Progress Report Three

Report of Progress

 

Situation

The group ran Performance Test 1 and 2 using the current wheel design proving that the direct drive system was a huge success. A current problem with the system is that the wheel has a tendency to fall off the motor, which destabilizes the AEV as a whole. Luckily, during testing when the wheel came off, not only was a member of the team waiting to catch the AEV but the back wheel kept the AEV on the track. A new support arm for the motor and a new wheel were designed and printed for the final design. The team has also proved that a powered braking method is extremely efficient and cost effective for the current design since a servo motor is unneeded.

 

Results and analysis

From Performance Test 1 the team was made aware of a major error in the AEV design. During trial runs for performance test 1 the powered drive wheel fell off of the motor which resulted in catastrophic failure. After this error occured the team switched from the red wheel to the yellow wheel because the yellow wheel was scarcely used. The team found the most success by switching out the wheel and and ensuring that the wheel was full on before the AEV is ran.

Performance Test 2 gave the group a chance to ensure the functionality of the code thus far. Performance Test 2 was supposed to go to the gate, wait 7 seconds then go pick up the caboose, and wait for another 5 seconds before going back. The group observed that the AEV reliably stopped near the caboose and attached at a minimized speed, resulting in the AEV rarely pushing the caboose back more than inches.

aR&D 3 The redesigned parts were tested by completing performance test two. During the rerun of performance test two with the redesigned parts it was noted that the new wheel design had a couple flaws. Due to printing imperfection the concavity of the wheel was uneven. This resulted in the wheel being initially unusable. In addition to uneven printing the outer lip of the wheel was too long and collided with certain parts of the rail. Both of these issues were resolved by using hand tools to refine the model.

Takeaways

 

From Performance Test 1 the group discovered a point of weakness in the AEV design. Because the wheel can fall off the group has to be more vigilant while testing to ensure safety. The cause of the wheel falling off is likely the deterioration of the interference fit between the wheel and the motor, this causes the motor to spin freely in the wheel and thread the wheel off the axel. Because of this, the group determined that it is best to keep two copies of the wheel so that the structural integrity of the wheel can be maintained. Performance Test 1 also showed the group that the code to get to the first gate is reliable and accurate. This can be seen in the consistency of the AEV from trial to trial.

From performance Test 2 the group continued making progress on the code, almost finalizing the code. While acquiring a new re-designed wheel, and testing, the group noticed the inner side of the wheel was hitting the support arm parts of the track. This was due to the extended outside of the wheel for more stabilization on the track. The group figured the best course of action was to sand down the one extended side, to allow perfect rolling across the track. This was done outside of the classroom using a dremel, and additional sandpaper to clean up the wheel and finish the edges for a clean look as shown in Figure B7. This wheel will now allow the group to complete the final performance test.     

From aR&D 3 the group changed the AEV design from a horizontal base design to a vertical hanging design, as well as changing the arm to a T-arm instead of the L-arm. The group wanted to test energy efficiency from the smaller vertical model. However, while designing and rearranging the pieces, the group understood that by using the motorized wheel and arm, it is very complicated balancing the hanging design. The group was able to find a good center of balance and test the AEV. After testing the group only saw a slight drop in energy usage between designs. However, the horizontal base, the AEV just ran smoother and had a much better center of mass allowing for optimal testing. Therefore the group has gone back to finishing the final performance test on a horizontal base.

Future Work

 

Situation

The AEV final body design will be completed and the coding will be refined to maximize the efficiency of power use, and minimize the time required to complete the course tasks. The finalization to the AEV body will allow for the best center of gravity of any design. This will create even less energy usage and more stability for the AEV. This will be done by using  T-shaped arm, connected to a T-shaped base. By using these 2 pieces, it makes the design simplistic, cost efficient, and entirely balanced. The final code written for the final body design will be through trial and error. Looking at what values of speed and marks work in certain areas of the run, creating a “perfect” run for the groups AEV.

 

Upcoming Goals

 

  • Refine AEV code to complete tasks in the most economical manner. This will be accomplished by running trials with different code and then doing power and time analysis on the runs. Comparing power consumption and time required to complete course runs will allow the group to develop code that meets both desired power and time restraints.
  • Create a finalized AEV design using a T-shaped arm attached to a T-shaped base. This will be the most efficient design with the best possible layout for our AEV. This design holds the best center of mass with the greatest stability.
  • The group still needs to meet and focus on working to complete the team poster for presentation. This will be done by possibly meeting out of class and formatting the correct way to create the poster.

