Download Final Test Plan

Document Revision No.: 2
Revised: 06/29/17
RIT KGCOE MSD Program
P09310 Automatic Shift Controls for ATV
Test Plans & Test Results
By: Ashley Shoum, Matt Dombovy-Johnson, Keith Cobb, Jon Willistein, Feng Li, Bibhu Shah,
Sarah Bicho
Table of contents
MSD I: WKS 8-10 TEST PLAN ........................................................................... 2
1.1. Introduction; Overview; Summary; Purpose; History, etc. ....................................................... 2
1.2. Project Description; Sub-Systems/ Critical Components Being Tested..................................... 3
1.3. Approval; Guide, Sponsor ............................................................................................................. 4
1.4. Test Strategy ................................................................................................................................... 5
1.5. Definitions; Important Terminology; Key Words ..................................................................... 12
2.
MSD II WKS 2-4: - FINAL TEST PLAN ..................................................... 13
2.1. Data Collection Plan; Sampling Plan .......................................................................................... 13
2.2. Measurement Capability, Equipment ......................................................................................... 14
2.3. Test Conditions, Setup Instructions ............................................................................................ 15
2.4. Sponsor/Customer, Site Related, Requests / Considerations .................................................... 15
2.5. Test Procedure, Work Breakdown Structure, Schedule ........................................................... 15
2.6. Assumptions .................................................................................................................................. 15
3.
MSD II – WKS 3-10 DESIGN TEST VERIFICATION ................................. 16
3.1. Test Results ................................................................................................................................... 16
3.2. Logistics and Documentation ...................................................................................................... 18
3.3. Contingencies/ Mitigation for Preliminary or Insufficient Results .......................................... 18
3.4. Analysis of Data – Design Summary ........................................................................................... 18
3.5. Function/ Performance Reviews.................................................................................................. 18
RIT KGCOE MSD Program
Page 1
Document Revision No.: 2
Revised: 06/29/17
RIT KGCOE MSD Program
P09310 Automatic Shift Controls for ATV
Test Plans & Test Results
MSD I: WKS 8-10 TEST PLAN
1.1.
Introduction; Overview; Summary; Purpose; History, etc.
1.1.1. Polaris Automatic Shift Controls is a project within the Systems and Controls Track.
1.1.2. System is designed to automatically shift Polaris Outlaw 525 using a programmable
microcontroller.
1.1.3. System integrates button shift override functionality and maintains full operation of manual
shifting.
1.1.4. System components include electric solenoid that actuates shifting; bracket to mount
solenoid to ATV; shift tab to attach solenoid to shift lever, and microcontroller to control
actuation.
1.1.5. New button shift and on board indicator interfaces were designed for ease of use,
ergonomics, shift status display and system errors.
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1.2.
Revised: 06/29/17
RIT KGCOE MSD Program
Project Description; Sub-Systems/ Critical Components Being Tested
Figure 1: System, Sub-system, Component Breakdown
Mechanical Shifting Subsystem Components
1.2.1. Electric Solenoid
1.2.1.1.
Force Output
1.2.1.2.
Shift Time
1.2.2. Shift Torque
1.2.2.1.
Without Engine Spark Cutout
1.2.2.2.
With Engine Spark Cutout
Electrical/Programming Subsystem Components
1.2.3. RPM vs. TPS
1.2.3.1.
Shifting points
1.2.4. Battery
1.2.4.1.
RIT KGCOE MSD Program
Total current drawn
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RIT KGCOE MSD Program
User Interface Subsystem
1.2.5. Button Functionality
1.2.5.1.
Upshift
1.2.5.2.
Downshift
1.2.6. Gear Indicator Functionality
1.2.6.1.
Gear Indication
1.2.6.2.
Upshift/Downshift Indication
1.2.6.3.
Bad Shift Indicator
1.2.6.4.
System Error Indicator
1.2.6.5.
All original indicators
Automatic Shift Controls System
1.2.7. Full System Functionality
1.3.
1.2.7.1.
Weight of all Components
1.2.7.2.
Shift Time
1.2.7.3.
Range RPM testing
1.2.7.4.
Lab test
1.2.7.5.
Field testing
Approval; Guide, Sponsor
Approved by:
Team Members:
Mechanical Subsystem: Ashley Shoum, Keith Cobb, Matt Dombovy-Johnson
Electrical Subsystem: Jon Willistein, Feng Li
User Interface: Ashley Shoum, Matt Dombovy-Johnson, Jon Willistein, Feng Li
Guide – Professor George Slack
Sponsor – Polaris, Joel Notaro
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1.4.
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RIT KGCOE MSD Program
Test Strategy
1.4.1. Product Specifications, Block Diagram, and Pass/ Fail Criteria
1.4.1.1. Electric Actuator Linear Force Output:

