Blog Posts

Gator Waves – Week of Jan. 31st

The (rather complicated) setup used to test the FPGA and sensor interface

On Monday morning, our team met with Dr. Subhash to discuss the solenoid inductance measurements taken last week, some design changes based on the magnetization of the striker rods, and the takeaways from QRB1. On Wednesday, the incremental encoder was mounted onto the striker rod using the 3D printed fixture designed by Hunter and Marissa. The sensor was tested with the magnetic strip to ensure that the outputs were correct and there weren’t issues with the alignment.

On Thursday, the mechanical engineers updated the housing base with a newly printed portion. Also, the electrical engineers met up later in the day to test the incremental encoder with the FPGA and determine if the code works for reading out the position of the striker rod. The preliminary testing showed that it does in fact work, though adjustments will need to be made to the placement of the magnetic strip and the alignment of the sensor. Moving forward, focus will be placed on incorporating the new design elements to avoid the striker rod and incident bar being stuck due to magnetization. Also, development and testing of the controller code will continue.

Gator Waves – Week of Jan. 24th

Adia measuring the resistance of one of the newly wound solenoids

While continuing to make progress with the project, this week Gator Waves also prepared for the QRB1 event held on January 25th. Our team presented the project milestones that have already been accomplished, as well as detailed plans for completing the design. After the presentation and a Q&A with the committee, our team received helpful feedback regarding our progress and improvements that can be made to our slides. The team addressed this feedback in a response memo that was sent out to the committee on Thursday, detailing action items related to each concern that was raised.

The team also met with Dr. Subhash to discuss what was accomplished last week. Another meeting was held with Dr. van Oostrom to go over expectations for the QRB1 event and report on plans for the upcoming days. The mechanical engineers worked on water jetting striker rods and incident bars from the stock material and then facing them. They also wound two more solenoids for testing. The electrical engineers met on Friday to calculate the inductance of these solenoids for characterization and comparison. Moving into next week, the team plans to begin testing the incremental encoder, as well as finalize models of the final assembly.

Gator Waves – Week of Jan. 17th

Some measurements taken while testing the magnetic field

Gator Waves has continued making good progress on the project this week, opting to meet with Dr. Subhash on Monday morning to discuss some adjustments to the design plan and receive his feedback. The electrical engineers met several times this week in order to order to measure the magnetic flux density of the solenoid and striker rod. This was necessary to ensure that the magnetic strip for the position sensor would not be damaged by being placed near the solenoid. There was also a meeting to test and adjust the instrumentation amplifier for the strain gauge readings. The mechanical engineers worked on water jetting materials for shipment to a manufacturer. They also faced the striker rods and 3D printed the solenoid spools and tie downs.

An image from the mechanical engineers’ work session

Moving into next week, the team is preparing for QRB1 on Tuesday. Plans also include testing the encoder with the FPGA, ordering more materials for scaling, and conducting tests to compare the behaviors of the solenoid subassemblies.

Gator Waves – Week of Jan. 10th

The testing set up for the finished PCB (before the event occurred)

This week, Gator Waves jumped right back into working on the project. The team met last Wednesday to discuss plans for the spring semester, including manufacturing timelines, resolving issues with the solenoid and striker rod interaction, and improving the facing of the striker rod. On Monday, our team met with our coach Dr. van Oostrom and liaison Dr. Subhash. We discussed the status of the project and our plans moving forward. That afternoon, the mechanical engineers met to begin attaching the striker rod to the newly acquired rail, which is intended to greatly reduce friction. The electrical engineers also met to continue soldering components onto the PCB that was designed and ordered last semester. The team also worked on clarifying our risk and mitigation strategies, work breakdown structure, and a timeline for the spring.

On Wednesday, the electrical engineers met once again to finish the PCB and test it with the solenoid. The spring semester has definitely started with a bang considering that two electrolytic capacitors were blown up in the process of testing the board. Though the explosion (and screams) were loud, no one was injured, and the board is still operable.

Gator Waves – Week of Dec. 6th

Gator Waves at the SLDR event!

This week, Gator Waves ended the semester with the SLDR event on Tuesday, December 7th. We presented our design, prototype results, and spring plans to the other attending teams and coaches. Our liaison, Dr. Subhash, was also in attendance for this event. During the time leading up to our presentation, we were able to chat with other teams about their progress, as well as enjoy the refreshments provided by the IPPD staff. Feedback on our presentation included some technical suggestions from Dr. Schwartz regarding the implementation of bearings, as well as some positive feedback from the other teams regarding our use of visuals to explain the theory and function of our design.

Our team waiting for the opening remarks (given by our coach Dr. van Oostrom) and keynote speaker

We also submitted the final draft of our SLDR report on Tuesday after implementing the adjustments suggested by our coach and the IPPD staff. We have also passed the document along to our liaison and await his approval and signature.

While wrapping up the week, our team also finished our prototype redesign and began taking data using a longer incident bar. Our results were still unexpected and did not align with our understanding of the theory, and so before moving forward into next semester, we will be focusing on making sure we have an explanation for our current results. Overall, the semester has been challenging, but with our plan in place for the spring, we look forward to what we can accomplish next year!

Gator Waves – Week of Nov. 29th

An image depicting the first revision of a PCB for the current circuitry. A second revision was made before sending the PCB to be manufactured

After returning from Thanksgiving break, Gator Waves spent this past week focusing on the upcoming SLDR event and the redesign of our fall prototype. Leading up to Tuesday, our team spent time preparing our presentation and finalizing the draft of our report. On November 30th, we participated in the peer review SLDR event. This allowed us to receive feedback from other teams regarding our presentation style and content. The suggestions were helpful and informative, and many of them are being incorporated into the final presentation for the real SLDR event on December 7th. Furthermore, after the peer review, we had a meeting with our coach Dr. Hans van Oostrom, where we discussed his feedback as well as some suggestions he had for proceeding with our redesign of the fall prototype.