 

Upcoming Schedule

4-8-19 – Lab 20

  •         Final Oral Presentation Draft due – whole group project

4-10-19 – Lab 21

  •         Final Performance Test – whole group project

4-11-19 – Lab 22

4-15-19 – Lab 23

4-16-19 – Final Oral Presentation Slides due

4-17-19 – Lab 24

4-18-19 – Lab 25

  •         Critical Design Review due – whole group project
  •         Final Website due – whole group project
  •         Final Team Evaluation due – whole group does on their own

Appendices

 

Appendix A

Code Used

 

Prototype Testing Powered Stop

 reverse(1);
// reverses motor one
 motorSpeed(4,15);
 goToAbsolutePosition(-130);
// sets motor one to 15% power and moves AEV 130 marks


 reverse(1);
 motorSpeed(4,30);
 goFor(1);

// braking mechanism; reverses motor one and runs motor at 30% power for 1 second

 brake(1);
// brakes motor one

 

Prototype Testing Coasting Code

 reverse(1);
 motorSpeed(4,30);
 goFor(1);
// reverses motor one and runs motor at 30% power for 1 second


 brake(1);

// brakes motor one

Code for Performance Test 1

// initial move forward

motorSpeed(4,15);

goToAbsolutePosition(-280);

// sets all motors to 15% power for 280 marks

// braking

reverse(4);

motorSpeed(4,20);

goFor(1);

brake(4);

// sets all motors in reverse and runs at 20% power for 1 second before braking

// waiting for gate

goFor(6.5);

// sets AEV to wait for 6.5 seconds

// move forward through gate

reverse(4);

motorSpeed(4,15);

goFor(1);

// sets all motors in reverse and runs at 15% power for 1 second

Code for Performance Test 2

// initial move forward

motorSpeed(4,15);

goToAbsolutePosition(-280);

// sets all motors to 15% power for 280 marks

// braking at gate

reverse(4);

motorSpeed(4,20);

goFor(1);

brake(4);

// sets all motors in reverse and runs at 20% power for 1 second before braking

// waiting for gate

goFor(6.5);

// sets AEV to wait for 6.5 seconds

// move forward through gate

reverse(4);

motorSpeed(4,15);

goToRelativePosition(-240);

// sets all motors in reverse and runs at 15% power for 240 marks

 

// braking before caboose/attaching by coasting

reverse(4);

motorSpeed(4,12);

goFor(1);

brake(4);

// sets all motors in reverse and runs at 12% power for 1 second, then brakes motor for a coasting stop

// a show of movement back/towing caboose

motorSpeed(4,20);

goFor(1);

// sets all motors to 20% power for 1 second

  

Appendix B

Figure

 

Figure 01: This figure shows the power vs distance plot for the AVE in a coasting stop while not towing in aR&D 3

 

Figure 02: This figure shows the power vs distance plot for the AEV in a coasting stop while towing in aR&D 3

 

Figure 03: This figure shows she power usage vs distance for the powered braking stop without towing the caboose in aR&D 3

 

Figure 04: This figure shows the power usage vs distance for the powered braking stop while towing in aR&D 3.

Figure 05: This figure shows the power usage over distance of the AEV with a vertical base design.

 

Figure 06: This graph shows the power usage of the AEV with a horizontal base configuration from aR&D 3.

Figure 07: This figure shows the new re-designed wheel as well as the extended side cut down


Figure 08: This figure shows the new motor arm

Appendix C

Tables

 

Table 01

Trial Speed Stopping distance (m) Stopping Distance (marks)
Trial 1 – Coasting Stop 30 0.8791 71.00
Trial 2 – Powered Stop 15 .3220 26.00
Trial 3 – Coasting Stop Towing 30 .1486 12.00
Trial 4 – Powered Stop Towing 15 .124 10.01

This table shows the stopping distance of the new AEV design as observed in aR&D 3

 

Appendix D

Team Meeting Notes

 

Meeting 11 – March 20 2019

3/20/19 – Hitchcock 308 – 1 hour

Attendance:

