Testbenk for større gjengestag

Fulltekst

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(2) Sensur av hovedoppgaver Universitetet i Sørøst-Norge Fakultet for teknologi og maritime fag Prosjektnummer: 2019-07 For studieåret: 2018/2019 Emnekode: SFHO3201-1 1H Bacheloroppgave Prosjektnavn Testbenk for større gjengestag Speedloc Stud Test Bench Utført i samarbeid med: TechnipFMC Ekstern veileder: Einar Totland Sammendrag: Vi fikk i oppgave å designe og tilvirke en spesialtilpasset automatisk boltetestebenk for større gjengestag brukt i stigrør-koblinger. Prosjektet var en multidisiplinær utfordring hvor samarbeid mellom disiplinene var viktig for å få skapt det ferdige systemet sammensatt av en fysisk testbenk, systemkontroller og softwareapplikasjon. Stikkord: • Maskindesign • Integrerte systemer • Softwareapplikasjon Tilgjengelig: JA. Prosjekt deltagere og karakter: Navn Andreas Hansen Espen Grønlie Georg Aarnes Nisja Sondre Nyhus Tyssen Steffen Lurås. Karakter. Dato: 14. juni 2019. ________________ Jamal Mohammed Attaya Safi Intern Veileder. _______________ Karoline Moholth Intern Sensor. _______________ Per Øystein Hansson Ekstern Sensor.

(3) Report - Group 7 Speedloc Stud Test Bench. Subject : Lecturer(s) : Group members :. Date : We confirm that this work is entirely our own.. SFHO3201-1 18H Bacheloroppgave Karoline Moholt Espen Grønlie Steffen Lurås Sondre Nyhus Tyssen Georg Aarnes Nisja Andreas Hansen 22/05-2019. Espen Grønlie. .............................................. Steffen Lurås. .............................................. Sondre Tyssen Nyhus. .............................................. Georg Aarnes Nisja. .............................................. Andreas Hansen. ..............................................

(4) Revision History. Revision History Revision. Date. Author(s). Description. 1.0 2.0 3.0 4.0 4.1. 24.01.19 11.02.19 25.02.19 19.05.19 23.05.19. Group Group Group Group Group. created First presentation milestone Second presentation milestone Finished in preparation for system assembly Finished for final assessment. ii.

(5) Revision History. Abstract For our bachelor’s project we were given the mission of designing and manufacturing a complete bolt testing system for Speedloc studs. By close collaboration between the disciplines and keeping a tight schedule we managed to get the complete system made in under five months. With the final system you could define and run a test automatically from a software application once the test bench was set up. The project was done for TechnipFMC who wanted to investigate the frictional characteristics of the bolted joints used in the Speedloc connection. With this product they have new possibilities of doing research on this bolted joint.. iii.

(6) CONTENTS. CONTENTS. Contents Revision History. ii. Abstract. iii. Contents. iv. List of Abbreviations. xvii. Glossary. xviii. Actors. xx. Main Report. 1. 1. . . . . . . .. 1 1 1 1 4 6 6 8. . . . . . . . . . .. 8 8 8 10 10 10 12 12 14 15 15. . . . . . . . . .. 17 17 17 17 18 18 18 19 19 19. 2. 3. Introduction 1.1 About us . . . . . . . . . . . . . . 1.2 Problem description . . . . . . . . 1.2.1 TechnipFMC’s problem . 1.2.2 Ways to solve the problem 1.2.3 Our mission . . . . . . . . 1.3 System context . . . . . . . . . . 1.4 Chain of command . . . . . . . . Project model 2.1 Rational Unified Process . . . 2.1.1 The inception phase . 2.2 The elaboration phase . . . . . 2.2.1 The construction phase 2.2.2 The transition phase . 2.3 Our implementation . . . . . . 2.4 Gantt chart . . . . . . . . . . 2.5 System modeling . . . . . . . 2.5.1 Implementation . . . . 2.6 Time report . . . . . . . . . . Iterations 3.1 Inception phase . . . . 3.1.1 Main goals . . 3.1.2 Implementation 3.1.3 Evaluation . . 3.2 Elaboration 1 . . . . . 3.2.1 Main goals . . 3.2.2 Implementation 3.2.3 Evaluation . . 3.3 Elaboration 2 . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. iv. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . ..

