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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. RIT KGCOE MSD Program Page 2 Document Revision No.: 2 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 Page 3 Document Revision No.: 2 Revised: 06/29/17 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 RIT KGCOE MSD Program Page 4 Document Revision No.: 2 1.4. Revised: 06/29/17 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 RIT KGCOE MSD Program Page 5 Document Revision No.: 2 Revised: 06/29/17 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 Page 6 Document Revision No.: 2 Revised: 06/29/17 RIT KGCOE MSD Program 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 RIT KGCOE MSD Program Page 7 Document Revision No.: 2 Revised: 06/29/17 RIT KGCOE MSD Program 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 RIT KGCOE MSD Program Page 8 Document Revision No.: 2 Revised: 06/29/17 RIT KGCOE MSD Program 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 Page 9 Document Revision No.: 2 Revised: 06/29/17 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 RIT KGCOE MSD Program Page 10 Document Revision No.: 2 Revised: 06/29/17 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 RIT KGCOE MSD Program Page 11 Document Revision No.: 2 Revised: 06/29/17 RIT KGCOE MSD Program 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 RIT KGCOE MSD Program Page 12 Document Revision No.: 2 Revised: 06/29/17 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 RIT KGCOE MSD Program Page 13 Document Revision No.: 2 Revised: 06/29/17 RIT KGCOE MSD Program 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. RIT KGCOE MSD Program Page 14 Document Revision No.: 2 2.3. Revised: 06/29/17 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. RIT KGCOE MSD Program Page 15 Document Revision No.: 2 Revised: 06/29/17 RIT KGCOE MSD Program 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 RIT KGCOE MSD Program Page 16 Document Revision No.: 2 Revised: 06/29/17 RIT KGCOE MSD Program 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. RIT KGCOE MSD Program Page 17 Document Revision No.: 2 3.2. Revised: 06/29/17 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 Page 18