test plan template - rochester institute of...

Document Revision No.: 2 Revised: 05/25/23 RIT KGCOE MSD Program

P11401 Portable High Power-Density Energy SystemTest Plans & Test Results

Table of contents

Note: Once you complete each of the three sections, right click on the table below and select Update Field to update the Table of Contents.)

1. MSD I: PRELIMINARY TEST PLAN 21.1. Sub-Systems/ Functions/ Features 2

1.2. Engineering Specificiations 3

1.3. Test Equipment 5

MSD II WKS 2-3 TEST PLAN – “HOW, WHO, WHEN” 62.1. Weight Test 6

2.2. System Size Test9

2.3. Sound Pressure Level Test 11

2.4. Power Test 13

2.5. Voltage Test 15

2.6. Ripple Test 16

2.7. Battery Charge Time Test 18

2.8. Battery Discharge Time Test 20

2.9. Quantity Test 22

2.10. Generator Test 23

2.11. Energy Storage Efficiency Test 26

2.12. Drop Test 28

2.13. Component Operating Temperature Range Test 30

2.14. Compatibility Test 33

2.15. Surface Operating Temperature Test 35

2.16. RoHS Compliance Test 37

2.17. Power Achievement Test 39

2.18. Test Procedure, timeline 41

3. MSD II – WKS 3-10 DESIGN VERIFICATION 423.1. Logistics 42

3.2. Analysis of Data – Design Summary 42

3.3. Conclusion or Design Summary 42

RIT KGCOE MSD Program Revision:


P11401Preliminary Test Plan

1. MSD I: PRELIMINARY TEST PLAN1.1. Sub-Systems/ Functions/ Features

Major Sub-Systems/ Features/ Function

1 Acquiring Energy to a Charge Li-ion Battery

2 Charging a Li-ion Battery

3 Giving Power to WOCCS System – Through Li-ion Battery



(continued)

1.2. Engineering SpecificiationsIf not already, apply specifications to each sub-system, feature and/or function. Project “clustered” into “chunks”, as described in MyCourses reading Ulrich Chap. 9: Product Planning & Systems Design. Review page 174; Exhibit 9-7, and page 183; Exhibit 9-14.

For previous team examples, see MSD I MyCourses/ Content/ Week 6 Detailed Design Test Plan (samples) and https://edge.rit.edu/content/P10232/public/TestPlan.

For example of completed test results, see https://edge.rit.edu/content/P10232/public/Project%20Test%20Reports.

P11401: Preliminary Test Plan

Test # Engineering Spec Verification Method

Fail Criteria

1 Net weight Measurement > 30 lbs2 System volume Measurement > 7 cubic feet

3System sound pressure level (audible noise)

Measurement > 90 dB

4 Power: rated, peak Measurement < 1 Watts5 Voltage: rated, peak Measurement < 3.2 Volts6 Ripple: % of battery voltage Measurement > 0.5%7 Li-Ion Battery charge time Measurement > 8 hours8 Li-Ion Battery discharge time Measurement < 6 hours

9 Battery Quantity during charging Observation Greater than 1

10 Energy generation efficiency Analysis < 15 %11 Energy storage efficiency Analysis < 50 %12 Withstand drop impact Measurement < 5 feet13 Operating temperature range Measurement > 32°F or > 100°F

14Compatible with P11201 test bench components

Demonstration Not Compatible

15Component surface operating temperature

Measurement > 140 °F

16RoHS Compliant with hazardous substances laws

AnalysisNot all parts are

compliant17 Achieve power Demonstration < 1.155 Watt-hr


https://edge.rit.edu/content/P10232/public/Project%20Test%20Reports

https://edge.rit.edu/content/P10232/public/TestPlan


Overall System

Engr. Spec. # Specification (description) Unit of Measure Marginal Value TestES1 Net weight Analysis > 30 lbs Weight TestES1 System volume Analysis > 7 cubic feet Volume Test

ES3 System sound pressure level (audible noise) Test > 90 dB

Sound TestES12 Withstand drop impact Test < 5 feet Drop Test

ES16 RoHS Compliant with hazardous substances laws Analysis Not all parts are

compliant Compliance Test

Generating PowerEngr. Spec. # Specification (description) Unit of Measure Marginal Value Test