  •         James Bott
  •         Joe Georges
  •         Michael Nedved
  •         Nick McLaughlin

Objective: Complete Performance Test 1

Completed tasks:

  •         Write code to get the AEV to go to the gate, stop then go through – Joe
  •         Test AEV on track and troubleshoot – whole group

Tasks to be Completed:

  •         Prepare for aR&D presentation – whole group
  •         Remodel drive wheel – Nick
  •         Brainstorm ways to secure the wheel on the axle better – whole group

Decisions/Notable Events:

  •         The AEV drive wheel began to fall off the motor while spinning resulting in catastrophic failure. To combat this the group will begin to incorporate the acceleration command rather than taking it straight up to speed. This should allow the motor to ease into motion and hopefully increase the stability of the AEV.
  •         The group will get 2 copies of the new design AEV wheel so that there is a backup once the first one deteriorates past the point of use.
  •         Each AEV wheel can also be used twice, once on either side of the wheel while maintaining relative stability.

Timeline

1-10-19 – Lab 1 – pR&d 1

  •         Preliminary R&D Quiz 1 due

1-17-19 – Lab 2 – pR&d 2

  •         Preliminary R&D Quiz ­­­­2 due
  •         Website update 1
  •         Team Meeting Minutes

1-31-19 – Lab 3 – pR&d3

  •         Preliminary R&D Quiz 3 due

2-7-19 – Lab 4 – pR&d 4 & 5

  •         Preliminary R&D Quiz 4 due

2-14-19 – Lab 5 – Grant Proposal & LPQ

  •         Progress Report 1 due
  •         Lab Practical Quiz
  •         Present Grant Proposal

2-21-19 – Lab 6 – aR&D 1

  •         Advanced R&D Quiz 1 due
  •         Committee Meeting

2-28-19 – Lab 7 – aR&D 1

3-4-19 – Lab 8 – aR&D 1

3-6-19 – Lab 9 – aR&D 2

  •         Application 16 due

3-7-19 – Lab 10 – aR&D 2

3-18-19 – Lab 11 – Performance Test 1

  •         Website Update 3 due

3-20-19 – Lab 12 – Performance Test 1

  •         Progress Report 2 due

3-21-19 – Lab 13 – R&D Oral Presentation

3-25-19 – Lab 14 – EXAM 4

3-27-19 – Lab 15 – Performance Test 2

3-28-19 – Lab 16 – Committee meeting 2

  •         Critical Design Review draft due

4-1-19 – Lab 17

4-3-19 – Lab 18

4-4-19 – Lab 19

  •         Progress Report 3 due

 

Meeting 12 – March 25 2019

3/25/19 – Hitchcock 308 – 1 hour

Attendance:

  •         James Bott
  •         Joe Georges
  •         Michael Nedved
  •         Nick McLaughlin

Objective: Take Exam 4, rerun pR&D 3 for new design, prep performance test 2

Completed tasks:

  •         Write code to get the AEV to go to the caboose and stop, then wait for 5 seconds – Joe
  •         Test AEV on track and troubleshoot – whole group
  •         Rerun code from pR&D 3 with the new AEV design, this was done so that the new group design could be contrasted with the original in the CDR – whole group
  •         Take data from the pR&D 3 rerun – James

Tasks to be Completed:

  •         Write CDR – whole group

Decisions/Notable Events:

  •         Performance test 2 code is complete and reliable

Timeline

1-10-19 – Lab 1 – pR&d 1

  •         Preliminary R&D Quiz 1 due

1-17-19 – Lab 2 – pR&d 2

  •         Preliminary R&D Quiz ­­­­2 due
  •         Website update 1
  •         Team Meeting Minutes

1-31-19 – Lab 3 – pR&d3

  •         Preliminary R&D Quiz 3 due

2-7-19 – Lab 4 – pR&d 4 & 5

  •         Preliminary R&D Quiz 4 due

2-14-19 – Lab 5 – Grant Proposal & LPQ

  •         Progress Report 1 due
  •         Lab Practical Quiz
  •         Present Grant Proposal

