1. 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 !

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

3. 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.

4. 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

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

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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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