engineering requirement test overviewedge.rit.edu/edge/p18310/public/build and test prep/test... ·...

Engineering Requirement Test OverviewTeam # 18310 Team Name: Shake n' BreakDate: 10/302017 Document Owner: N. EhnotRev. #: 1

Post-Build TestsReq. # Eng Requirement Test # Date to Run Complete?ER01 Two Separate, Identical Vibration Systems T01 Feb 28ER02 Low Frequency Sine Wave Operation T02 Feb 28ER03 Single DOF Systems T03 Feb 28ER04 Live Processing And Data Graphing T04 Feb 15ER05 Self Contained Software Package T05 Apr 3ER06 Accurate Vibration Measurement T06 Feb 15ER07 Rugged Design T07 Mar 29ER08 Display Contains Replacement for Wear Susceptible Parts T08 Mar 29ER09 No signal Interference T09 Feb 15ER10 Guarded Moving Parts T10 Mar 22ER11 Aesthetically Pleasing T11 Mar 22

ER12 Switch between technical (Quantitative Data) and non-technical (Qualitative Data) displays T12 Mar 20

ER13 Fully Commented and Explained Code T13 Feb 20ER14 Setup Time < 15 mins for untrained non-technical person T14 Mar 22

Additional TestsTest Name Test # Date to Run Complete?Motor Durability Test TA15 Nov 20ABS Plastic Bonding Test TA16 Jan 23Adafruit NeoPixel LED Strip Test TA17 Jan 23

Satisfactory - Marginal - Unacceptable -

Test # T01, T02, T03 Subsystem: Mechanical Test Name: Vibration Systems TestPerformed By: Date: xx/xx/xxxx Test Conclusion:

SpecificationsER Satisfied Test Time Target Value Marginal Value Unit of Measure Comments

ER01, ER02, ER03 30 minutes 0 +/- 0.1 G Force (g)0 +/- 1 Hertz (Hz)

Equipment Required/State of BuildFully assembled and tuned vibration generation systems for both the TVA and non-TVA system, fully capable dataacquisition and graphical display output, Excel, Matlab, Computer

Testing ObjectiveTo verify the system is generating the predicted vibration, running at predicted speeds, vibrating in only the desireddirection, and vibration mitigation is working as intended

Testing ProcedureOrdered Step Description

1 Plug the power cable into the wall outlet and power box on the display2 Plug the usb into the computer and the display usb port3 Start the software on the computer4 Switch on the power button on the power supply, and the two individual systems via the swtiches5 Tune the display to 10 Hz via the software6 Press the "Collect Data button" on the system interface to collect data for 5 minutes at 10Hz7 Save the data and export to Excel, plot the output force versus time8 Copy the excel data into the columns in the table below 9 Plot a graph of time versus y=(force)*sin(10*x) and overlay this plot on the previous one10 Paste a copy of the graph into the table below11 Visually check graphs and confirm that any differences between the graphs are < 0.1 g and < 1 Hz12 Compare the amplitude and frequency of the collected data to the sine curve, confirm frequency and amplitude match within 1 Hz and 0.1g13 Observe the force output data in the y and z direction data and confirm values are < =/- 0.1 g14 Switch off the two systems, turn off the power supply, close the GUI, and unplug the cables from the system.

Acquired Data & ResultsTime out X force Y Force Z Force Y=Xforce*sin(10*time)

Insert Graph Hereadd rows as needed to inser datra into above columns

Acceptance Criteria: difference in g <0.1 and differences in Hz<1 btween theoretical and actual dataConclusion

Test # T04, T06, T09 Subsystem: Controls, Data ProcessingTest Name: Data Processing & GraphingPerformed By: Stephen, KyleDate: 2/15/2018 Test Conclusion: PASS/ACCEPTABLE


ER04, ER06, ER09 30 minutes 0 *+/- 0.1 G Force (g) *G Force for accelerometer can be confirmed oncefull system is assembled with LORD mounts.0 +/- 1 Hertz (Hz)

Equipment Required/State of BuildElectrical subsystem only, complete with one motor, accelerometer, PC, Arduino program, and created code.This test can be repeated with entire system assembly once applicable.