On Wednesday morning, our team met with Dr. Subhash to discuss the upcoming SLDR event and our progress with the project. We received a great deal of feedback regarding the update of the fall prototype, which has led to a new design of the housing and the need to order a number of additional materials (steel bars, strain gauges, etc). On Wednesday afternoon, the electrical engineers met to discuss the design of a PCB for the circuits currently used in operating the prototype. During this meeting, we also reached out to some professors for advice on selecting sensors for the control system.

Moving forward, our team is putting the final touches on the SLDR report and presentation for Tuesday, December 7th. Furthermore, the plan is to have new timing measurements taken using the redesigned prototype by the end of the semester. This information will help influence our plans moving forward for the spring.

Gator Waves – Week of Nov. 15th

Solenoid set up
One of the testing setups used during the electrical engineer meeting on Saturday

This week was centered around the Prototype Inspection Day event held on the afternoon of Tuesday, November 16th. On Sunday of the previous week, the team met to collect data on the timing precision and stress wave propagation in preparation for the event. Furthermore, our team created an eight minute presentation that summarizes our project, design challenges, and prototype results. On Tuesday, we gave this presentation to eight different judges. After presenting, we were able to answer questions they had regarding our material, demo our prototype, and receive their feedback.

The feedback from some of the judges indicated to our team that we need to adjust our plans for the rest of the semester to better address some additional design challenges that were identified. Concerns about the physical capabilities of our proposed system and the timing requirements were raised. Our team held several meetings during the remainder of the week to discuss these concerns and how we want to proceed with tackling them. An action plan was developed and sent to our coach as a feedback memo.

On Thursday, our team visited LDRAM once again to discuss our test set up with the lab members. After receiving helpful advice on how to mitigate noise in strain gauge signals, we were able to spend time testing aspects of our prototype with the oscilloscope at the laboratory, which is of much higher quality than the one that was available to our team during our Sunday tests.

On Saturday of this week, the electrical engineers met to further investigate the mitigation of noise within the measurement system, and also attempt to interface with an accelerometer we were able to obtain from the IPPD stock. During this meeting, some preliminary data was collected regarding the acceleration of the striker rod while being fired using the solenoid.

Gator Waves – Week of Nov. 8th

Marissa working on the assembly of the prototype

This week, Gator Waves continued the manufacturing and assembly of a prototype in preparation for November 16th. The mechanical engineers manufactured the brass bushings, and the 3D printing of the housing was completed. The electrical engineers met to set up a measuring system for the timing consistency. We spoke with our coach on Tuesday to review our progress and expectations for Prototype Inspection Day, and on Wednesday we discussed the same topics with our liaison, Dr. Subhash.

During meetings on Thursday and Friday, the housing was assembled and strain gauges were attached to the appropriate steel rods for measuring the stress wave propagation. Also, the solenoid shell was wrapped with copper wire and tested with the steel rod to make sure that everything was in working order.

On Sunday, the team met to collect data on the timing precision and the stress wave propagation. The meeting featured a good amount of troubleshooting, but ultimately data on the consistency of the timing was collected and will be used in the upcoming Prototype Inspection Day presentation. Moving forward, Gator Waves will continue to prepare their presentation and visual materials for the event. Moreover, while collecting the test data on Sunday, several design considerations were brought to light that will be investigated in the coming days.

Gator Waves – Week of Nov. 1st

Mark and Hunter working on the nylon track

After gaining approval for manufacturing from our liaison last week, Gator Waves utilized this week to turn our focus to working on the prototype. The mechanical engineers of the team spent time on Thursday manufacturing components such as the bushings, track, and steel bars. Also, files for the solenoid casing were sent to the lab for 3D printing as well.

Will working in the lab

On Sunday, the electrical engineers of the team met to discuss the current driving circuit that Ian designed, and also to discuss the progress and future plans for testing a control system with the solenoid. Additionally, there were considerations of the measurement method that will be used for the prototype.

As Prototype Inspection Day approaches, our team has also been considering what type of feedback we wish to receive, and how we plan on collecting that feedback. Moving into next week, the team will continue with the manufacturing and assembly process. Data collection will also need to occur in order to be analyzed and presented by November 16th. We will seek feedback from our coach and liaison on our progress, and any suggestions they might have regarding how to approach Prototype Inspection Day. 

Gator Waves – Week of Oct. 25th

A depiction of the solenoid design, one of the many drawings the mechanical engineers developed for the prototype

This week, Gator Waves moved forward with working on the development of a prototype. We met with our coach Dr. van Oostrom in order to discuss our progress on the design, as well as to discuss scheduling for one on one meetings to go over peer feedback.

The mechanical engineers of the team compiled a bill of materials and created drawings of the prototype we will be building. On Wednesday, we met with our liaison Dr. Subhash to present these items as well as our progress on the control system. After presenting the drawings and bill of materials, we were given the okay by Dr. Subhash to begin manufacturing the necessary components of our prototype. Also, Ian was able to build and test the circuit design for driving current through the solenoid. With a nail as the test plunger, the circuit functioned as anticipated.

Moving forward, our team will begin the manufacturing, testing, and assembly of our prototype. Also, the testing of control loop designs on an FPGA will be underway.