Prototyping Definition, D&C
Iteration 1: Data Collection to Validate Assumptions
Prototype 1 Goals
- Validate torque requirements so that we can reliable choose our gear ratios
- Verify the effectiveness of our wheel treads/handling system
- Identify weak points and flawed areas in the drivetrain and chassis design
- Gain a better understanding of how the rover will interact with the field
Prototype 1 Plan
- Collect data from driving the rover climbing out of different positions & while turning
- 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
- Compare the different tread styles while field testing, looking at each style's climbing VS turning abilities
- 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?)
- How well do the treads hold to the wheel? How long can we drive before they start to wear and worsen in performance?
- Document any high-stress points in the drivetrain and chassis system that required repair at the end or throughout the tests
- Based on this initial testing, we'll update the design based on the areas we believe don't have enough reinforcement
- What is the effectiveness of the differential bar, in its current position and with its current design?
- Test the rover driving over real terrain and obstacles
- Document any initial, sticky points in the design that can be modified in Prototype 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:
- Verify structural integrity of the overall system
- Verify climbing, turning ability, and repeatability
- Verify assembly, tolerances, fits, and maintenance ability
- Integrate electrical components, cable routing, etc
Prototype 2 Plan:
- Perform FEA on the structure before manufacturing
- Document any high-stress points in the drivetrain and chassis system that required repair at the end or throughout the tests
- How robust are our components?
- How much does the chassis rock during traversal? Are the electronics enduring any shock?
- Determine qualitatively through field testing
- 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