Required: 37.5 lbs to complete a shift

Manufacturer Specification: Actuator will provide 40 lbs
Pass/Fail Criteria:

Pass: Cylinder provides a linear force in both directions (retraction and
extraction) greater than or equal to 37.5 lbs

Fail: Cylinder provides a linear force in either direction (retraction or
extraction) less than 37.5 lbs
Block Diagram:
The test will require one input and provide a force output.
Force Output Test
+
Pressurized
Resistance
Cylinder
12V
-
Measured
Force: lbs
1.4.1.2. Electric Actuator Shift Time:

Required: Complete a shift in 0.1s
Pass/Fail Criteria:

Pass: Electric actuator is able to move from Neutral to fully extended or
retracted in less than 0.1s

Fail: Electric actuator is unable to move from Neutral to fully extended or
retracted in less than 0.1s.
Block Diagram:
The test will require one input and provide a distance travelled within a certain time.
+
12V
Shift Time Test
Measured
Time:
seconds
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RIT KGCOE MSD Program
1.4.1.3. ATV Shift Torque without Engine Spark Cutout

Required: < 150 in-lbs

Previous Specification: 150 in-lbs
Pass/Fail Criteria:

Pass: Torque measured is less than or equal to 150 in-lbs

Fail: Torque measured is greater than 150 in-lbs
1.4.1.4. RPM vs. TPS Shifting points

Required: Manually drive ATV and bench test the controller for obtaining
normal shifting points, Electric actuator need to shift up or down when pass
shifting point
Pass/Fail Criteria:

Pass: Electric actuator shift up or down when pass shifting point

Fail: Electric actuator didn’t shift up or down or shift to the wrong direction
when pass shifting point
RPM vs. TPS Test
Apply
RPM to
the microcontroller
For each TPS(different
Voltages), one RPM value
needed for shift up, and one for
shift down.
Compare
RPM:
Correct ShiftPassed
1.4.1.5. Total current drawn from battery

Required: total current needed for the design should be less than current rate
on the battery.
Pass/Fail Criteria:

Pass: Total current drawn is less than current rate on the battery

Fail: Total current drawn is greater than current rate on the battery
Battery Test
Total
current out
from the
whole
system
RIT KGCOE MSD Program
Current rate on the
battery
Compare
Currents
Less- passed
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1.4.2. Functions (hardware) and Features (software, customer needs)
1.4.2.1. Mechanical:
Test Name:
Test #:
Description of Test
Spec #:
Specification
Description:
System
Component:
Force Output
1
Measure the force
provided by the Electric
Cylinder by moving a
pneumatic cylinder
pressurized to create a
force of 40 lbs
ES6
Corresponds to our
system completing a
shift
Electric
Actuator
Shift Time
2
Measuring the time
required for the electric
actuator to move from the
N position to full up or
down
ES2
Time required to
complete a shift
Electric
Actuator
Shift Torque
w/o Engine
Spark Cutout
3
Measure the internal
spring torque or
transmission without
clutch simulation
ES6
Internal return torque
is equivalent to force
required to shift
OEM ATV
component
Shift Torque
with Engine
Spark Cutout
4
Measure the internal
spring torque of the
transmission with clutch
simulation
ES6
Internal return torque
is equivalent to force
required to shift
OEM ATV
component
1.4.2.2. Electrical:
Test
Name:
Test #:
Description of Test
Spec.
#:
Specification
Description:
System
Component:
RPM vs.
TPS
1
A voltage supply will drive the TPS
input, and a frequency generator will
drive the RPM input with a square
wave. Increasing the frequency of the
function generator which acts as an
rpm input until it shifts for every
shifting point, same way for getting
down shifting points.
ES12ES17
Shift up or
down depend
on the RPM
and TPS
values
Electric
Actuator
Battery
2
Connected a multi-meters in series
with the battery and the system for
getting reading of current
ES19
Current rate
on the battery
Battery
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1.4.2.3. Rider Indicators
Test
Name:
Test #:
Description of Test
Spec.
#:
Specification
Description:
System
Component:
Gear
Display
1
Display what gear the ATV is in while
in any mode
F3
Feature
User
Interface
Up/Dow
n
2
Arrow illumination when system
performs an upshift or a downshift
F3
Feature
User
Interface
Bad
Shift
3
Illumination when request for upshift
or downshift is performed outside of
safe range of RPM/TPS
F3
Feature
User
Interface
System
Error
4
Illumination when shift is not
completed or a malfunction occurs
during shifting
F3
Feature
User
Interface
Original
Indicator
s
5
No test is available to determine if
sensors are working properly without
trying to simulate ATV malfunction
F3
Feature
User
Interface
Spec.
#:
Specification
Description:
System
Component:
F2,F3
Design
Requirement
User
Interface,
Autoshift
Spec.
#:
Specification
Description:
System
Component:
1.4.2.4. Gear Indicator
Test
Name:
Test #:
Gear
Indicator
1
Description of Test
Test voltage output signal in each gear
with 12V input
1.4.2.5. Complete System Functionality
Test
Name:
Test #:
Description of Test
Button
Shifting
1
Shift 1-5 while accelerating, Shift 5-1
while decelerating
F1
Button
Feature
Final Design
Automat
ic Mode
2
Determine if ATV shifts up and down
automatically based on RPM vs. TPS.
Must be smooth.
F2
Automatic
Feature
Final Design
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Test Equipment available
1.4.2.6.
Force Output of Electric Actuator

Pneumatic Cylinder – provides a resistive force by pressurization

Scrap metal – machine shop metal to create a small L-bracket mount for
pneumatic cylinder

Air supply – shop air will be used to pressurize the cylinder

12V power supply – used to produce the input required to actuate the cylinder

Two piece clamp – mount electric actuator
1.4.2.7.
Shift Time

Force Output test stand – integrate shift time test into the force test stand

Cylinder position magnets – used to provide a signal to tell the position of the
cylinder

12V Supply

Oscilloscope

Electric timer – measure the time to move from N to fully extended or
retracted
1.4.2.8.
Shift Torque w/o clutch activation

Torque wrench – attach to the gear lever mounting bolt to determine spring
torque

ATV running – place the ATV on blocks to allow shifting through gears

Sockets – 10 mm
1.4.2.9.
Shift Torque w/clutch activation

Torque wrench – attach to the gear lever mounting bolt to determine spring
torque

ATV running – place the ATV on blocks to allow shifting through gears

Sockets – 10 mm
1.4.2.10. RPM vs. TPS
RIT KGCOE MSD Program

Power supply – act as a battery and TPS position

Function generator – play as RPM input
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
RIT KGCOE MSD Program
Oscilloscope – measure how input, output and other things works as a check.
1.4.2.11. Battery

Multimeter – measure total current of the system
1.4.3. Test Equipment needed but not available
1.4.3.1.
1.4.3.2.
Force Output of Electric Actuator

Metal coupler to attach electric cylinder directly to pneumatic cylinder will need
to be fabricated

Grainger valve – will be required to set the relief valve pressure

Air line T - to attach the grainger valve in the pressure line

Air hose – may be able to use the left over from last year’s team along with
the quick disconnects