Testing ObjectiveVerify the system is graphing data as it is produced with minimal lag time, confirm the accuracy and precision of the data,confirm there is minimal impact of signal interference on the sensors


1 Plug the power cable into the wall outlet for DC supply.2 Plug the Arduino MEGA USB into PC USB port.3 Start the MEGA Arduino code (most current revision).4 Ensure proper board and COM port is selected.5 Switch serial to accelerometer. Using hand, lightly impact accelerometer 3-5 times in x direction.6 Confirm the appropriate directional spikes are shown on the data graph display at each impact with no lag7 Confirm there are no unexpected spikes in the data plot that would be the result of noise.8 Take a snapshot of the noiseless output and paste into the data section below9 Confirm that the frequency in the MEGA code is set to 10Hz.10 Switch serial to motor frequency.11 Switch on the DC supply and again confirm that there is no noise in the graphs12 Paste a snapshot of the vibration in the data section below13 Perform the same experiment on a seperate PC. Compare results.14 Include description of necessary action taken to further prevent noise, line reflection, and interference.15 Confirm the difference between the data is negligible on each PC, tolerance +/-1 Hz, *+/- 0.1 g16 Turn off the power supply, disconnect the USB cable to PC.

Acquired Data & Results

Figure 1 - PC1, accelerometer at 0 (not moving). PASS Figure 2 - PC2, accelerometer at 0 (not moving).Spikes on output are limitations on Arduino plotter resolution. Spikes are negligible (see left).Therefore, noise is negligible. No other interference sources detected. No other interference sources detected. PASS

Figure 3 - PC1, accelerometer shaking in X direction. Figure 4 - PC2, accelerometer shaking in X direction.Waveform generated, with no noticable lag/delay. PASS Waveform generated, no noticable lag/delay. PASS

Figure 5 - PC1, Frequency = 10Hz output, measured quantities. Figure 6 - PC2, Frequency = 10Hz, measured quantitesDigital output causes square wave, therefore, take averageof two data points once stable. Avg PASS PASS

10.72 8.58 9.65 Within +/-1 Hz 10.72 8.58 9.65 Within +/-1 Hz

Figure 7 - PC1, Frequency = 10Hz, waveform PASS Figure 8 - PC2, Frequency = 10Hz, waveform PASSno spikes or unwanted interference no spikes or unwanted interferencemotor is stable, holding frequency well motor is stable, holding frequency well

Additional Test Supporting DataLive processing and data graphing: Use of serial data, ability to switch between displaying frequency and acceleration

data, and use of plots confirms that live processing and data graphing is feasible.The GUI will be able to interpret and display this data in a more appealing and efficient manner once completed.

Line Reflection: Per Adafruit's website, they reccommend using a 470ohm resistor on the same wire that passes data. This prevents reflection in the wire, causing unwanted ringing that can causeunpredictable behavior. We utilized this in our tests for the accelerometer and rotary encoderon the motor, producing clean data for the Arduino serial plots. This can be referenced below:Note: Adafruit's product is the LEDs that we are utlizing (TA17). However, this practice isuseful in all applications regarding serial data from the Arduino. LINK

Accelerometer Tolerance: The accelerometers used in this test have a range of +/- 200 g, which is significantlymore than we anticipate for our system. These will be used until the full system is tested with the LORD mounts. Once the actual G force measurement is taken,we will order new accelerometers to better display the force generated, giving moreresolution in the plotting points for our GUI. Therefore, G force measurement is not needed in this test until this is possible. But we can confirm that the use of the accelerometer is accurate and stable with no delay from sensor to PC.

Use of 2 PCs: The use of two PCs in this experiment compare noise measurements and reliablility of the codebetween two seperate machines. Since it is expeceted that multiple laptops will have the self-contained software installed, it is important to test these functions on multiple PCs.

