Testing and Test Results
Introduction:
The underwater remote operated vehicle (ROV) is a controlled robot that can perform a specific set of functions to accomplish an assigned task at hand using versatile tools and other on-board equipment. The electronic portion of the underwater ROV is the heart of the project as it controls the propulsion and tools installed on the hull. The apparatus that was tested included the controller box (the land unit) and the underwater unit in the housing. Above, the controller box is shown (Figure 1) and functions as the primary unit for providing control. This unit was tested in the systems engineering lab, which is an adequate environment for confirming future testing will be successful. The expectations of the final solution are to accurately and precisely maneuver through the water in order to complete the SeaPerch challenge in correspondence with the 2011 challenge. Above (In Figure 2), the challenge is stated with all of the pieces of equipment utilized in the event. The testing procedures that were used for ensuring the effectiveness of the device and the quality of the work were the original ones stated on the blog. The same facilities were used for evaluating each component in the design. The images on the blog are different than the actual testing facilities because the procedures that were uploaded were written before actual testing was conducted with photography. One example is the facility on the right, which is the Neptune Aquatic Center (seen in Figure 3 on the right) which replaced the original swimming pool image in the document because of the inconvenience of conditions and availability. At the Neptune Aquatic Center, every member of the group was actively participating in testing and recording feedback. DM recorded information about the disposition of the hull, how it sat in the water, and took some photos. SR made slight alterations to hardware as needed and noted any failing components for adjustment at a later date. I took note of the motor positioning, tested motors for sound clarity, observed temperature of the wire operating at maximum current draw. The overall testing conducting at Neptune Aquatic Center, systems laboratory testing, and at-home small scale tests were conducted and all notes were recorded more modifications to be implied in the future as required. Final adjustments will be made according to testing feedback to work towards final evaluation.
Testing Procedures
Introduction
The expectations of the Underwater ROV are very high on my personal standards. Through rigorous evaluation of the alternate solutions and determining the best fit for the requirements my group is asking of me, The design has expectations of performing precisely and to respond quickly. Through the onboard components, the ROV will have 3 axis of motion on the X, Y, and Z axes. The design will offer numerous types of pressure response and various buttons to meet the needs of both SR and DM. The final design will be professionally done, have a clean installation, have solid connections, and be very responsible.
The final product has to meet our specifications to the best of the design’s capabilities. The design is going to perform as an independent system to operate under no human input besides controller operation. The electronics will complete the task from SeaPerch replicating the British Petroleum experiment. The design will conquer the task of stopping flow of the ‘oil’ spill, capping the well of flowing “oil” every 10 seconds, and to collect oil that rose to the surface.
The overall project consists of 3 major components: the hull, the arm, and the electronics. The electrical components of the ROV will undergo testing in steps. Starting with the foundation of the project and adding hardware to the design, testing in between each addition will ensure that each component works smoothly with other components. They go through testing with computer apparatus for quality control and performance.
The electrical components underwent construction in the Systems Laboratory. The components register with a serial monitor to be functioning correctly. The design needs to perform in a water-exposed environment. After it works successfully underwater, the team combines each unit together and tests the product as a whole on the surface, and then underwater. Afterwards, conduct the test outside the Systems Lab in order to test different medians to prepare for the final testing challenge.
Testing Stages
Exploratory Testing:
Ensure that the design is versatile, adaptable, user friendly, and meet the needs of the competition standards. At this stage, the solutions aren’t in a finalized state.
Check the following for updates for modifications since the release date:
Design Brief
o Is the design still plausible or able to be constructed?
o Are the proper tools and equipment available to you?
o Is the design possible to build in the atmosphere available to you?
Specifications / Limits
o Are the competition requirements the same?
· Did the task at hand deviate from the original?
Assessment Testing:
Final alternate solution is chosen from a strict criteria used in a design matrix. Create and publish a rationale discussing the evaluation measures. How does it meet the needs of the other group members?
- Observation of the alternate solution for flaws or glitches
- Talk to others to ensure the coherence between pieces.
o Do the electronics work within the hull design?
o Do the electronics require any type of mounting hardware others should be aware of
o Does the electronics meet the requirements of the arm?
o Is my project versatile enough to work with every subcategory?
- Revise the alternate solutions as required to unionize all work in one coherent final alternate solution.
o Make corrections to drawing and upload them to the blog with a thorough rationale and decision process to explain why it is the paramount design.
Validation Testing:
The final design is complete in the construction phase and product testing begins. The validation testing overall is in 4 different pieces: primary, secondary, tertiary, quaternary
- Primary Testing
1. Obtain and inspect each acquired component.
2. Measure components with a caliper.
3. Document the measurements for future drawings / dimensional analysis.
4. Ensure that waterproofing is a viable option with the working components.
- Secondary Testing
1. Test joints, connections, the joints that were waterproof through potting methods.
2. Test wires out of water and ensure continuity and current flows through the cables.
3. Ensure that all joints of the components are in place and acknowledge that impact may be a possibility with the ROV and failure is not an option.
- Tertiary Testing
1. Using the final electronics prototype, test the project as a whole.
2. Assembly is complete
3. Test components of the whole manually (motors and enclosures) at a depth of 15 feet.
- Quaternary Testing
1. Compilation of all of the individual systems is complete at this point in time.
2. All components / individual pieces are secure on the ROV
3. Run through quick visual checks to ensure all individual components are safe and in contact.
4. Send current/electric to the ROV and test each individual component on the Underwater ROV while on land.
5. After all systems are clear to go, place the ROV in a small tub of water (i.e. Bathtub)
6. Run diagnostics on the devices and ensure that there are no malfunctions, failures, and that everything is running up to par and expectations
7. If all systems are perfectly in check, test the ROV in an environment 15 feet below the surface to ensure it is capable of running with that amount of atmospheric pressure and to check that no complications arise such as cable length, or problems occur.