ES10 Energy generation efficiency Analysis < 15 % Generator TestES17 Achieve power Demonstration < 1.155 Watt-hr Power Capture Test

Charging BatteryEngr. Spec. # Specification (description) Unit of Measure Marginal Value Test

ES7 Li-Ion Battery charge time Test > 8 hours Charge Time Test

ES11 Energy storage efficiency Analysis < 50 % Energy Storage Efficiency Test

ES13 Operating temperature range Test > 32°F or > 100°F

Temperature Operating Test

ES15 Component surface operating temperature Test > 140 °F

Temperature Test

Supplying PowerEngr. Spec. # Specification (description) Unit of Measure Marginal Value Test

ES4 Power: rated, peak Test < 1 Watt Power TestES5 Voltage: rated, peak Test < 3.2 Volts Voltage TestES6 Ripple: % of battery voltage Test > 0.5% Ripple TestES8 Li-Ion Battery discharge time Test < 6 hours Discharge Time TestES9 Battery Quantity during charging Observation Greater than 1 Quantity Test

ES13 Operating temperature range Test > 32°F or > 100°F

Temperature Operating Test

ES14 Compatible with P11201 test bench components Demonstration Not Compatible

Compatibility Test

ES15 Component surface operating temperature Test > 140 °F

Temperature Test



1.3. Test Equipment Focus on any equipment that the team requires to measure specifications but is not available to measure specifications. Discuss this with your Guide. Some examples of specifications that teams could not measure were: measurement of forces, vibration, rf frequency spectrum, field strength, serial communication data accuracy, static and dynamic force measurements, very accurate velocity measurements, rf noise (S/N), complex data acquisition. Contact your Department Guide for any further equipment that may be necessary.

Engr. Spec. # Instrumentation or equipment not available (description)

ES1 ES2ES3 ES4



MSD II WKS 2-3 TEST PLAN – “HOW, WHO, WHEN”

2.1. Weight Test

Date Completed: ___________________Performed by: _____________________

SPECIFICATION TEST

Tested Specification Description Unit of Measure Marginal ValueES1 This test is designed to determine the

weight of the entire system which includes the wind turbine, charge circuitry and Li-ion Battery.

Lbs. Less than 30lbs.

Revision History

Revision Description Date1 Document created Dec. 18, 2010

EQUIPMENT_____ Scale – accurate to within 0.5 lb _____ #1 Phillips head screwdriver_____7/16 wrench _____ #2 Phillips head screwdriver_____5/64 Allen wrench _____ 7/16 socket wrench

PROCEDURE_____ 1. In EE senior design lab, disassemble blades from hub using 7/16 socket wrench. Place bolts and nuts back into hub to ensure that none are misplaced. Set blades and hub aside.

Figure 1: Hub and blades assembly

Figure 2: Disassembled 4' galvanized pipes (step 2)Left – Bottom pipe



Right – Top Pipe

_____ 2. Disassemble turbine stand to most basic components by unscrewing threaded connections. There are two 4’ galvanized pipes (see image above) that makeup the turbine stand. Leave the connector coupling attached to the bottom 4’ pipe, and keep the top coupling and 3” pipe attached to the top 4’ pipe. The joint connections of the entire tail assembly are permanently fixed and will not unscrew. Disconnect the motor mount from this assembly, leaving the motor attached to the mount.

Figure 3: Support cables and spikes Figure 4: Tail assembly with motor disconnected

Figure 5: Tail assembly with motor attached

_____ 3. Weigh each individual component listed below and record in respective column

_____ 4. Sum the weight and record total weight of system

_____5. Check the box indicating pass or fail

_____6. Reassemble components, or leave components disassembled for the System Size Test.

RESULTS

Component Weight (lbs)Turbine Blade 1Turbine Blade 2Turbine Blade 3



Hub with nuts and boltsTail assemblyCab les with flange and carabineers4’ Galvanized Pipe #1 with coupling (bottom half of stand)4’ Galvanized Pipe #2 with coupling and 3” pipe ( top half of stand)Spikes (4)Electronics Box with Charge Circuitry and 20 gage generator wireGenerator with mount

Total

Pass/Fail CriteriaThe system passes the weight test if the total weight is less than or equal to 30 lbs. The system fails the weight test if the total weight is greater than 30 lbs.