Acceptance Criteria: Appropriate directional spikes are registered by accelerometer upon impact with no recognisable lag

https://learn.adafruit.com/adafruit-neopixel-uberguide/basic-connections

no noise registered in data, freq. output within 1 Hz.Conclusion

Live processing and data graphing: PASS Notes: Use of Arduino serial plotter and monitor successfulAccurate Vibration Measurement: ACCEPTABLE Notes: No lag during shaking, acceptable, a new device will be

chosen for specfic G force range when full system assembled.No Signal Interference: PASS Notes: system noise free, changing PCs did not change interference

Test # T05, T12, T13 Subsystem: ProcessingTest Name: Data Processing & GraphingPerformed By: Date: xx/xx/xxxx Test Conclusion:


ER05, ER12, ER13 30 minutes yes yes Binary (y/n)

Equipment Required/State of BuildFully assembled and tuned vibration generation systems for both the TVA and non-TVA system, Completed electronics subsystem and finished user interface/data processing subsystem, computer other than the one the program was designed on, 3 to 5 technical people who are willing to review the program's code

Testing ObjectiveVerify that the program runs as a standalone requiring no additional resources, can be modified to hide or displaytechnical data with a single button push and is written in code which can be understood by a technical person.


1 Copy the single program executable file from the computer it was programmed onto a different windows computer2 Set up the electronics of the display per the written instructions using the new computer with the copied .exe3 Run the software from the new computer and confirm that the interface loads and displays properly4 Start the display's mechanical systems per the written instructions5 Confirm the live graphing functionality is working properly6 Press the button on the user interface to toggle between technical and non-technical views, confirm functionality works7 Shut down the display per the normal process8 Have the 3 - 5 people identified for this test individually open the program code per the troubleshooting instructions9 Have the people read through the code at their own pace (no more than 15 mins) and comment on their confidence

in being able to modify the code, if given time to research specific functions used.10 Have the people close and save the code without making changes

Acquired Data & ResultsTime to review instructions Confidence range Acceptance Criteria: GUI can be launched from one executable,[minutes] [1 poor -10 excellent] GUI can be switched between a basic and technical view

Subject 1 Confidence ratings average 8.0 or higherSubject 2Subject 3

Subject 4Conclusion

Test # T07, T08 Subsystem: MechanicalTest Name: Design Ruggedness and LongevityPerformed By: Date: xx/xx/xxxx Test Conclusion:

SpecificationsER Satisfied Test Time Target Value Marginal Value Unit of Measure CommentsER07, ER08 10hr x 4day 0 +/-0.1 frequency (Hz) Allowable drop in cycles per second during testing

No wear No wear visual wearRoom Temp Warm to Touch Relative Temp216 million 216 million Cycles Components designed to live greater than # cycles*Number of cycles count assumes 15Hz operation @10hr/day x 4days x 10shows/year for 10 years

Equipment Required/State of BuildFully assembled and tuned vibration generation systems for both the TVA and non-TVA system, fully capable dataacquisition and graphical display output, Excel, thermometer

Testing ObjectiveVerify that all components are robust enough to survive a full tradeshow and are expected to last the duration of the display's expectedlife. Any parts that fall below this standard must have spare parts included which can be easily and cheaply replaced


1 Plug the power cable into the wall outlet and power box on the display2 Plug the usb into the computer and the display usb port3 Start the software on the computer, take temperature of room4 Switch on the power button on the power supply, and the two individual systems via the swtiches, record start time5 Tune the display to 10 Hz via the software6 Take 3 minutes of data once the display is running and export to Excel7 Leave the display running for 10 hours8 Take 3 minutes of data and export the data to Excel at the end of the 10 hours9 Shut down the system per the written instructions (do not disassemble)10 Record motor temperatuere with thermocouple paired with the thermocouple reader11 Inspect the display and make note of any visible wear12 Restart the system at the same time on the next day as it was started on the day previous13 Repeat steps 2-9 until 4 consecutive days worth of data has been logged to Excel (24 total minutes of data)14 Plot the data in Excel and record any change in the driving frequency or resonance of the system15 For mechanical components subject to rotational/translational motion, confirm expected life > 216 million cycles


