1. P16221 – FSAE Shock Dynamometer Detailed Design Review December 8, 2015

2. Aung Toe – EE Jim Holmes – EE – Project Manager Sal Fava – ME – Chief Engineer Chris Batorski – ME – Facilitator Andrew Dodd – ISE P16221 – MSD Team

3. Address concerns from PDDR Safety Considerations and Test plans Engineering Spec Updates Current Bill of Materials Model Overview Mechanical Systems Analysis Electrical Schematics Risk Management Project Plan Agenda

4. What is the timing on getting money? – $1250 total between Baja and Hotwheelz Is the table cheaper to make than buy? – Purchased table will not meet our requirements How did you come to 350lb marginal, 500 lb ideal weight? – 350lbs are FSAE shock specifications, 500lbs is example of sport automotive damper What is the factor of safety in isolator sizing? – 1.5 as defined by ratio of natural frequency of rig to natural frequency of isolator Questions from PDDR

5. Hire electrician for 208V – Motor circuit is finished, working with ME shop Test plans using function generator for data transfer – Will generate random data from micro to pc to test transfer rates Develop an Engineering Analysis vs. Risk vs. Verification Test metric to make sure everything is covered. – Updated continuously (discussed later in presentation) Issues from PDDR

6. Do you need to monitor motor temperature? – Generates more heat under load Thermocouple for validation testing Temp sticker during normal operation Will have an electric fan instead of mechanical to deal with heat What do you most worry about the project? – Items highlighted on risk assessment Expectations for this review (addressed throughout) – Test plans Testing implies some level of confidence How you are going to stress the system beyond design intent Start thinking how and what data to test Questions from PDDR

7. System Level Design Flowchart

8. Mechanical Test (MT) – MT1: Planned to occur after base manufacturing and assembly is complete – MT2: Planned to occur once full test stand is assembled Electrical Test (ET) – ET1: Safety circuit test to occur before any full system testing begins – ET2: Sensor testing scheduled for after system is assembled (initial bench tests are also included) Program Test (PT) – PT1: Program communications and data saving test Test Plans Full System Tests

9. Test Plans Corresponding Eng. Rqmts.

10. Goals of sub-system: – Protect user from serious damper failure – Not impede user activities within working zone – Low cost Important features – Enclosure – Emergency Stop Switch – Door Interlock – Safety Circuit Subsystem Design Safety

11. Major Components Aluminum Extrusion Frame – Minitec 45x45 F Plastic Shielding – Polycarbonate sheeting Door Safety Latch Safety Circuit – test plan test plan Interfaces Test stand base – Bolted to base Work Area – Surrounds the masts and test area Emergency Stop Switch – Will be mounted to the frame Safety Sub-System Overview

12. Overall Dimensions – Height: 48 in – Depth: 12 in – Width: 36 in Bolted to table – 8X 5/16-18 Bolts Held together with custom designed brackets – An effort to reduce cost of the system Safety System Enclosure Design

13. Overall Dimensions – Height: 46 in – Depth: 12 in – Width: 32 in Currently Designed with Standard MiniTec hinges and handles – Could replace with custom parts Safety System Door Design

14. Top Plate – Used to hold top of enclosure to the uprights – Thickness: ¼ in – Material: Aluminum Bottom Plate – Bolts the enclosure assembly to the test stand – Thickness: 7/16 in – Material: Aluminum Safety System Custom Plates

15. Used to lock the enclosure when test is being run IDEM 16.5mm Mount – Safety Switch: $29.50 – Actuator Key: $11.50 Available from Automation Direct Safety System Door Interlock

16. MiniTec 45x45 Extrusion Lengths – 49” QTY: 4Part: Uprights – 32.456” QTY: 2Part: Front and Rear Cross – 8.456”QTY: 2Part: Left and Right Cross – 28.519”QTY: 2Part: Door Top and Bottom – 46.978QTY: 2Part: Door Left and Right – Minimum Total Length: 35’ 9” Polycarbonate Sheeting 5/16” thick – 47.83” x 33.66”QTY: 1Part: Back Shield – 47.83” x 9.66”QTY: 2Part: Left and Right Shields – 33.66” x 9.66”QTY: 1Part: Top Shield – 44.63” x 29.72”QTY: 1Part: Door Shield – Minimum Total Area: 4185 in 2 ( less than 5’ x 6’ sheet ) Safety System Manufacturing Cut List

17. Engineering Requirements

18. BOM

19. Overall System Geometry From SSLDR From PDDR DDR

20. DDR Geometry

21. 350lb marginal, 500lb ideal vertical force through the actuator, damper and into the crossbar FOS of 2 used in all calculations Design for stress levels under the endurance limit, infinite fatigue life Welded structure Knockdowns – Aluminum weld-area strength= 0.5 base material – Steel weld-area strength= 0.8 base material Ideally every component in a system would have Margin=0 – Positive = over-designed – Negative = under designed Review of Load Cases/Constraints

22. Analysis: Isolator Sizing Efficiency: Isolator Sizing – Initially took 1 evening, could repeat in 1 hour.

23. Beam deflection Applied LoadP[lb]500 factor of safetyXs[-]2 LengthL[in]36 ModulusE[lb/in2]2.9000E+07 baseb[in]2 heighth[in]4 wall thicknesst[in]0.1875 Moment of inertiaI[in4]2.2966E+00 motor mount deflectiondelta[in]7.2970E-03 side bar deflectiondelta[in]7.2970E-03 Total base deflectiondelta[in]0.014594

24. Analysis: Clamp Load

25. Actuation Assy

26. NICE ball bearings – RBC 3030 Meet dynamic load rating with FOS>2 on ideal spec Sealed Bearing Selection

27. Check for Buckling

28. High Impulse load of 1730lbf including force from motor Possibly use a shear keyway to protect motor Impulse

29. Actuator rail binding test – No product specs on side load Isolator sizing test – Weigh the completed system for the foot isolators – Weigh all electronics for mount sizing System deflection test – Use dial indicators Electric motor fan sizing – Measure CFM output Anemometer Mechanical Test Plans

30. Finish prints Complete hardware order Complete stock order Touch up model Look into shear keyway vs electrical failsafe Mechanical to do for Gate Review

31. Monitor Safety Circuit Loop Collect Sensor Data – Temperature – Force – Position – Time Send/Receive data via UART Motor Control System Software Features

32. Arduino Dataflow

33. TI ISO124 Analog Isolator

34. VISHAY CNY17 Digital Isolator

35. Electrical System Schematic

36. Electrical Wiring Schematic

37. Serial Interface Test

38. IR sensor test Proof of Concept: Testing so far

39. Analog Isolation Digital Isolation Motor Drive Load Cell – Resolution Tests Planned

40. Goals of Subsystem – Provide user with a way to control and program the test stand – Post processes the raw data and saves it in.csv format Important Features – Car Parameter Inputs – Post Processing – Live Graph Display Subsystem Design Software Interface

41. Software Interface (SI Units)

42. Software Interface (US Standard Units)

43. EquationsVariables K w = Wheel Rate K s = Spring Rate MR = Motion Ratio ω s/us = Natural Frequency (sprung/unsprung mass) m s/us = Mass (sprung/unsprung) c crs/us = Critical Damping (sprung/unsprung mass) Software Interface Calculations

44. Power Management

45. Serial Interface Test

46. Serial Interface Test (Automated)

47. Risk Assessment

49. Updated Project Plan

50. Questions?