P07203 Dynamometry Laboratory Infrastructure Members: Matt Antonio Project Manager On Board Power (EE) Matt Chabot DAQ, On Board Control, Processing (EE) Eric Chapin External Interface, Instrumentation (ME) Jason Hochman Safety, Configurability (EE) Craig Hupp Structure (ME) Gerald Lim Coupling, Test Fixture (ME) Jeremy Wilson Loading (ME) Sponsor: Dr. Edward Hensel DYNOM TE !

P07203: Project Description Design a dynamometer to: Characterize DC motors Motor with attached transmission Full robot chassis with multiple drive wheels

P07203: Project Description Key Customer Needs / Engineering Specs: Provide characteristic curve Scalable Modular Fully Instrumented Open Source and Open Architecture Compliant with OSHA and all applicable laws/regulations.

P07203: Selected Concept Movable cart with portable treadmill Electronics will be located inside the cart Motor & Transmission components on top of cart Labview interface Fully compliant with safety standards and regulations

Test Fixture and Loading System P7203: Design Concept Test Fixture and Loading System Treadmill Loading System

P7203: Design Concept Brake Caliper Brake Actuator Master Cylinder Load Cell

P7203: Technical Risk Assessment Risk: Braking System Design Uncertainty - 100 kg motor module team shift in motor design - Change in stall torque - 300% decrease Control and Accuracy of Braking Actuation Proposed Mitigation Linear screw device driven stepper motor Design Stall Torque Revised Utilization of Mechanical Friction Brake

P7203: Technical Risk Assessment Risk: Measurement Instrumentation Original Strain gauge design - Inaccurate, inconsistent, and difficult to calibrate More accurate measurements required Scalability required greater measurement range Proposed Mitigation Load Cells - Easily Calibrated - Precise and consistent measurements - Greater Measurement range

P7203: Technical Risk Assessment Risk: Data acquisition of torque measurements Communication with motor - Must send and receive data - Compatibility of user interface and DAQ - Reliable Synchronization of data - Synchronous data collection not feasible Proposed Mitigation Utilize National Instruments data acquisition unit - LabView Interface - Onboard microprocessor Integrate board-to-board communication (PC-104 Stack) Internal data conversion - Introduces a sampling delay - Later analysis proves any delay to be negligible

P7203: Technical Risk Assessment Risk: Power System Motor Module Team Last Minute Modification - Change from 12V to 24V Motor Proposed Mitigation Changes motor controller Modified battery configuration Requires 24V charging capability

P7203: Technical Risk Assessment Risk: Motor Loading Expand the range of testable motors beyond the current scope Proposed Mitigation Purchase more robust load cells Perform additional stress analysis

P7203: Product Development Process Phase Phase 4: Finalize Design / Order parts Phase 6: Finish Final Product Phase 5: Testing and Refinement Phase 0: Planning Sep Oct Nov Dec Jan Feb Phase 1 Phase 2 Phase 3 Phase 1: Concept Development Phase 2: System Level Design Phase 4 Phase 3: Detailed Design MSD I MSD II Phase 5 Phase 6 Phase 0

P07203: Current State of Design Design meets all customer needs Design meets engineering specifications for full system and subsystems On target to meet project budget of $3700

P7203: MSD II Project Schedule Milestones Dec 15 - Design finalized Date - All Parts on Order Date - Design Verification Testing complete, Initiate any design revisions Date - Design Review: Design Verification Testing Results Date - Documentation Finalized: DHF, Formal Paper, Poster Date - Project review – Phase 5 Completion