Fittings – NPT port blocker since we will only be applying pressure to one side
of the piston at a time, we will need to block the other port
Shift Time
 N/A
1.4.3.3.
Shift Torque w/o clutch actuation
 Torque Wrench Calibration machine – use to calibrate torque wrench
 ATV that will run
1.4.3.4.
Shift Torque w/clutch actuation
 Torque Wrench Calibration machine – use to calibrate torque wrench
 Clutch
 ATV that will run
1.4.3.5.
RPM vs. TPS
 N/A
1.4.3.6.
Battery
 N/A
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RIT KGCOE MSD Program
1.4.5. Phases of Testing
1.4.5.1. Component
1.4.5.1.1.
Shift Torque without spark cutout
Required to be completed in MSD I in order to properly size an electric solenoid. This will
determine our confidence with the electric activation of shifting which is replacing the
pneumatic system.
1.4.5.1.2.
Shift Torque with spark cutout
Required during MSD I, the test will incorporate a more realistic example of our operating
system since we will be cutting spark between shifts in the final design. The test will also
determine the difference between the shift torque required with or without spark cutout.
1.4.5.1.3.
Solenoid Force Output – Bench Test
Actual force output on the bench will provide us with a better understanding of design
feasibility, since we were unable to obtain an exact data sheet for the cylinder we are
purchasing. If system does not provide required force as per shift torque test, then the
next step is to install the system on the ATV and ensure the force output is sufficient.
1.4.5.1.4.
Solenoid Cycle Time – Bench Test
The time required to complete a shift on the bench will provide a decent representation of
the time required after full system integration. Since we are unsure if shift time is a
function of cylinder loading we can use the force output test to simulate an actual load on
the cylinder and measure the time required to shift. This will provide us with complete
simulation of the final product minus the activation time of the buttons and microcontroller
processing speed which will be assumed to be negligible
1.4.5.2. Subsystem
1.4.5.2.5.
Mechanical and Electric Solenoid
Test the smoothness of operation, with all mechanical shift parts and electric solenoid
attached. This will simulate manual override situation and determine if the mechanical
system has any binding or loss of functionality. Changes can then be made to the design
if any major errors are found.
1.4.5.3. Integration
1.4.5.3.6.
System smoothness and Ease of Operation
Test will involve subjective rider testing to determine smoothness of operation during
button shifting and automatic mode. Ease of operation will be determined in a similar
manner. Testing will occur after all parts are integrated and proven to work on the test
stand.
1.4.5.4. Reliability
1.4.5.4.7.
Overall System Reliability
This test will incorporate all weather extremes, component functionality, misalignment
caused during use, damage to design. Full reliability testing will not be completed by our
Senior Design teamP09310 because we have limited resources for testing. System
reliability will be considered complete if the design provides maintenance free operation
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during testing. Product testing will take months of testing and may be completed by
Polaris in the future.
1.5.
Definitions; Important Terminology; Key Words
1.5.1. Grainger Valve- adjustable ball spring relief valve
1.5.2. Electric Solenoid- refers to dual action (push/pull) cylinder that is activated with 12V power
supply from ATV power system
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RIT KGCOE MSD Program
2. MSD II WKS 2-4: - FINAL TEST PLAN
Introduction: A brief description that states the purpose of the team’s testing needs.
2.1.
Data Collection Plan; Sampling Plan
2.1.1. Test Templates/ Tables/ File Locations
Test #1: Force
Output
Test Force (lbs)
1
24
2
22
3
20
4
24
5
25
6
18
7
17
8
16
9
24
10
20
Test #2: Shift Time
Test
Time(s)
1
0.05
EE Test #2
Total current(A)
Battery
40+
ME Test #3
Gear Indicator Voltage Measurements
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2.1.2. Phases of Testing
2.1.2.1. Electric Solenoid (ME)
Test 1: Force Output must yield at least 35lb of force.
Test 2: Shift time must be less than 0.1 second.
2.1.2.2. Shift Torque (ME)
Test 3: Shift torque measurement without Spark Cutout
Test 4: Shift torque measurement with Spark Cut
2.1.2.3. RPM vs. TPS (EE)
2.1.2.4.
2.1.2.5.
2.1.2.6.
2.1.2.7.
Test 1: Shifting points are determined to be used in the program – the table
above for RPM vs. TPS will be used many time as needed for finding final
shifting points.
Battery (EE)
Test 2: Total current drawn from battery should be less than current rate on the
battery.
Integration
Bench testing of electric solenoid functionality with button and microcontroller
program. All simulated shifts, up and down, are fully functional and meet spec
shift times.
Reliability
Full system testing of all up and down shifts at least ten trials using manual,
button and auto shifting capabilities.