8. Test quality of the underwater camera in 15 feet of water.
9. Use test objects underwater to test utilities onboard the ROV including the arm. Ensure there is enough light for easy operation.
10. Report testing qualities on the observation sheet and survey.
Tools and Equipment (Used in the Brainstorming Phase)
- Orthographic Paper
- Isometric Paper
- Utility Pencils
- Straight edges
- Rules
- Laptop for Research
Tools and Equipment (Used in the Development Phase)
- Laptop / Desktop with AutoCAD
- Internet Capabilities
- Desk Surfaces
- Calipers
Tools and Equipment (Used in the Construction Phases)
- Drill Press
- Band saw
- Scroll Saw
- Table Saw
- Drill Gun
- Drill bit set
- Hot Glue Gun
- Caliper
- Architect Rulers
- Box Cutters
- X-Acto Knives
- Heat gun
- Laptop
- Orbit Sander
- Belt Sander
- Allen Key / Hex Key Set
- Socket Wrench Set
- Screwdrivers
- Chisels / Pry Tools
- Testing Conditions, Location, and Atmosphere
- Testing will begin with brainstorming thoughts, images, and ideas at workshop tables like the one below:
- Afterwards, construction will occur and the end product will be a prototypes of products. These will be tested in a 5-gallon bucket for quick testing considering that this stage is mostly individual component testing. This is an example below:
After this stage, we can test motors / bilge pumps in tanks such as the one below to observe water flow rate and how it performs with water resistance. This is an example of a tank similar to what we can use:
- Afterwards, once the electronics are in one unit, the team can test the ROV in an atmosphere like the one below: This is a swimming pool, but due to the deadlines we have to meet, a pool might not be available to us (due to the winter proofing process). If a pool is available to us, it is very convenient for the group to perform tasks and test for waterproofing
Below would be our second to last testing stage:
Testing Survey
General Feedback
Functionality on Land:
Do the parts function correctly?
Are the modifications on the ROV and functioning since the last test?
Electronic Component Securing and Strength:
Are all electrical components in check and secure in the waterproof box?
Is the installation on the OtterBox secure with a proper mount and stable?
Are all of the epoxy seals on the side of the OtterBox well maintained and appear exemplary?
Do the electrical components operate with the enclosure locked?
Do the electrical components work from a remote location?
Functionality Underwater:
Do the materials rust after taken out of the water for a long duration of time?
Do the functions and components work at their peak performance 15 feet underwater?
Motor Controller
Does the motor controller support the amperage demand of the components?
Does the motor controller heat up to a concerning amount during operation?
Motors
Does the motor operate properly?
Does the motor rotate counterclockwise and clockwise motions to concur with the groups expectations?
Tether
Does the tether reach the expectations of the group and the project?
Does the tether heat up to a concerning amount where consideration has to occur?
Does the tether have any kinks, dents, scratches, rips, tears, or imperfections?
Testing Results
Exploratory Testing:
- Design Brief
o Design remains plausible
o Tools and equipment is still available
o Design is still possible to build with facilities / atmosphere
- Specs / Limits
o Yes – SeaPerch Competition
o No Deviation from the task has been made
Assessment Testing:
- No flaws or glitches were round in the design
- All pieces of my construction coherently adjoin with Mr. Marketta’s hardware
- No alterations have to be made at this time in accordance with the Neptune Aquatic Center Testing Results
Validation Testing
- Primary Testing was fulfilled with the components at hand and the supplies acquired.
- Secondary Testing was ensured independently
o Instead of using Potting method, we ended up using waterproof enclosures in order to possible salvage the electronics or equipment for future use.
o Continuity Checked and Confirmed between connections of components
o Construction is solid and should not fail under plausible impacts
- Tertiary Testing
o Assembly was not completed at this stage to ensure it would work together, but each component works individually knowingly at this time.
- Quaternary Testing
o Cannot be conducted at this time because of time constraints. Securing of equipment is going underway in the next 2 weeks to meet testing dates. There should be testing results within the next two testing days for quaternary procedures.
- The tools stated in the procedures were used, and there were no additional tools used throughout the construction that need to be amended to the existing list.
- The ROV was tested dry, out of water, with a quick motor test to ensure electrical connections maintained continuity. This was followed by a wet, placed in water, test where we observed buoyancy and disposition in the water as far as horizontal, vertical, and transcending tilts. Lastly, the ROV was positively buoyant, meaning in the upside-down test, it would right itself automatically.
- Testing facility was humid (slightly warmer than room temperature), with approximately 80 degree Fahrenheit air temperature and about 73 Degrees pool temperature.
Conclusion
The Underwater Remote Operated Vehicle went under some extensive testing exclusively at the Neptune Aquatic Center on Wednesday, February 29, 2012. Our team successfully went through every test we could have completed and went through the testing procedures strategically. The ROV overall performed very well in the grand scheme of things. The only testing we were not able to get to was the tertiary and quaternary testing of the validation testing in the testing procedures. The day went over very well, and the results were outstanding with successful knowledge of working components and the only thing left to integrate was integration of components and some fine tuning. We have high expectations for final testing on the last date and fine tuning on the middle testing date. All dates and work is coming together as expected.