Pass □ Fail □

COMMENTS



2.2. System Size Test

Volume Measurement


SPECIFICATION TESTED

Tested Specification Description Unit of Measure

Marginal Value

ES2

The system volume test determines the total volume of the charging system in its most compact form. It is a test for transportability, with the underlying idea being that the marginal value is the maximum size desirable to be carried by a soldier in the field.

ft3 Less than 7 ft3

Revision History

Revision Description Date1 Document created 01/03/2011

EQUIPMENT_____ 25’ Tape measure _____ 7/16” wrench and 7/16” socket_____ 12” Ruler _____ #1 Phillips head screwdriver_____#2 Phillips head screwdriver _____ Flathead screwdriver_____ Micrometer

PROCEDURE_____ 1. Disassemble turbine stand and assembly to individual components in the laboratory. This test would be best performed after the weight test, since each component will be already disassembled. _____ 2. Organize turbine components and charge circuit into compact form on table, as if system was to be packaged. Stack blades together, group galvanized steel pipe_____ 3. Using equipment listed above, measure length, width, and height of layout to determine the overall space volume occupied by the disassembled system_____ 4. Record the length, width, and height measurements in the table below_____5. Reassemble components

RESULTS



Disassembled Charging System Volume

Length inchesWidth inchesHeight inches

System Volume in3

ft3

Pass/Fail CriteriaThe system passes the size test if the total measured volume is less than 7 ft3. The system fails the size test if the total volume exceeds the limit of 7 ft3.

Pass □ Fail □COMMENTS



2.3. Sound Pressure Level Test



Tested Specification Description Unit of Measure Marginal Value

ES3

The sound pressure level test is a measure of the audible noise produced from the blades, generator and charge circuit during the charging phase.

dB 90 dB

Revision History


EQUIPMENT

_____ Decibel Meter _____ Anemometer

PROCEDURE

_____ 1. Set up wind turbine in test stand on the hill behind RIT building 78. *Note: average wind must be at least 1.5 m/s (~3.5 mph) on the day of testing

_____ 2. Connect generator motor to charge circuit. See assembly instructions for more detail.

_____ 3. Place discharged battery into charge circuit battery holder. See assembly instructions for more detail on properly discharging a lithium ion battery.

_____ 4. As the turbine blades spin, measure blade sound pressure level at a distance of approximately 3 feet from blades.Note: use caution as spinning blades can cause injury

_____ 5. As generator motor is spinning and battery is charging, measure sound pressure level output using decibel meter from both the generator and charge circuit at each voltage input level

_____6. Record results in Table 1

_____7. Repeat steps two more times to ensure consistency in measurements



RESULTS

TABLE 1: Recorded Measurements

Average Windspeed Sound Pressure Level

mph dB

Pass/Fail Criteria

The system passes the sound pressure level test if the total sound pressure level does not exceed 90 dB. The system fails the test if, at any point, the sound pressure level exceeds the threshold limit of 90 dB.




2.4. Power Test


SPECIFICATION TEST


ES4This test is designed to determine the instantaneous power the power board produces for the WOCCS system.

Watt 1Watt

Revision History

Revision Description Date1 Document created Jan. 2, 2011

EQUIPMENT_____12 ohm Load with Mating Connector*_____EE senior design room lab bench_____Digital Multi-meter_____Oscilloscope_____Scope Probe_____Power Board_____TI-83 Calculator or equivalent

* 12ohm load is used based on1 Watt = (3.5 Volts)2/R, where 3.5 Volts is the average battery voltage. Resistance R was solved to be 12 Ohms

PROCEDURE_____ 1. Measure the resistance of the load with the multi-meter and record in the table below_____ 2. Connect load to the RF connector on the Power Board_____ 3. Connect the scope probe across the load _____ 4. Record the voltage value and record in the table below_____ 5. Find the Power by multiplying Voltage by Voltage and divide it by the Resistance and record the value in the table

below _____6. Check the box indicating pass or fail

RESULTS

Measured ValueLoad Resistance (Ohm) Voltage (V)



(W)

Pass/Fail CriteriaThe system passes the power test if the power is greater than 1W. The system fails the power test if the total power is less than 1W.