(7) CONTENTS. . . . . . . . . . . . . . . . . . . . . . . .. 19 20 20 20 20 20 21 21 21 22 22 23 23 23 23 24 24 24 25 25 25 25 26. . . . . . . . . . . . . . . . . . .. 26 26 27 28 30 32 32 32 32 34 36 37 37 38 38 39 40 43 43. Requirements verification and validation 5.1 Continuous testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Verifying the requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 45 46. 3.4. 3.5. 3.6. 3.7 3.8. 3.9. 4. 5. 3.3.1 Main goals . . 3.3.2 Implementation 3.3.3 Evaluation . . Construction 1 . . . . . 3.4.1 Main goals . . 3.4.2 Implementation 3.4.3 Evaluation . . Construction 2 . . . . . 3.5.1 Main goals . . 3.5.2 Implementation 3.5.3 Evaluation . . Construction 3 . . . . . 3.6.1 Main goals . . 3.6.2 Implementation Evaluation . . . . . . . Construction 4 . . . . . 3.8.1 Main goals . . 3.8.2 Implementation 3.8.3 Evaluation . . Transition . . . . . . . 3.9.1 Main goals . . 3.9.2 Implementation 3.9.3 Evaluation . .. CONTENTS. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. Requirements 4.1 User stories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Creating top-level requirements from the user stories . . . . . . 4.3 Categorizing the top-level requirements . . . . . . . . . . . . . 4.4 Concept screening from top-level requirements . . . . . . . . . 4.5 System partitioning . . . . . . . . . . . . . . . . . . . . . . . . 4.6 Design concept . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.1 Mechanical design . . . . . . . . . . . . . . . . . . . . 4.6.2 Electrical design . . . . . . . . . . . . . . . . . . . . . 4.6.3 Software design . . . . . . . . . . . . . . . . . . . . . 4.7 Low-level requirements . . . . . . . . . . . . . . . . . . . . . . 4.7.1 Linking low level requirements to top level requirements 4.7.2 Interface requirements . . . . . . . . . . . . . . . . . . 4.7.3 Design requirements . . . . . . . . . . . . . . . . . . . 4.7.4 Non-temporal performance requirements . . . . . . . . 4.7.5 Temporal performance requirements . . . . . . . . . . . 4.7.6 Functional requirements . . . . . . . . . . . . . . . . . 4.7.7 Obsolete requirements . . . . . . . . . . . . . . . . . . 4.8 Storing the requirements . . . . . . . . . . . . . . . . . . . . .. v. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . ..

(8) CONTENTS. 6. 7. CONTENTS. Project budget 6.1 Initial budget . . . . . . . . . . . . . . . . 6.2 Second version of budget . . . . . . . . . . 6.3 Final cost of project . . . . . . . . . . . . . 6.3.1 Measures to ensure budget was held Risk Management 7.1 Risk Management Routine . . . . 7.2 Risk Analysis . . . . . . . . . . . 7.2.1 People risk analysis . . . . 7.2.2 Safety risk analysis . . . . 7.2.3 Technical risk . . . . . . . 7.2.4 Technical risk conclusion .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. . . . . . .. . . . .. 54 54 55 56 57. . . . . . .. 59 62 63 65 65 65 67. 8. Results. 69. 9. Conclusion 9.1 Market value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Further work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70 70 71. Appendices. 72. A System modeling document A.1 System structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2 Communication between software and test bench . . . . . . . . . . . . . . . .. 72 72 75. B Introduction to bolting theory B.1 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . B.2 Introduction to the threaded joint . . . . . . . . . . . . . . B.2.1 The bolt’s function . . . . . . . . . . . . . . . . . B.2.2 Assembly process . . . . . . . . . . . . . . . . . . B.2.3 The challenge . . . . . . . . . . . . . . . . . . . . B.3 The relationship between torque and preload . . . . . . . . B.3.1 The different frictions in bolted joints . . . . . . . B.3.2 Torque vs preload - long form equation . . . . . . B.3.3 Torque vs preload - short form equation . . . . . . B.4 Calculating the friction . . . . . . . . . . . . . . . . . . . B.4.1 Combining the friction coefficients . . . . . . . . B.4.2 Expressing the total friction explicitly . . . . . . . B.5 Applying this to the Speedloc and our test bench . . . . . . B.5.1 The Speedloc connection . . . . . . . . . . . . . . B.5.2 Ensuring correct clamping conditions for Speedloc B.5.3 Resolving the uncertainty . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. 82 82 82 82 82 83 84 84 85 86 87 87 87 87 87 88 88. C Software Design Document C.1 Why C++ and the Qt framework . . . . . . . . . . . . . . . . . . . . . . . . . C.2 Signals and slots in Qt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C.3 Third party library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 89 89 89 89. vi. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . ..

