Integrated System Build and Test

Team Vision for Integrated System Build & Test Phase

What did your team plan to do during this phase?

• Planned to test the cart in its full capacity
• Planned to optimize problems from the problem tracking sheet
• Planned to carry out test plans and update documentation

What did your team actually accomplish during this phase?

• We tracked problems, optimized some, and also found new problems.
• We spent several days outside testing the cart to its full capacity.
• Carried out test plans.
• Began Wind Turbine prototyping.
• Updated risks extensively.

Purchasing update

Some additional materials have been added to our BOM in order to accommodate for the updates and changes that have been occurring during the building phases.

These updates include:

• Screw terminals to prevent wires on the Arduino coming loose
• bigger inductors to generate more electricity for the wobble wind turbines
• Zener diodes to prevent overloading of Arduino pins
• M3 hardware to fasten electronics to the electrical box
• Velcro and a breadboard for the wobble wind turbine box

Problem Tracking

Wobble Wind Turbine Clutter

In order to clear up the clutter of the wobble turbine system, a box was created that holds the breadboard - LED system. The side components on the left will be used to store extra components such as spare inductors, magnets, and rubber bits. The top right compartment will hold spare electrical parts such as resistors and wiring for the breadboard. The breadboard will be wired such that the number of LEDs that light up correspond to how much power is being produced by the wobble turbine. Power lines will be fit through holes on the side of the box to connect the wobble turbine to the breadboard. The box is 3.5 inches wide by 8.5 inches long by 1.5 inches tall. There will be a notch on the right side wall of the electrical box that this box will hang on to / slip in to via the clip in the back. The entirety of the box will be made out of extra acrylic and the parts cut out by a laser cutter. The top of the box (not shown) will be slightly larger than the bottom of the box. The top of the box will connect to the base of the box via velcro. The velcro will line the walls of the base, making for easy removal of the lid whenever needed. The circuit diagram to be used on the breadboard can be seen below:

Where R are resistors and D are the LEDs. If needed, Zener diodes will be added before the LEDs to prevent overload.

The wobble wind turbine can be seen below where it is being testing for amperage.

Currently, the inductors are too small to produce enough power. The design will be slightly modified for the next phase.

Scissor Module Updates

• Lateral stabilization
  • Significant decrease in wobble identified in the previous phase
  • Short term solution made to fit with what we already had built rather than redesigning whole sections of the cart to address the issue
  • Must be removed to collapse cart

• Base panel reinforcement
  • Added holes to bottom panel and rails
  • Minimizes deflection at the end of the panel

Stand Update

• Got rid of the handicap walker

• Cut down legs of handicap walker

• Used specific lengths based on the carts work platform

• Stand is now sturdy and does not slide down under weight

• Able to be stored compactly on bottom of cart

Solar Module Latch Stopper

• Latch kept slipping out of track
• Installed metal bracket to mitigate problem

Jam Nuts Install

• Changes to jam nuts on rollers to mitigate self loosening over time
  

Threaded Connection Location Change

• Moved threaded location to middle of scissor module to ensure threads can be put through both modules

Solar Testing

• Solar Panels were fully set up on cloudy day

• Monitored power generation under cloud cover

• Verified that each panel was contributing equal power

• Solar panels were fully set up on sunny day

• Monitored power generation in direct sunlight

• Generated power, and charged laptops using the inverter and the sun

Electrical Box Update

Test Results Summary

In this phase, on top of collecting data on our solar panel performance, we carried out more of our planned testing. The tests that we conducted were the standing test, tilt test, and the assembly test.

• Standing test
  • Standing alone for more than an hour while using panels to charge battery
  • Required to be able to stand with no assistance
• Assembly test
  • Assembled and functioning from modules in less than five minutes
  • Required to take less than 10 minutes
• Tilt test
  • Stable at 10 degree incline
  • 5 degree incline was required
  • Achieved without some electrical components on the bottom that act as counterweight

Live Testing Spreadsheet

Risk and Problem Tracking

Risks

Eleven risks, 1,3,7,8,11,12,2123,24,25,30,31,33, and 35, were modified, and three risks were removed. These changes can be seen below and the rest of the risks in the following document: Updated Risks MSD II .

The likelihood of risk 1, Covid related university shutdown, was reduced from a 1 to a 0. We are essentially done with the design and do not need to be on campus anymore to finish our work.  The severity of risk 3, Do not fully understand the environment our cart will be placed in, was reduced from a 2 to a 1. We believe that after some modifications to our cart, it is much more durable over rough terrains. The likelihood of risk 7, Inability to access labs, was reduced from a 1 to a 0. We no longer need any lab spaces on campus to finish our remaining work. The likelihood of risk 8, If lots of changes are needed we may not be successful, was reduced from a 1 to a 0. We are essentially done with the design and do not need to make any design changes. The severity of risk 11, Poor analysis from the previous team affected design, was reduced from a 1 to a 0. The previous team's design no longer affects our work.  The severity of risk 12, The cart will not function properly, was reduced from a 3 to a 2. We have set the cart up many times now and know it can withstand most basic forces for a prolonged period of time. Risk 21, communication to the charge controller is too difficult to complete, was removed. We have communication with the charge controller successfully. The likelihood of risk 23, cart does not reach adequate working height, was reduced from a 1 to a 0. We have used the design many times and the height works well. The likelihood of risk 25, scissor lift technology is not effective, was reduced from a 1 to a 0. We know the design works. Risk 30, overcharging and deep discharging the battery was removed. We have implemented into the design that this cannot happen. The likelihood of risk 31, choosing a non adequate roller and track system, was reduced from a 1 to a 0. Our roller system works well.  The severity of risk 33, conflicting customer ideas, was reduced from a 1 to a 0. We are at a point where all ideas are cemented in stone. Risk 34, necessary design changes push us behind schedule, was removed. We have no more required design changes.

Include links to:

• Pre-read
• Presentation
• Notes from review
• Action Items

Plans for next phase

• As a team, where do you want to be in three weeks at your next demo with your customer (if you haven't already done this)?
  • We want to be fully done with the final documentation and creation of the renewable sources.  

Jake Three-Week Plan

Garrett Three-Week Plan

Matt Three-Week Plan

Christian Three-Week Plan