Pass □ Fail □

COMMENTS



2.5. Voltage Test


SPECIFICATION TEST


ES5This test is designed to determine the voltage the power board outputs at a set load over a period of time.

Volts 3.2V

Revision History


EQUIPMENT_____16 ohm Load with Mating Connector*_____Lab Bench_____Oscilloscope_____Scope Probe_____Power Board

* Load resistance calculated by R = V/I, where V = 3.5 Volts (average battery voltage) and I = 0.220 Amps (max current supplied to the WOCCS transceivers)

PROCEDURE_____ 1. Connect load to the RF connector on the Power Board_____ 2. Connect the scope probe across the load_____ 3. Record the voltage value and record in the table below_____4. Check the box indicating pass or fail

RESULTS

Measured ValueVoltage (V)

Pass/Fail CriteriaThe system passes the voltage test if the voltage is greater than or equal to 3.2V. The system fails the voltage test if the total voltage is less than 3.2V.

Pass □ Fail □



COMMENTS

2.6. Ripple Test


SPECIFICATION TEST


ES6 This test is designed to determine the ripple voltage the power board produces. Percentage 0.5%

Revision History


EQUIPMENT

_____16 ohm Load with Mating Connector_____Lab Bench_____Oscilloscope_____Scope Probe_____Power Board_____Calculator

* Load resistance calculated by R = V/I, where V = 3.5 Volts (average battery voltage) and I = 0.220 Amps (max current supplied to the WOCCS transceivers)

PROCEDURE

_____ 1. Connect load to the RF connector on the Power Board_____ 2. Connect the scope probe across the load _____ 3. Find the peak-to-peak voltage value and record it in the table below_____ 4. Find the average voltage value and record it in the table below_____ 5. Find the percentage by taking the peak-to-peak voltage value and dividing it by the average voltage value and

multiply by 100 and record it in the table below_____6. Check the box indicating pass or fail

RESULTS

Measured ValuePeak-To-Peak Voltage (V) Average Voltage (V)



(%)

Pass/Fail Criteria

The system passes the ripple test if the percentage is less than or equal to 0.5%. The system fails the ripple test if the percentage is greater than 0.5%.

Pass □ Fail □

COMMENTS



2.7. Battery Charge Time Test Date Completed: ___________________

Performed by: _____________________



ES7

The battery has a 3.7 nominal voltage. Discharge battery to 3.2 V (this is the voltage level at which the WOCCS group will no longer be able to pull power). Charge battery to 4.2 V and measure the time duration to reach this voltage.

Minutes (Hours) 480 (8)

Revision History


EQUIPMENT

Check Off Item Detailed DescriptionBatteryCharging CircuitWind TurbineMultimeterStopwatch

PROCEDURE

_____ 1. Ensure battery is fully discharged (VBATT < 3.2 V). Use discharge circuit from the Battery Discharge Test Plan to completely discharge battery if necessary.

_____ 2. Setup wind turbine. See Wind Turbine Assembly Plan for details.

_____ 3. Place battery in battery holder. Connect battery charge circuit to turbine. Place voltmeter (multimeter) across battery. Simultaneously start stopwatch.

_____ 4. Measure and note the voltage across the battery at 30 minute intervals.



RESULTS

Time (Minutes)

Voltage (V) Time (Minutes)

Voltage (V)

30 510 60 540 90 570 120 600 150 630 180 660 210 690 240 720 270 750 300 780 330 810 360 840 390 870 420 900 450 930 480 960

Pass/Fail Criteria

The system passes the charging test if the voltage across the battery reaches 4.2 V (or fluctuates above 3.7 V) before or at the 480 minute mark.