(9) CONTENTS. CONTENTS. C.4 Communication and Workload Distribution . . . . . . . . . C.5 Functionality and Requirements . . . . . . . . . . . . . . . C.5.1 Begin Test Use Case . . . . . . . . . . . . . . . . . C.5.2 Stop Test Use Case . . . . . . . . . . . . . . . . . . C.5.3 Receiving live measurements from the MCM . . . . C.5.4 Add New Bolt Use Case . . . . . . . . . . . . . . . C.5.5 Compare Tests Use Case . . . . . . . . . . . . . . . C.5.6 Save Test Results Use Case . . . . . . . . . . . . . C.6 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . C.7 Measures to prevent invalid operator input . . . . . . . . . . C.7.1 When setting up a test . . . . . . . . . . . . . . . . C.7.2 When a test is running . . . . . . . . . . . . . . . . C.7.3 When setting up an advanced test: . . . . . . . . . . C.7.4 When adding a bolt: . . . . . . . . . . . . . . . . . C.7.5 When changing comport settings: . . . . . . . . . . C.7.6 When changing system controller (MCM) settings: . C.8 Sequence Diagram . . . . . . . . . . . . . . . . . . . . . . C.8.1 Begin Test Sequence Diagram . . . . . . . . . . . . C.8.2 Stop Test Sequence Diagram . . . . . . . . . . . . . C.9 Real-Time Data Sequence Diagram . . . . . . . . . . . . . C.10 View Earlier Results Sequence Diagram . . . . . . . . . . . C.11 Add New Bolt Sequence Diagram . . . . . . . . . . . . . . C.11.1 Implementation . . . . . . . . . . . . . . . . . . . . C.12 Compare Tests Sequence Diagram . . . . . . . . . . . . . . C.13 Save Test Results Sequence Diagram . . . . . . . . . . . . . C.14 Data storing . . . . . . . . . . . . . . . . . . . . . . . . . . C.14.1 Local Storage . . . . . . . . . . . . . . . . . . . . . C.15 Moving Average Algorithm . . . . . . . . . . . . . . . . . . C.15.1 Visual illustration of the moving average algorithm . C.15.2 Problems with the algorithm . . . . . . . . . . . . . C.15.3 Big O time complexity of moving average algorithm C.15.4 Moving Average conclusion . . . . . . . . . . . . . C.16 Testing the application . . . . . . . . . . . . . . . . . . . . C.16.1 First measurements . . . . . . . . . . . . . . . . . . C.16.2 Verifying instruction sent from the application . . . C.16.3 Verifying received error messages . . . . . . . . . . C.16.4 Demo testing with the Arduino . . . . . . . . . . . . C.16.5 Verifying changing comport settings . . . . . . . . . C.16.6 Properly enables and disables functionality . . . . . C.16.7 Manual control with air . . . . . . . . . . . . . . . . C.16.8 Generating a report . . . . . . . . . . . . . . . . . . C.16.9 Starting a test with air #1 . . . . . . . . . . . . . . . C.16.10Starting a test with air #2 . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90 90 91 91 91 92 92 92 94 95 95 95 107 107 107 107 108 108 108 108 110 110 113 113 114 115 115 115 120 122 123 127 127 127 127 127 128 128 128 128 129 129 129. D Class document 132 D.1 MainWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 D.1.1 Using QStackedWidgets . . . . . . . . . . . . . . . . . . . . . . . . . 133. vii.