Start Time End TimeRoom temperature

After: Motor Temperature

After: Piston Temperature Wear

[am pm] [am pm] C C C [1 new - 5 used]Day 1Day 2Day 3Day 4

Acceptance Criteria: Successful competiton of runs with no breakage, temps <140F, Wear = 1Conclusion

Test # T10, T11, T14 Subsystem: MechanicalTest Name: User FriendlinessPerformed By: Date: xx/xx/xxxx Test Conclusion:


ER10, ER11, ER14 40 mins/person 10 8 Points system User rates aesthetics on 1-10 scale (10=best)0 0 Hazards User looks over the display and identifies potential safety hazards

<10 <15 Minutes User time for setup and teardown (each)Equipment Required/State of Build

Fully assembled and tuned vibration generation systems for both the TVA and non-TVA system, fully capable dataacquisition and graphical display output, 3-5 individuals from non-technical, mildly technical, and technical backgrounds, stopwatch

Testing ObjectiveVerify that the display is aesthetically attractive to a wide audience, does not contain any hazards for people who may not be familiar with operationand does not take longer than 15 minutes to be set up or torn down by an unfamiliar individual


1 For each person, begin with the display fully packed for shipping2 Time the person while they set up the display, including the reading of printed instructions, stopping when the display is running properly3 Have the person look at the display closely and identify any potential hazards they can find being unfamiliar with the display4 Have the person step back 5-10 feet from the display and rate the aesthetics and attractiveness of the display5 Have the person comment on the visibility of the vibration from 5-10 feet6 Time the person while they disassemble the display including reading any instructions, stopping when the display has be repacked properly

Acquired Data & ResultsTime to setup Hazards Attractiveness Visibility Disassemble Acceptance criteria: Setup and disassembly

time <15 minutes, Hazard, visibility, attractiveness ratings = 1

[minutes] [1 low - 5 high] [1 good - 5 poor] [1 good - 5 poor] [minutes]Subject 1Subject 2Subject 3

Conclusion

Test # TA15 Subsystem: ElectricalTest Name: Motor DurabilityPerformed By: Kyle KellyDate: 11/20/2017 Test Conclusion:


ER07

8 days, 10 hours per day 0.5 2 % Pulse width duty cycle at the end of test vs the begging of test (percent error)

8 days, 10 hours per day 0.5 2 % Motor frequency at the end of test vs the begging of test (percent error)

8 days, 10 hours per day 0.5 2 % Current draw of motor shield at the end of test vs the beginning of test (percent error)

Equipment Required/State of BuildTwo identical motors chosen to satisfy design requirements, a microcontroller and motor shield/driver that supply sufficient power to the chosen motors, rotary encoders (if not already incorporated into the motor chosen), a power supply (capable of supplying sufficient voltage and current required by the motor shield) and a computer or device capable of recording the data. A script that will control the speed of the motors and capture the information from the rotary encoder. A multimeter to record the current drawn from the power supply and to verify the supply voltage stays constant.

Testing ObjectiveMeasure the deterioration rate of the motors, driver shield and power supply. Since the motor is required to run constantly for 10 hours a day, 4 days in a row, it is essential that the motor be consistent and robust. As the motor wears, certain will change, resulting in a different range of pulse width duty cycle in order to maintain frequency. Ensuring the motor is operating in the mid range (50% duty cycle) allows for confidence in the longevity of the system.


1 Follow the electrical drawings in order to wire up the motor/encoder circuit correctly. The drawing is specific to the requirements based off of the motor selected. Any change in the motor will potentially result in different requirements for the devices chosen.

