Test Plan Template - ? Â· How to test: equipment and materials needed, ... Results from each test are posted in the test plan, ... T9 Weld Inspection Test

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  • 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

  • Revised: 02/18/10 RIT KGCOE MSD Program

    RIT KGCOE MSD Program Page 2 Revision:

    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, RITs 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

  • Revised: 02/18/10 RIT KGCOE MSD Program

    RIT KGCOE MSD Program Page 3 Revision:

    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

    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

    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 in 0.62 1

  • Revised: 02/18/10 RIT KGCOE MSD Program

    RIT KGCOE MSD Program Page 4 Revision:

    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 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

  • Revised: 02/18/10 RIT KGCOE MSD Program

    RIT KGCOE MSD Program Page 5 Revision:

    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 DAQs 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

  • Revised: 02/18/10 RIT KGCOE MSD Program

    RIT KGCOE MSD Program Page 6 Revision:

    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

  • Revised: 02/18/10 RIT KGCOE MSD Program

    RIT KGCOE MSD Program Page 7 Revision:

    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 DAQs compatibility with Windows XP and Vista 2/12/2010 Pass

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

  • Revised: 02/18/10 RIT KGCOE MSD Program

    RIT KGCOE MSD Program Page 8 Revision:

    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 D...