2-21-19 – Lab 6 – aR&D 1

  •         Advanced R&D Quiz 1 due
  •         Committee Meeting

2-28-19 – Lab 7 – aR&D 1

3-4-19 – Lab 8 – aR&D 1

3-6-19 – Lab 9 – aR&D 2

  •         Application 16 due

3-7-19 – Lab 10 – aR&D 2

3-18-19 – Lab 11 – Performance Test 1

  •         Website Update 3 due

3-20-19 – Lab 12 – Performance Test 1

  •         Progress Report 2 due

3-21-19 – Lab 13 – R&D Oral Presentation

3-25-19 – Lab 14 – EXAM 4

3-27-19 – Lab 15 – Performance Test 2

3-28-19 – Lab 16 – Committee meeting 2

  •         Critical Design Review draft due

4-1-19 – Lab 17

4-3-19 – Lab 18

4-4-19 – Lab 19

  •         Progress Report 3 due

4-8-19 – Lab 20

  •         Final Oral Presentation Draft due

4-10-19 – Lab 21

  •         Final Performance Test

4-11-19 – Lab 22

4-15-19 – Lab 23

4-16-19 – Final Oral Presentation Slides due

4-17-19 – Lab 24

4-18-19 – Lab 25

  •         Critical Design Review due
  •         Final Website due
  •         Final Team Evaluation due

 

Meeting 13 – March 27 2019

3/27/19 – Hitchcock 308 – 1 hour

Attendance:

  •         James Bott
  •         Joe Georges
  •         Michael Nedved
  •         Nick McLaughlin

Objective: Complete Performance Test 2

Completed tasks:

  •         Performance Test 2 was run on track – whole team
  •         Testing began for the remaining parts of the final performance test – whole team
  •         Group began work on the CDR draft – whole team

Tasks to be Completed:

  •         Write CDR – whole group

Decisions/Notable Events:

  •         Performance test 2 was successful, the team received full marks for their effort.
  •         Team F and Team C both also completed their performance test for full marks.
  •         The AEV still must work on stopping at the right point when returning to the launch bay.

Timeline

1-10-19 – Lab 1 – pR&d 1

  •         Preliminary R&D Quiz 1 due

1-17-19 – Lab 2 – pR&d 2

  •         Preliminary R&D Quiz ­­­­2 due
  •         Website update 1
  •         Team Meeting Minutes

1-31-19 – Lab 3 – pR&d3

  •         Preliminary R&D Quiz 3 due

2-7-19 – Lab 4 – pR&d 4 & 5

  •         Preliminary R&D Quiz 4 due

2-14-19 – Lab 5 – Grant Proposal & LPQ

  •         Progress Report 1 due
  •         Lab Practical Quiz
  •         Present Grant Proposal

2-21-19 – Lab 6 – aR&D 1

  •         Advanced R&D Quiz 1 due
  •         Committee Meeting

2-28-19 – Lab 7 – aR&D 1

3-4-19 – Lab 8 – aR&D 1

3-6-19 – Lab 9 – aR&D 2

  •         Application 16 due

3-7-19 – Lab 10 – aR&D 2

3-18-19 – Lab 11 – Performance Test 1

  •         Website Update 3 due

3-20-19 – Lab 12 – Performance Test 1

  •         Progress Report 2 due

3-21-19 – Lab 13 – R&D Oral Presentation

3-25-19 – Lab 14 – EXAM 4

3-27-19 – Lab 15 – Performance Test 2

3-28-19 – Lab 16 – Committee meeting 2

  •         Critical Design Review draft due

4-1-19 – Lab 17

4-3-19 – Lab 18

4-4-19 – Lab 19

  •         Progress Report 3 due

4-8-19 – Lab 20

  •         Final Oral Presentation Draft due

4-10-19 – Lab 21

  •         Final Performance Test

4-11-19 – Lab 22

4-15-19 – Lab 23

4-16-19 – Final Oral Presentation Slides due

4-17-19 – Lab 24

4-18-19 – Lab 25

  •         Critical Design Review due
  •         Final Website due
  •         Final Team Evaluation due

 

Meeting 14 – March 28 2019

3/28/19 – Hitchcock 308 – 1 hour

Attendance:

  •         James Bott
  •         Joe Georges
  •         Michael Nedved
  •         Nick McLaughlin

Objective: Complete Committee Meeting 2

Completed tasks:

  •         Each team member went to their respective meetings, Nick went to HR, Michael went to public relations, and Joe and Jimmy went to research and development.
  •         The group began to reassemble the AEV using the T bracket arm instead of the L – whole group

Tasks to be Completed:

  •         Progress Report 3 – whole group
  •         aR&D 3 Methodology – Nick

Decisions/Notable Events:

  •         The new 3D parts came in, but they have too much friction with the track due to printing errors, so the group has made the decision to sand down the wheels
  •         Nick will take the AEV home this weekend so that it can be properly assembled and sand down the wheels slightly
  •         Ben (TA) offered to bring files to the next class to shave it down more.