2Program the microcontroller selected to control the motor and provide the frequency and duty cycle as an output. If a microcontroller based on C/C++ is used, the script provided will suffice. Depending on the motor and motor shield characteristics, the values chosen in the script may have to be altered.

3 Power up the system and let the motor warm up (say 10 minutes). Record the frequency and duty cycle of the motor and the current drawn from the motor shield . This will be the baseline values used to determine wear.

4 At the end of the day (10 hours later) record the same information. 5 Record the values every day to get an idea of how the test is going and allow for a graphical representation.6 On the eighth day, calculate the percent in change from the baseline values.


Conclusion

Test # TA16 Subsystem: Electrical BoxTest Name: ABS Plastic Bonding TestPerformed By: Shayne Hollands, Connor Jensen, Nathan EhnotDate: 1/23/2018 Test Conclusion: Exceeded Expectations - Max weight > 8 kg (Nominal Value 2 kg)

SpecificationsTest Purpose Test Time Target Value Marginal Value Unit of Measure CommentsDetermine if

epoxy is robust enough to be used for box constuction

2 hrs prep time24 hrs curing time2 hrs test time

2 kg weight supported or greater

1.5 kg weight supported or greater

kilograms Two different samples were run. 3 sets of 3.5" x 3.5" ABS corner angles and two sets of 3" x 3" corner angles

Equipment Required/State of BuildTwo part epoxy 7524A13, disposable mixing tool, disposable mixing tray, clean microfiber towels, rubbing alcohol, parts to be joined, 100-180 grit sandpaper, clamps and stands necessary for holding parts in proper orientation and to keep the joint under light pressure, band saw, drill press/milling machine, hanging scale, masses

Testing ObjectiveThis test will be used to determine whether or not ABS epoxy is a valid method or assembling the electrical box components. Consult the specific instructions included with the epoxy 7524A13 from McMaster-Carr before use. The included instructions are to be followed in addition to the procedures listed in this testing document.


1Obtain two ABS pieces to be joined for testing, the sides to be joined should be at least 3 inches in length and be joined at a 90 degree angle. The length of the piece from the joined edge should be at least 3 inches. For this testing six 3.5" x 3.5" pieces were joined @ 90 degree angle to make three angle brackets and four 3" x 3" pieces were joined @ 90 degrees to make two angle brackets.

2 ABS plastic pieces should have a 1/4" hole drilled one inch from the side opposite the joining, centered on the piece which will be used for mounting the weights

3 Edges to be joined should be milled flat and deburred, then roughed manually in multiple directions with 180 grit sandpaper4 Pieces should be thouroughly wiped down with rubbing alcohol and a microfiber towel to remove any particles foreign to the plastic piece

5Follow the Epoxy Application Procedure 1.0 as defined on the Edge document to join the two ABS components together. Equal length beads of Epoxy and hardener were mixed by plastic fork on a piece of cardboard until a uniform color was reached. The mixture was then spread thinly on both surfaces to be joined.Wait a full 24 hours for the epoxy to cure before handling the parts

10 Separate two of the brackets to perform a drop test. Place the bracket on a flat surface with Epoxy joint facing up.11 Drop weights onto the Epoxy joint at increasing heights until part breaks, record height at which part broke in table.

6 Clamp the remainder of the parts off the ground by the longer side of the bracket (the side that does not have the hole in it) so that the drilled hole is facing downward.

7 In a series of 200g increments, hang weights from the hole in the clamped ABS bracket. Allow approx 1-2 minutes for each mass increase to determine if any deformation of the part has begun. Record observation in table below.

8 Continue adding weights until the part breaks, or no more weights are available in the mass set, whichever comes first. Mark the point at which the part breaks in the table below.