2.8. Battery Discharge Time Test Date Completed: ___________________

Performed by: _____________________

SPECIFICATION TEST


ES8Pull average current of 220 mA from the fully charged battery, measure time it takes for voltage to drop to 3.2 V.

Minutes (Hours) < 360 (6)

Revision History


EQUIPMENT

Check Off Item Detailed DescriptionBatteryBattery HolderBreadboardPower SupplyBJT (x4) Q2N3904Resistor 100 OhmMultimeter (x2)Stopwatch

PROCEDURE

_____ 1. Use digital multimeter, verify that battery is fully charged (VBATT > 3.7 V)

_____ 2. Construct circuit shown in diagram below. Do not ground circuit yet.

Figure 1 Improved Wilson Current Mirror

_____ 3. Place voltmeter across battery to measure voltage concurrently. Place ammeter in series with battery to measure current concurrently.

_____ 4. Simultaneously connect ground and start stopwatch.



_____5. Monitor Current and Voltage, noting both at 30 minute intervals.

_____6. Stop measurements when VBATT drops below 3.2V.

RESULTS

Time (Minutes) Current (mA) Voltage (V)306090120150180210240270300330360390420450480

Average Values

Pass/Fail Criteria

The system passes if the voltage across the battery is above 3.2 V after 360 minutes and the average current drawn from time 0 minutes to time 360 minutes is greater than or equal to 220 mA.

Note: If the average current does not pass spec, retry using a smaller resistance value.




2.9. Quantity Test

Date Completed: ___________________Performed by: ___________________

SPECIFICATION TEST


ES9

This test is designed to determine the total batteries that are charged in a single charge cycle, as well as the number of batteries used in a single phase of the WOCCS mission.

Binary 1

Revision History


EQUIPMENT

_____ MSD lab notebook and pen

PROCEDURE_____ 1. Locate WOCCS power board. _____ 2. Observe total battery holders. Record value in Table 1

RESULTS

TABLE 1 Battery QuantityWOCCS Power Board

Pass/Fail Criteria

The system passes the battery quantity test if the number of batteries used on the WOCCS board is equal to one. The test fails if the quantity of batteries in the WOCCS power board is greater than one.

Pass □ Fail □

COMMENTS



2.10. Generator Test

Energy Generation Efficiency

Date Completed: ___________________

Performed by: _____________________

SPECIFICATION TEST

Tested Specification Description Unit of

Measure Marginal Value

ES10

This test is to determine the efficiency of energy captured from the wind through the power electronics, blade, and generator efficiency losses. The power in the wind will be determined using the equation P = ½ ρAv3. The power output from the generator will be measured at this wind speed. The system efficiency is determined by dividing generator power output by power in the wind.

% 15%

Revision History


EQUIPMENT

_____ Anemometer

_____ Digital Multi-meter

_____ Generator (Pacific Scientific Stepper Motor)

_____ Wind Turbine (Blades and Stand Assembly)

_____ Connected Load Device (Battery Charger IC and Lithium Ion Battery)

_____ Calculator

_____ Data Logger Model ___________ P/N ____________



PROCEDURE

_____ 1. The wind turbine will be constructed outside with the generator connected during the daytime with average wind conditions present.

_____ 2. Use the Anemometer to determine the current wind speed. The power in the wind is calculated using the equation shown in [1].

Pw = 1/2ρAv3 [1]

Where;

Pw = Power ρ = Air Density A = Swept Area of the Blades v = wind speed

______ 3. Connect the Anemometer to the Data Logger and begin recording wind speed data. This will be used to verify average wind speed conditions to compare against the output power of generator.

_____ 4. Measure the voltage and current output of the generator using a digital multi-meter under no load conditions. This is to verify proper operating function of the generator. The power of the generator is calculated using the equation shown in [2].

PG = V∙I [2]

Where;

PG= Power of Generator V= Voltage Output I = Current Output.

_____ 5. The output will then be connected to the battery charging circuit to simulate a load connection. The Charger IC LED should indicate the battery is properly charging. Use the digital multi-meter to test the DC rectified voltage and current from the generator. Use equation [2] to determine the generator power.

