughout all of the tests, the frame didn’t show any signs of buckling or breaking in any areas.



Figure 12: Weight of Cross Piece, Drive System, and Motor on Frame

Then our group sat on the frame, as shown in the figure below, and it proved able to hold this weight, as well.

Figure 13: Weight of Team Sitting on Frame

7. Electronics Wiring Results: Pass Wires are secured properly to all the electronics, as shown in the figures below. There is no overlapping in the wires close to the connections. All wires were stripped enough to achieve a good connection but not so much that the wires can cross and possibly short circuit. Also, the wires are bundled together for neater routing. The power wires are separated from the signal wires to reduce any noise created in any signal. Finally, there was no apparent damage in any of the wires used.



Figure 14: Insulated Wires Not Overlapping

Figure 15: Wire Connections

Figure 16: Wire Connections

8. Lid Placement Initial Result: Fail The test stand was assembled, and the lid was slid on. The lid slid on but there was too big of a gap in the front of the stand. The lid was not the correct size. This is due to the fact that the lid needs to be 51” wide, but the plywood sheets only came in 48” pieces. The plywood lid was able to support itself without bowing in the middle, however, so it proved to be sufficient material for the lid. Actions Taken: A tarp-type of material was added to the bottom of the lid to help provide water-resistance for the lid and to take up some of the space not completely covered by the lid. Quarter-inch flat stock was used to create inserts for the tarp instead of wood pieces, and brackets were made that can be bolted to the tarp and flat stock and used to support the lid. Final Result: Pass The brackets for the lid were made, as shown in the first figure, below, and the lid was slid back on and retested. With the above actions taken, the lid fit correctly onto the frame. It slid easily onto the frame and was sized correctly for the new requirements, as shown in the second figure.



Figure 17: Lid Bracket and Attachment

Figure 18: Lid on Frame

9. Stand Grounding Initial Result: Fail This qualitative analysis showed that most of the test stand has a good connection. All parts of the main frame have a good connection; all parts of the drive mechanism have a good connection; all electronics parts have a good connection. Issues were found between the connection of the electronics enclosure and main frame and between the main frame and the drive mechanism. The multimeter showed that these connections were not consistent, as movement of the stand caused these connections to break temporarily. Actions Taken: Since the test failed due to the connections between the electronics enclosure and the frame and between the frame and the drive mechanism, grounding wires were installed to bridge these connection gaps and ensure proper grounding. Final Result: Pass The test was repeated with these grounding wires in place and it passed.

3.1.4. Customer Acceptance




Results: Pass The test stand was assembled by 4 younger members of the Baja team. Any of the directions that were unclear to them they pointed out and these were noted and revised in the SOP. Some mistakes were caught, like bolts stating they needed to be 3” when they needed to be 3 ½”. These types of changes were also noted and changed in the SOP. Even with the few unclear steps in the SOP, the test stand was able to be completely assembled in about 45 minutes.

3.2. Logistics and Documentation

The results of all tests are documented on EDGE. All test information is located in the Test Stand Build section of the EDGE homepage, under the heading Test Plans and Results. This page is broken down into individual tests. The results from each test are recorded following the test procedure in the same document.

3.3. Definition of a Successful Test, Pass / Fail Criteria

A successful test is one that meets the Pass Criteria listed in the individual test plan and in the test plan documentation in section 2.1.2, above. If a test does not meet the Pass Criteria, it is considered a failure and must be revised by the responsible team members and re-tested.

3.4. Conclusion or Design Summary

This design was determined to be a success based on adherence to customer needs and the successful completion or remedy of all test plans. These conclusions are reported in the full project report, posted on the project webpage on EDGE.

3.5. Function/ Performance Reviews

3.5.1. Dry Test Run with Sponsor and Guide

The test stand was assembled and run with a used tire from Baja. The tire was run slowly at first, and then accelerated until about 80% capacity. (Baja would routinely run the stand at about 50% capacity.)

It was observed that the stand vibrated slightly at around 30% capacity, then quieted, then began to vibrate significantly above 60% capacity. A Baja team member added weight to the top of the sliding structure and the vibration quieted but did not cease. The team determined that they would add more structural support on the sliding structure to hold the motor in a more stable position. It was also observed that the stand did not vibrate when the tire was removed, so the team decided to try balancing the tire to see whether the unbalanced tire and bent rim were the main contributor to the vibrations.

The customer also commented that there was no drain on the test stand. The design team had intended that the stand be emptied using a large siphon but the Baja members would prefer a drain or spigot. The design team members in charge of the tank will add a drain or spigot for faster, easier water removal during testing.

Finally, the customer noted that the shaft on which the tire is mounted requires a step stool to raise and lower before the tire can be switched. They asked that a rod or rope be attached to



the end of the shaft so it can be manipulated from the ground. The team members in charge of the drive system will implement.

3.5.2. Wet Test Run with Sponsor

For this demonstration, the test stand was assembled with the liner intact and a fender in place above the wheel, with the same used tire from the dry test run. The tire was run slowly at first and then accelerated until about 30% capacity. It was immediately noted that the vibration observed during the last demonstration was completely gone at all speeds.

At 30% speed, approximately 1,170 rpm, the tire stopped accelerating. The motor control knob was turned slowly all the way to 100% capacity, with no change in the speed of the wheel. A significant amount of rubbing was observed between the tire and the fender, though. The team determined that this additional friction, along with the added force required to run the tire in the water versus in air, was causing the motor to hit utilize enough power that it hit the limit switch on the breaker. Because this breaker is set in place to protect the wiring in the building, the limit switch probably cannot be removed. An electrical engineering team member will work to see if there is another way to provide more power to the motor without reaching the breaker limit. In addition, it was recommended to the Baja team that new fenders be designed that do not rub against the tires so much. This will increase the speed of the vehicle in the water, save gasoline, and increase the lifespan of the fenders used.

Initially, the test stand was run with the lid in place. No splashing or leaking occurred around the edges of the lid or anywhere near the motor or electronics. Slight splashing was noted around the pulley, though, where the pulley rotates above the lid. This water only fell in a small area of the lid, though. During the test, in order to show the customer what was happening in the tank, the lid was removed. It was observed that no splashing occurred outside the tank or around the electronics or motor, and that the water brought up by the pulley was able to fall directly back into the tank without dripping. At the highest speed achieved, no splashing occurred. It was recommended, therefore, that the customer run the stand without the lid until further testing necessitates its use.

A draining pump was also given to the customer at this time, in order to empty the tank quickly without needing to cut into the liner to install a drain. The customer was very happy with this solution. The customer was also shown a rope that had been attached to the shaft that raises and lowers the tire. They were also satisfied with this solution, so they would not have to raise and lower the tire from a step stool.

Finally, the LabVIEW program was tested with the running tire. The program was started without incident and the force measurements from the load cell were collected. Unfortunately, the speed measurements from the hall sensor were not working properly. The engineer responsible for the program tested several different methods for processing the speed measurements, without success. She is going to consult with professors and one of the Baja members tomorrow to try to determine a solution.

Documents

Test Plan Template - EDGEedge.rit.edu/edge/P10225/public/TestPlan.pdf · How to test: equipment and materials needed, ... Results from each test are posted in the test plan, ... T9