Timeline

1-10-19 – Lab 1 – pR&d 1

  •         Preliminary R&D Quiz 1 due

1-17-19 – Lab 2 – pR&d 2

  •         Preliminary R&D Quiz ­­­­2 due
  •         Website update 1
  •         Team Meeting Minutes

1-31-19 – Lab 3 – pR&d3

  •         Preliminary R&D Quiz 3 due

2-7-19 – Lab 4 – pR&d 4 & 5

  •         Preliminary R&D Quiz 4 due

2-14-19 – Lab 5 – Grant Proposal & LPQ

  •         Progress Report 1 due
  •         Lab Practical Quiz
  •         Present Grant Proposal

2-21-19 – Lab 6 – aR&D 1

  •         Advanced R&D Quiz 1 due
  •         Committee Meeting

2-28-19 – Lab 7 – aR&D 1

3-4-19 – Lab 8 – aR&D 1

3-6-19 – Lab 9 – aR&D 2

  •         Application 16 due

3-7-19 – Lab 10 – aR&D 2

3-18-19 – Lab 11 – Performance Test 1

  •         Website Update 3 due

3-20-19 – Lab 12 – Performance Test 1

  •         Progress Report 2 due

3-21-19 – Lab 13 – R&D Oral Presentation

3-25-19 – Lab 14 – EXAM 4

3-27-19 – Lab 15 – Performance Test 2

3-28-19 – Lab 16 – Committee meeting 2

  •         Critical Design Review draft due

4-1-19 – Lab 17

4-3-19 – Lab 18

4-4-19 – Lab 19

  •         Progress Report 3 due

4-8-19 – Lab 20

  •         Final Oral Presentation Draft due

4-10-19 – Lab 21

  •         Final Performance Test

4-11-19 – Lab 22

4-15-19 – Lab 23

4-16-19 – Final Oral Presentation Slides due

4-17-19 – Lab 24

4-18-19 – Lab 25

  •         Critical Design Review due
  •         Final Website due
  •         Final Team Evaluation due

 

Meeting 15 – April 1 2019

4/1/19 – Hitchcock 308 – 1 hour

Attendance:

  •         James Bott
  •         Joe Georges
  •         Michael Nedved
  •         Nick McLaughlin

Objective: Complete aR&D 3

Completed tasks:

  •         The code for aR&D 2 was rerun with the new design (part of aR&D 3) – whole group
  •         Power usage was analyzed for the new design using a vertical base – whole group
  •         The current performance test code was ran with the new parts so that the group can see whether it still works – whole group

Tasks to be Completed:

  •         Progress Report 3 – whole group
  •         Do power usage analysis of AEV with horizontal base – whole group

Decisions/Notable Events:

  •         The new 3D parts have been sanded down to usable dimensions and can be ran on the track
  •         The current progress report code still mostly works but has minimal discrepancies such as the AEV not fully making it to the caboose, the group will trouble shoot as necessary.

Timeline

1-10-19 – Lab 1 – pR&d 1

  •         Preliminary R&D Quiz 1 due

1-17-19 – Lab 2 – pR&d 2

  •         Preliminary R&D Quiz ­­­­2 due
  •         Website update 1
  •         Team Meeting Minutes

1-31-19 – Lab 3 – pR&d3

  •         Preliminary R&D Quiz 3 due

2-7-19 – Lab 4 – pR&d 4 & 5

  •         Preliminary R&D Quiz 4 due

2-14-19 – Lab 5 – Grant Proposal & LPQ

  •         Progress Report 1 due
  •         Lab Practical Quiz
  •         Present Grant Proposal