_____ 6. The system efficiency is determined by dividing the generator power output by the power in the wind during proper operation.

RESULTS

Data Set Average

Wind Speed (m/s)

Generator

Voltage (V)

Generator Current (I)

Power of Generator (W)

Power in Wind (W)

1



2

Pass/Fail Criteria

The system passes the Energy Generation Efficiency test if the total system efficiency during average wind conditions and proper operation is greater than or equal to 15%. The system fails the Energy Generation Efficiency test if the system efficiency falls below 15%.




2.11. Energy Storage Efficiency Test

Date Completed: ___________________

Performed by: ___________________

SPECIFICATION TEST


ES11

A bench test that compares output from the generator with input to the charging circuit using similar techniques described in energy generation efficiency test.

Efficiency (Percentage) > 50%

Revision History


EQUIPMENT

Check Off Item Detailed DescriptionWind TurbineRectification CircuitLoad CircuitMultimeter (x2)Calculator

PROCEDURE

_____ 1. Setup Wind Turbine. See Wind Turbine Assembly Plan for details.

_____ 2. Setup Rectification Circuit. See Rectification Circuit Assembly Plan for details.

_____ 3. Setup voltmeter and ammeter (Multimeter #1) after generator but before rectifier.

_____ 4. Setup voltmeter and ammeter (Multimeter #2) after rectifier but before charge circuit.

_____5. Measure voltage and current both before and after rectification circuit. Repeat 10 times.



RESULTS

After Generat

orAfter

RectifierPost-

Generator Power

Post-Rectifier Power

Efficiency

Measurement Voltage Current Voltage Current (P = V*I) (P = V*I) PG/PR1 2 3 4 5 6 7 8 9

10

Pass/Fail Criteria

The system passes the energy storage test if all 10 calculated efficiencies are greater than 0.5 (50%).

Pass □ Fail □

COMMENTS



2.12. Drop Test


SPECIFICATION TEST


ES12

The drop test is a measurement of the durability of the wind turbine and charging circuitry. The intention is to test for the components’ ability to withstand being dropped on the ground during transport or setup.

ft 5 ft

Revision History


EQUIPMENT_____ 25’ Tape measure _____ #1 and #2 Phillips head screwdrivers_____ 5 ft galvanized pipe _____ Flathead screwdriver_____7/16” socket wrench _____ 5/64 Allen wrench, 3/32 Allen wrench

PROCEDURE_____ 1. Disassemble turbine to individual components (blades, hub, motor w/ mount, tail)_____ 2. Place charge circuitry in charging box with lid securely attached_____ 3. Place all components in flat grass behind the parking loop of the KGCOE building_____ 4. Using the 5 ft galvanized pipe as a reference height, drop each component in Table 1 from

a five foot height onto the earth_____ 5. Record and describe any damage in Table 1. _____ 6. After performing the test, reassemble the turbine, check for functionality_____ 7. Test generator motor in the lab with charge circuit to verify functionality_____ 8. Record functionality and description in Table 2

RESULTSTable 1: Drop Test Results

Component Damage InducedBladesHubGenerator motorTail Assembly4 ft stand pipesCable supportsCharge circuit



Table 2: Functionality Verification

Component Functional (Y/N) DescriptionTurbine StandBladesGenerator motorCharge Circuit

Pass/Fail Criteria

The system passes the drop test if there is minimal to no damage recorded in Table 1, and if each component in Table 2 is verified to be functional after the drop test. The drop test will result in failure if one or more of the components of Table 2 is listed as “No” for functional.

Pass □ Fail □

COMMENTS



2.13. Component Operating Temperature Range TestDate Completed: ___________________

Performed by: ___________________

SPECIFICATION TEST


ES13

The Operating Temperature Range Test determines the minimum and maximum

temperatures for which the system operates effectively.

Celsius Minimum = 0º CMaximum = 40 º C

Revision History


EQUIPMENT




_____ Access to Wind Tunnel Facility

PROCEDURE

_____ 1. TitanX is a company that provides rental access to a climatic wind tunnel. To perform this test this company will be contacted and the steps involved to access and use their facilities will be documented and evaluated.

