Note: Our team has compressed our images, but the image upload quota is still full, so this report does not have photos that we would have liked to attach.
Presently our most significant risk is a mounting failure destroying our Visor making it so that we cannot show it off at Demo Day. This risk is being managed with most of our full system tests and data collection ride being performed on our PLA version. The CAD is very similar between the PLA and CF-PLA versions with the most significant different being their material. By testing with our PLA version we still have a manufactured Visor that is ready for electronics. This was critical since we did have a mounting failure that was likely do to some extreme cold that resulted in zip ties snapping and the visor coming off of the bike. Luckily no electronics were broken and we were able to swap to the CF-PLA version. Since we no longer have a backup Visor we stopped on the bike testing and instead moved the Visor with a car for any other data collection.
No changes were made to the system design or to our schedule.
List all unit tests and overall system test carried out for experimentation of the system.
We tested dam actuation where we looked for visible wear in the servos and the rack and pinion system after 10,000 actuations. We tested for weather resistance, testing to see if water leaks into the visor under 10 minutes of shower water, which our prototype visor partially failed but our CF-PLA final visor passed. We also tested bike mounting and biker comfort, for which our visor performed well, unobstructing the bike user’s experience. We also tested website clarity, and our group received positive feedback from users, and users maintained an average comprehension speed of 30 seconds or less.
For overall system testing, we checked to make sure that while the Visor is on the bike, it is able to collect data, store that data until it reaches a SNIFF Station, and pass the data to the Station which uploads it so that the website is updated with that data.
List any findings and design changes made from your analysis of test results and other data obtained from the experimentation.
The sensor lid height was increased to accommodate the sensors and dam clearance, with the battery cavity size increasing to visually match extra sensor lid height.
The sensor lid layout was also adjusted as we realized that two sensors had fans facing each other directly, as well as to allow for wire clearance.
We switched from using heatset inserts to just screw holes as applying the heatset inserts offset the screw placement just enough to compromise our lid closure, making manufacturing basically impossible to get correct..
We also added a recess to the sensor lid screw holes so that the screw itself could be shorter and less likely to bite into the PLA at an angle, which would prevent the lid from closing.
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