Customer Acceptance
Performance review, customer testing approval.
2.1.3. Sampling Techniques
Due to the subjective nature of our testing we are unable to quantify all our results.
Therefore, we have performed a variety of full system capability tests which include,
numerous shifting scenarios and applied loadings.
2.1.4. Reporting Problems; Corrective Action
If a problem, component failure, or a failed test were to show up following this test plan or
during normal use time needs to be spent to qualify the severity of the problem or failure. A
recreation of the error will prove the issue and a solution will need to be formed and followed
through to ensure the same problem or failure (or future errors as a result of the change)
does not happen again.
2.2.
Measurement Capability, Equipment
2.2.1. A test bench will be designed and constructed to test the output force using supplies from
machine shop and any additional hardware needed will be ordered.
2.2.2. Testing of the full range of RPMs for the ATV may be limited due to weather and riding
location available at RIT.
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2.3.
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RIT KGCOE MSD Program
Test Conditions, Setup Instructions
2.3.1. Testing will be performed on the bench and at room temperature, but the system may be
portable for possible outdoor testing at lower temperatures.
2.3.2. Connect pingel shifter to pneumatic shifter by attaching a nut and bolt through the spherical
rod ends.
2.3.3. Connect the air line with the grainger valve to the shop supply line. Regulate the shop
supply line down to desired psi and adjust the grainger valve until it begins to relieve
pressure. The valve has now been adjusted to relief at the desired pressure.
2.3.4. Attach the pressure gauge to one port on the cylinder and the air supply line to the other
port. Pressurize the system and then disconnect the line from the supply side.
2.3.5. Activate electric solenoid to simulate a shift.
2.3.6. Repeat steps to perform addition shift tests.
2.3.7. Switch the lines to the ports to perform a shift in the opposite direction.
2.4.
Sponsor/Customer, Site Related, Requests / Considerations
2.4.1. Racetrack testing not available to students at RIT and may need to be further evaluated
after completion of system integration and installation testing.
2.5.
Test Procedure, Work Breakdown Structure, Schedule
2.5.1. Interdependencies between subsystems is illustrated in Figure 1.
2.5.2. Schedule/Responsible Characters
Test Pingel Solenoid
Torque Testing (with, w/o spark)
Test Gear Indicator
Test EE Software
Test EE Hardware
Test Button Shifting
Test Auto Shifting
Test User Interface
Test System
2.6.
1/7/09
1/16/08
1/7/09
1/23/08
1/23/09
2/2/09
2/6/09
2/6/09
2/13/09
Week 4
Week 5
Week 4
Week 6
Week 6
Week 8
Week 8
Week 8
Week 9
Jon/Keith
Keith/Matt
EE/Keith
EE
EE
EE
EE
Sarah/EE
Team
Assumptions
2.6.1. Since there is only access to one sample of each component the assumption is that they are
a true representation of the mean of a sample size large enough to form a normal curve.
Thus testing will be of each component over 10 iterations instead of testing 10 of each
component several times.
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3. MSD II – WKS 3-10 DESIGN TEST VERIFICATION
Note to Teams: Populate the templates and test processes established in Final Test Plan.
These elements can be integrated or rearranged to match project characteristics or personal/team
preferences.
3.1.
Test Results
3.1.1. Component
Electric Solenoid
Force Output:
Solenoid was unable to meet the required 37.5 lbs on the bench test. Only once
was the solenoid able to provide 24 lbs. Therefore, the cylinder fails the bench
testing. Failure could be due to the inability to switch the cylinder on using the
clean signal provided to the mosfets by the microcontroller. We were just
touching the wires to the battery terminals which does not provide a clean
switching signal to the mosfet and since the ability to flow current through the
mosfet is dependent on the gate voltage, then we might have not been able to
provide enough current flow to the electric solenoid. Force is directly proportional
to current flow through the cylinder. Additionally, we were basing the opposing
force on Bimba’s power factor of 0.4 for our cylinder. Foutput = 0.4 x Air Pressure.
This was an assumption and could have been wrong. Finally, we were using a
poppet style relief valve to relieve the cylinder of pressure during solenoid
activation. This style of relief valve is not very accurate and it would have been
much more accurate to use a ball and seat style valve that is more sensitive to
pressure changes. This valve was not readily available.
Shift Time:
Solenoid shift time was under the required 0.1s on the bench. Using the force
test stand the opposing cylinder was pressurized and a magnetic reed switch
was used to determine when the cylinder had reached the full shift position. An
oscilloscope was used to measure the activation voltage across the gate and the