_____ 2. TitanX US Wind Tunnel - The climatic wind tunnel is a powerful tool for TitanX’s internal product development, but it’s capabilities are also available on a rental basis for testing of cars, trucks and buses. Testing can also be performed on non-vehicle products such as outdoor storage and structures, alternative energy technologies, etc.



Figure 1: Diagram of Wind Tunnel Set-up.

_____ 3. Once the needed instrumentation has been determined, TitanX technicians prepare the device, installing test components and the sensors (thermocouples, flowmeters, pressure transducers, fiberoptic rpm pickups, current shunts, etc.) that will interface with the data acquisition system.

_____ 4. US contact Info Below

Phone: 716-665-7166

Fax: 716-665-7184

Website: http://www.titanx.com/

Email: jmt _ titanx _ vwtinfo @ titanx . com

Mail: Vehicle Climatic Wind Tunnel

TitanX Engine Cooling, Inc.233 Blackstone AvenueJamestown, New York 14701

RESULTS


mailto:[email protected]









http://www.titanx.com/


Pass/Fail Criteria

The system passes the temperature range test if the system operates in a minimum temperature of 0 degrees Celsius and in a maximum temperature of 40 degrees C.

Pass □ Fail □

COMMENTS



2.14. Compatibility Test


SPECIFICATION TEST


ES5 This test is designed to determine the compatibility with the WOCCS System Demonstration Compatible

Revision HistoryRevision Description Date1 Document created Jan. 2, 2011

EQUIPMENT_____WOCCS Box_____WOCCS RF Board_____WOCCS Test Bench Board_____Power Board

PROCEDURE_____ 1. Load the power board and RF Board into the WOCCS Box _____ 2. Connect the WOCCS test bench board to the power board_____ 3. Look to see if the Power board fits into the WOCCS box with the lid close and check the table below_____ 4. Check to see if the connectors connect properly to the RF Board, with the switch on, check to see if the power LED

lights up and check the table below_____ 5. Take out the jumper connector and connect the WOCCS test bench board to the power board and see if it properly

is connected and check the table below_____6. Add all the passes and failures up in the table below_____7. Check the box indicating pass or fail

RESULTS

Test Pass Fail Power Board Fits into the WOCCS Box Connector mates with the RF Board Power LED lights up Connector mates with the WOCCS Test Bench Board

Total



Pass/Fail CriteriaThe system passes the compatibility test if the table above has no failures. The system fails the compatibility test if the table above has one or more failures.

Pass □ Fail □

COMMENTS



2.15. Surface Operating Temperature Test




ES15

The surface operating temperature test will measure and evaluate the surface temperature of the generator and charge circuitry during normal charging operation.

°F 140°F

Revision History


EQUIPMENT_____ Motor test stand _____ Oscilloscope ____ Phillips head screwdriver_____ Thermocouple _____ Power Supply_____ Thermometer _____ Alligator clips

PROCEDURE_____ 1. In the EE Senior Design lab, set up the generator motor in the motor test stand and connect the shaft to a driver motor_____ 2. Connect driver motor to power supply using alligator clips_____ 3. Connect generator motor to charge circuit using alligator clips_____ 4. Place discharged Li-Ion battery into battery holder of the charge circuit_____ 5. Place charge circuit into its containing box and secure the lid _____ 6. Begin charging battery at 0.25C_____ 7. Set thermocouples on surface of generator motor and surface of container box_____ 8. Record temperature of generator and container box at 10 minute intervals in Table 1

RESULTS

Time Interval Driver Motor Input Voltage

Container Box Temp

Generator Temp

Minutes Volts °F °F01020



30405060708090100110120

Pass/Fail CriteriaThe system passes the surface operating temperature test if the temperatures of both the container box and the generator motor do not exceed 140°F at any time interval during the charge rate of 1C. If at any point the temperature of either container box or generator motor exceeds 140°F, the test is failed.

Pass □ Fail □

COMMENTS



2.16. RoHS Compliance Test

Date Completed: __ 12/29/10_________Performed by: ____Trevor Smith______

SPECIFICATION TEST


ES16

The RoHS Compliance test determines the overall system compliance by collecting and verifying documented evidence outlining each components adherence to the EU Directive.