9 Record the last mass successfully held in the below tableAcquired Data & Results

Testing DataPart Part Type Part Flexure / Deformation / Break ObservationsA 3.5"x3.5" Static Load Test - Minor Flexure Noticed @ 500g - Flexure from ABS Plastic not Epoxy JointB 3.5"x3.5" Static Load Test - Flexure Noticed @ 500g, Tested to 18 lb (8.164 kg) - Passed, Broke on high impactC 3"x3" Drop Test - 5lb from 3.75 in above bracket - Broke at Epoxy JointD 3.5"x3.5" Drop Test - 2lb from 5.25 in above bracket - Passed, Broke @ 2lb @ 9.25" dropE 3"x3" Static Load Test - 160 lb person standing test - Break at estimated 1/4 weight (40lb)

Left: All Test Samples

Near Right: Test Sample with 5lb weight

Far Right: Test Sample with 15lb weight

By estimating the amount of flexure possible for the joint to withstand without breaking as .5 inches, and using the data from Sample D @ 5.25 inches drop height and 9.25 inches drop height, the force that the epoxy joint withstood is estimated at 36 lb and the force at which it broke is estimated at 45lb.

ConclusionThe epoxy held significantly stronger than what was expected. We were unable to break any of the ABS brackets in static loading. The maximum weight held by a bracket was 18lb (8.164 kg), and this was limited by the number of weights we could fit onto our test rig. The brackets were able to be broken by dropping weights from a height directly onto the Epoxy joint and using this method we estimated a withstod force of 35lb. This is more than acceptable, as the joints in the EE Box will be much longer (more surface area for epoxy adhesion) and will be oriented into a 3D Box shape, which will be much more structurally stable than a cantilevered bracket.

Test # TA17 Subsystem: ElectricalTest Name: Adafruit NeoPixel LED Strip TestPerformed By: Stephen GiordanoDate: 1/23/2018 Test Conclusion: Exceeded Expectation - LEDs individually addressable w/color

SpecificationsTest Purpose Test Time Target Value Marginal Value Unit of Measure Comments

Determine how to assign colors

to LEDs via Arduino code

4 hours

LEDs individually assignable with different colors

LED strip can be assigned single color

Observation

Equipment Required/State of BuildArduino Uno/Mega microcontroller, 470ohm resistor (optional but recommended), 1000uF capacitor (optional), Wire of various lengths, Power supply, NeoPixel LED Strip, Arduino Software (free)

Testing ObjectiveThis document provides the reader with insight about the use of the Adafruit NeoPixel LED Strip, and tips on how to implement them into the final self contained software package with commented code listed in Engineering Requirement ER5 and ER13. To utilize this document, it is assumed the user already has knowledge of installing and using the Arduino software, and installed the NeoPixel libraries as needed. Steps for library installation can be found here, or from the URL in the appendix.


1 Wire up arduino microcontroller, resistor, capacitor, and NeoPixel strip seen in the figure below.2 Download and open the Arduino_NeoPixel_01.ino file from the Code folder in Google Drive.3 Power Arduino through USB.4 lash the microcontroller without the leds connected to the 5V pin.

5

Disconnect USB, connect LED to 5V pin, and turn on Power supply. LED script should run. (External supply recommended due to the 60mA each NeoPixel draws at full brightness. The Arduino 5V pin only supplies a max of 500mA, and will shut down if exceeded. This also simulates how the strip will be used on the final project build.)

Acquired Data & ResultsThe commented code for the LED demo pattern is below:

ConclusionThe LEDs work as intended and can be implemented within the final code for this project, and give the user endless possibilities for color customization and visual appearance of the trade show display.AppendixLibrary installation URL: https://learn.adafruit.com/adafruit-neopixel-uberguide/arduino-library-installationSetup URL reference:https://learn.adafruit.com/adafruit-neopixel-uberguide/basic-connections

https://learn.adafruit.com/adafruit-neopixel-uberguide/arduino-library-installation

https://learn.adafruit.com/adafruit-neopixel-uberguide/basic-connections

engineering requirement test overviewedge.rit.edu/edge/p18310/public/build and test prep/test... ·...

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