Prototyping Definition, D&C

Iteration 1: Data Collection to Validate Assumptions

Prototype 1 Goals

1. Validate torque requirements so that we can reliable choose our gear ratios
2. Verify the effectiveness of our wheel treads/handling system
3. Identify weak points and flawed areas in the drivetrain and chassis design
4. Gain a better understanding of how the rover will interact with the field

Prototype 1 Plan

1. Collect data from driving the rover climbing out of different positions & while turning
   1. This should be data that we can derive torque from – i.e. speed and/or current draw – so that we have a comparison of our theoretical torque calculations versus actual
2. Compare the different tread styles while field testing, looking at each style's climbing VS turning abilities
   1. Qualitative comparison, but also compare the torque data (which ones were visually successful at the different trials, while also requiring the least amount of torque?)
   2. How well do the treads hold to the wheel? How long can we drive before they start to wear and worsen in performance?
3. Document any high-stress points in the drivetrain and chassis system that required repair at the end or throughout the tests
   1. Based on this initial testing, we'll update the design based on the areas we believe don't have enough reinforcement
   2. What is the effectiveness of the differential bar, in its current position and with its current design?
4. Test the rover driving over real terrain and obstacles
   1. Document any initial, sticky points in the design that can be modified in Prototype 2
   2. Determine the rover's centre of gravity. Can also do this by placing it on a platform and tilting it to different angles up to 45 deg

Task List for Prototype 1

• Develop a wooden prototype with a functioning controls system
  
  • Select FRC motors and gear ratios to operate under our assumed torque calculations
  • Come up with a mechanical build plan for the wooden model
  • Determine what tools to use to collect motor data
  • Develop controls system plan
  • Write the code that will log the field data
• Assemble prototype wheels with a variety of different tread styles
• Perform wheel testing
• Perform simulation testing

Iteration 2: Flesh Out a Near Finished Project (i.e. Initial Build of Design)

Prototype 2 Goals:

1. Verify structural integrity of the overall system
2. Verify climbing, turning ability, and repeatability
3. Verify assembly, tolerances, fits, and maintenance ability
4. Integrate electrical components, cable routing, etc

Prototype 2 Plan:

1. Perform FEA on the structure before manufacturing
   1. Document any high-stress points in the drivetrain and chassis system that required repair at the end or throughout the tests
   2. How robust are our components?
   3. How much does the chassis rock during traversal? Are the electronics enduring any shock?
2. Determine qualitatively through field testing
   1. How much does our climbing ability require on driver precision?

Iteration 3: Final Touch Ups / Optimization

• Integrate higher quality production materials such as carbon fiber for structural members
• Consider FEA for mass optimization
• Reduce unique parts and BOM
• Aesthetics