Demonstration Pass

Revision HistoryRevision Description Date1 Document created 12/18/2010

EQUIPMENTN/A

PROCEDURE

_____ 1. Obtain RoHS Letter of Certification for electrical components used in this design. _____ 2. Obtain a Material of Declaration test report to verify the absence of prohibited substances in relevant components.

RESULTS

See Attached RoHS Compliance Certificates and Declaration Sheets. Note that batteries are not included within the scope of RoHS.

Pass/Fail Criteria

The system passes the RoHS Compliance test if every relevant subsystem and component is compliant. The system fails the test if one or more components are non-compliant. Compliance Certificates must be obtained for each relevant component. The directive applies to equipment as defined by a section of the WEEE directive. The following numeric categories apply:

1. Large and small household appliances.2. IT equipment.3. Telecommunications equipment (although infrastructure equipment is exempt in some countries)4. Consumer equipment.5. Lighting equipment—including light bulbs.



6. Electronic and electrical tools.7. Toys, leisure, and sports equipment.8. Medical devices (currently exempt)9. Monitoring and control instruments (currently exempt)10. Automatic dispensers.

As such the Wind Turbine Assembly does not apply to this test.

Pass ■ Fail □

COMMENTS



2.17. Power Achievement Test

Date Completed: ___________________

Performed by: _____________________

SPECIFICATION TEST


ES17

The power achievement test determines the measured power output from the generator and verifies the minimum power required to charge the battery (1.115 Watts) is achieved during average wind conditions.

Watts 2 W

Revision History


EQUIPMENT

_____ Anemometer

_____ Digital Multi-meter




PROCEDURE

_____ 1. The wind turbine will be constructed outside with the generator connected during the daytime under average wind conditions (5 – 15 mph).

_____ 2. Use an Anemometer to determine the current wind-speed. Verify that the speed at least 4 MPH.

_____ 3. Measure the voltage and current output of the generator using a digital multi-meter.



_____ 4. The output will then be connected to the battery charging circuit to simulate load connection. The Charger IC LED should indicate the battery is properly charging.

RESULTS

Include any tables, charts, and space for figures needed

Pass/Fail Criteria

The system passes if the wind turbine is able to turn the generator at a speed of 110 RPM’s under average wind conditions while the battery load is connected. At this speed the generator output should be approximately 4V at 0.5A (equivalent of 2 Watts). The system fails the power achievement test if the turbine generator system fails to deliver the required power when the battery load is connected.




2.18. Test Procedure, timelineWho is testing what and when? Are there interdependencies between subsystems (Block Diagram)? Can test equipment enable preliminary simulation of needed signals prior to integrating into the next level of completion?



3. MSD II – WKS 3-10 DESIGN VERIFICATION

For an example of completed test results, see https://edge.rit.edu/content/P10232/public/Project%20Test%20Reports

3.1. Logistics Each individual test plan will be printed out, and results shall be recorded in ink on the hard copy. These results will then be electronically entered into this document, and the hard copy will be filed in a Test Plan folder for record. The electronic version of the test plan will be uploaded to the Edge website at https://edge.rit.edu/content/P11401/public/MSD%20II%20Documents.

Project notebooks will be used for recording data and making observations and necessary notes while performing the tests.

3.2. Analysis of Data – Design SummaryThis section is to be completed at the conclusion of the testing.

3.3. Conclusion or Design SummaryCan you explain why a particular function doesn’t work? Conclusions are reported or summarized (i.e. significance with confidence, pass/fail, etc.) as applicable.

3.3.1. Lab Demo with your Guide and Faculty Consultants

Perform each of the specifications and features.

3.3.2. Meeting with Sponsor

See Customer Acceptance above. Field Demonstration. Deliver the project. Demonstrate to the Sponsor. Customer needs met / not met.


https://edge.rit.edu/content/P11401/public/MSD%20II%20Documents

https://edge.rit.edu/content/P10232/public/Project%20Test%20Reports