2-21-19 – Lab 6 – aR&D 1

  •         Advanced R&D Quiz 1 due
  •         Committee Meeting

2-28-19 – Lab 7 – aR&D 1

3-4-19 – Lab 8 – aR&D 1

3-6-19 – Lab 9 – aR&D 2

  •         Application 16 due

3-7-19 – Lab 10 – aR&D 2

3-18-19 – Lab 11 – Performance Test 1

  •         Website Update 3 due

3-20-19 – Lab 12 – Performance Test 1

  •         Progress Report 2 due

3-21-19 – Lab 13 – R&D Oral Presentation

3-25-19 – Lab 14 – EXAM 4

3-27-19 – Lab 15 – Performance Test 2

3-28-19 – Lab 16 – Committee meeting 2

  •         Critical Design Review draft due

4-1-19 – Lab 17

4-3-19 – Lab 18

4-4-19 – Lab 19

  •         Progress Report 3 due

4-8-19 – Lab 20

  •         Final Oral Presentation Draft due

4-10-19 – Lab 21

  •         Final Performance Test

4-11-19 – Lab 22

4-15-19 – Lab 23

4-16-19 – Final Oral Presentation Slides due

4-17-19 – Lab 24

4-18-19 – Lab 25

  •         Critical Design Review due
  •         Final Website due
  •         Final Team Evaluation due

 

Meeting 15 – April 3 2019

4/3/19 – Hitchcock 308 – 1 hour

Attendance:

  •         James Bott
  •         Joe Georges
  •         Michael Nedved
  •         Nick McLaughlin

Objective: Complete aR&D 3

Completed tasks:

  •         Assembled AEV with horizontal base – Joe
  •         Power usage analysis of horizontal base AEV – whole group

Tasks to be Completed:

  •         Progress Report 3 – whole group
  •         Make new solid works assembly to reflect current design – TBD
  •         Final project poster – whole group

Decisions/Notable Events:

  •         The group unanimously decided to use the horizontal base design, although the power usage is slightly higher it is a lot more convenient and allows for a more flexible design.
  •         The group observed that the new wheel clips into the track support arms which causes the AEV to bounce mid run, Michael will take the drive wheel home and trim down the diameter of the wheel so that it will fit on the track and will be tested at next meeting.

Timeline

1-10-19 – Lab 1 – pR&d 1

  •         Preliminary R&D Quiz 1 due

1-17-19 – Lab 2 – pR&d 2

  •         Preliminary R&D Quiz ­­­­2 due
  •         Website update 1
  •         Team Meeting Minutes

1-31-19 – Lab 3 – pR&d3

  •         Preliminary R&D Quiz 3 due

2-7-19 – Lab 4 – pR&d 4 & 5

  •         Preliminary R&D Quiz 4 due

2-14-19 – Lab 5 – Grant Proposal & LPQ

  •         Progress Report 1 due
  •         Lab Practical Quiz
  •         Present Grant Proposal

2-21-19 – Lab 6 – aR&D 1

  •         Advanced R&D Quiz 1 due
  •         Committee Meeting

2-28-19 – Lab 7 – aR&D 1

3-4-19 – Lab 8 – aR&D 1

3-6-19 – Lab 9 – aR&D 2

  •         Application 16 due

3-7-19 – Lab 10 – aR&D 2

3-18-19 – Lab 11 – Performance Test 1

  •         Website Update 3 due

3-20-19 – Lab 12 – Performance Test 1

  •         Progress Report 2 due

3-21-19 – Lab 13 – R&D Oral Presentation

3-25-19 – Lab 14 – EXAM 4

3-27-19 – Lab 15 – Performance Test 2

3-28-19 – Lab 16 – Committee meeting 2

  •         Critical Design Review draft due

4-1-19 – Lab 17

4-3-19 – Lab 18

4-4-19 – Lab 19

  •         Progress Report 3 due

4-8-19 – Lab 20

  •         Final Oral Presentation Draft due

4-10-19 – Lab 21

  •         Final Performance Test

4-11-19 – Lab 22

4-15-19 – Lab 23

4-16-19 – Final Oral Presentation Slides due

4-17-19 – Lab 24

4-18-19 – Lab 25

  •         Critical Design Review due
  •         Final Website due
  •         Final Team Evaluation due