turn on voltage of the reed switch. These graphs were overlayed the time to
activate and full stroke of the solenoid were determined to be the full shift time.
The results provide a consistent 50 ms of shift time which is half of the customer
requirement.
Shift Torque without Spark Cutout:
Shift force without spark cutout was determined during MSD I with the rear
wheels raised providing no loading on the wheels. The force was determined to
be 37.5 lbs.
Shift Torque with Spark Cutout:
Spark cutout was provided by momentarily switching the off/run/off with the rear
wheels raised and a torque wrench placed on the shift lever mounting bolt. After
performing a trial test this was determined to difficult to time the spark cutout and
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get a measurement with the torque wrench during this short period of time.
Since you were required to move the torque wrench slowly to hear the clicking
sound and get an accurate reading, the motor would die and not re-fire when the
switch was returned to the run position. A more accurate and faster means of
measuring the torque is required. Therefore, time was not wasted on performing
this test and the shift torque without spark cutout was used for our analysis.
3.1.2. Subsystem
Rider Display:
It is cleanly integrated and provides visible display to the rider for each gear
position. Occasionally, gear position will flicker for a moment before it shows up
on the display. Upshift and downshift arrows are wired but not yet fully integrated
into the program to be fully functional. Bad shift indicator and system error
indicator also not fully functional.
Gear Indicator:
Factory gear indicator was removed and fabricated by the team members. Four
additional copper contact posts were fabricated as well as an additional contact
for the transmission drum. A resistor was placed inline with the 5 volt supply to
1st post, then resistors were wired in series between each remaining post to
provide a changing output signal voltage. The original wires were reused as well
as the waterproof connector to retain serviceability. With the indicator installed,
resistance was checked for each gear position and then 5 volts was supplied and
output voltage was checked for each gear position to verify a difference in
voltage at each gear. The gear indicator works properly, but if slightly out of gear
the voltage will automatically ground completely and read a voltage output equal
to the neutral position.
3.1.3. Integration
Gear Indicator:
The microcontroller is able to read each gear position consistently and provide
the required output to the proper led located in the rider display.
Solenoid and Microcontroller Operation:
Mechanical system performs smoothly with no binding errors. Clamping system
works properly and bracket performs full functionality. Buttons perform shifting
properly and mode select button is fully functional.
Button Shifting:
Upshifts:
Occur very smooth and fast. No bucking caused during spark cutout. Improved
acceleration times.
3.1.4. Customer Acceptance
The ATV will be available for testing at the customer’s convenience. A full evaluation of
feedback will be reported for future teams to work off of. All documentation will be turned
over to customer at the conclusion of the project.
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3.2.
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RIT KGCOE MSD Program
Logistics and Documentation
All test data, analysis, conclusions and results will be documented on EDGE at the following
location:
https://edge.rit.edu/content/P09310/public/Testing
3.3.
Contingencies/ Mitigation for Preliminary or Insufficient Results
Testing of components that failed were tested within the system to be fully functional. Further
investigation into the errors among the gear display system errors needs to be developed.
3.4.
Analysis of Data – Design Summary
The concept has been proved as a feasible way to complete customer needs. Some hardware
components could be replaced to further satisfy needs for reliability and durability, especially for
normal ATV use that is subject to variety of ground surface and weather conditions. The subsystem
designs were successful in relaying the status of the ATV shift to the user.
3.5.
Function/ Performance Reviews
3.5.1. Debriefing your Guide and Faculty Consultants
Project review was complete 2/20/2009 to update participants with a managerial review of the
project including budget, schedule, successes and failures.
3.5.2. Lab Demo with your Guide and Faculty Consultants
Lab demo to be completed in front of Engineering building on 2/27/2009 to demonstrate ability for
up and down shifting in both micro-controlled modes.
3.5.3. Meeting with Sponsor
Customer will receive design packet including all parts, pricing, drawings, wiring diagrams,
connector pinouts, and summary of test results. Opportunity to ride and test functionality will be
available at the convenience of the customer.
RIT KGCOE MSD Program
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