(10) CONTENTS. D.2. D.3 D.4. D.5. D.6 D.7 D.8. D.9 D.10 D.11. D.12 D.13. CONTENTS. D.1.2 Setting up a normal test . . . . . . . . . . . . D.1.3 Advanced settings . . . . . . . . . . . . . . . D.1.4 Run window . . . . . . . . . . . . . . . . . . D.1.5 Creating plot widgets . . . . . . . . . . . . . D.1.6 Updating the plot and display widgets . . . . . Test class . . . . . . . . . . . . . . . . . . . . . . . . D.2.1 Begin a test . . . . . . . . . . . . . . . . . . . D.2.2 Setpoint reached . . . . . . . . . . . . . . . . D.2.3 Test done . . . . . . . . . . . . . . . . . . . . D.2.4 Receiving measurement data . . . . . . . . . . Data calculations . . . . . . . . . . . . . . . . . . . . D.3.1 Calculating torque . . . . . . . . . . . . . . . Calculating torque distribution . . . . . . . . . . . . . D.4.1 Calculating angle . . . . . . . . . . . . . . . . D.4.2 Calculating friction . . . . . . . . . . . . . . . Bolt settings . . . . . . . . . . . . . . . . . . . . . . . D.5.1 File type . . . . . . . . . . . . . . . . . . . . D.5.2 Main functions . . . . . . . . . . . . . . . . . GUI . . . . . . . . . . . . . . . . . . . . . . . . . . . Alert Window . . . . . . . . . . . . . . . . . . . . . . The serial class . . . . . . . . . . . . . . . . . . . . . D.8.1 Sending the run command . . . . . . . . . . . D.8.2 Checking if the run command was received OK D.8.3 Sending the stop command: . . . . . . . . . . D.8.4 Checking the stop command was received OK D.8.5 Reading from the MCM . . . . . . . . . . . . D.8.6 Parsing and handling received messages . . . . D.8.7 Error handler (#E) . . . . . . . . . . . . . . . D.8.8 OK handler . . . . . . . . . . . . . . . . . . . D.8.9 Measurement handler (#M) and (#MM) . . . . D.8.10 Setpoint reached (#SR) . . . . . . . . . . . . . D.8.11 Test is done (#D) . . . . . . . . . . . . . . . . D.8.12 Cyclic redundancy check in the serial class . . The serialportsetting class . . . . . . . . . . . . . . . . controllersettings class . . . . . . . . . . . . . . . . . Logger class . . . . . . . . . . . . . . . . . . . . . . . D.11.1 Logger class functions . . . . . . . . . . . . . D.11.2 newFile . . . . . . . . . . . . . . . . . . . . . Graph class . . . . . . . . . . . . . . . . . . . . . . . D.12.1 Graph class conclusion . . . . . . . . . . . . . StudThreads class . . . . . . . . . . . . . . . . . . . . D.13.1 QThread implementations . . . . . . . . . . . D.13.2 StudThreads implementation . . . . . . . . . . D.13.3 StudThreads constructors . . . . . . . . . . . . D.13.4 Threading hierarchy . . . . . . . . . . . . . . D.13.5 Finding the setpoint values . . . . . . . . . . . D.13.6 StudThreads - MainWindow connections . . .. viii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 133 133 139 139 139 140 140 143 143 146 147 147 147 148 148 149 149 149 150 152 153 153 154 154 155 155 157 157 160 160 160 160 160 163 164 165 165 166 170 171 172 172 173 174 177 178 179.

(11) CONTENTS. CONTENTS. D.13.7 StudThreads - StudThreads connections D.13.8 StudThreads - MAThreads connections D.13.9 StudThreads conclusion . . . . . . . . D.14 Report class . . . . . . . . . . . . . . . . . . . D.14.1 Report class implementation . . . . . . D.14.2 Report content . . . . . . . . . . . . . D.14.3 The perfect resolution fit . . . . . . . . D.14.4 Report conclusion . . . . . . . . . . . D.14.5 Next iteration for the report . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. 179 180 183 185 185 186 194 194 194. E Mechanical design E.1 Abstracting the system . . . . . . . . . . . . . . . . . . E.1.1 The main functions of an arbitrary bolt test bench E.1.2 The functions our test bench will need . . . . . . E.2 Finding components to fulfill the functions . . . . . . . . E.2.1 Preload/extension measurement . . . . . . . . . E.2.2 Torque application and measurement . . . . . . E.2.3 Stud fixture . . . . . . . . . . . . . . . . . . . . E.2.4 Angle measuring device . . . . . . . . . . . . . E.3 Finding the performance parameters for the components E.3.1 Load cell for measuring preload . . . . . . . . . E.3.2 Angle measurement . . . . . . . . . . . . . . . E.3.3 Torque application device . . . . . . . . . . . . E.3.4 Torque measurement device . . . . . . . . . . . E.3.5 Performance parameters . . . . . . . . . . . . . E.4 Choice of individual components . . . . . . . . . . . . . E.4.1 Preload load cell . . . . . . . . . . . . . . . . . E.4.2 Handheld torque tool . . . . . . . . . . . . . . . E.4.3 Rotary encoder . . . . . . . . . . . . . . . . . . E.4.4 Stud mounting fixture and solid frame . . . . . . E.4.5 Torque measurement solution . . . . . . . . . . E.4.6 Calculating the torque applied . . . . . . . . . . E.5 Design timeline from concept to manufacture . . . . . . E.5.1 Timeline diagram . . . . . . . . . . . . . . . . . E.5.2 Early concept review . . . . . . . . . . . . . . . E.5.3 Phone call with Hytorc engineer . . . . . . . . . E.5.4 Formal design review at TechnipFMC . . . . . . E.5.5 Feedback from load cell supplier . . . . . . . . . E.5.6 Structural analysis of the design . . . . . . . . . E.5.7 Manufacturing drawings . . . . . . . . . . . . . E.6 Walkthrough of final concept . . . . . . . . . . . . . . . E.6.1 The test cell . . . . . . . . . . . . . . . . . . . . E.6.2 Torque tool . . . . . . . . . . . . . . . . . . . . E.6.3 Torque measuring mechanism . . . . . . . . . . E.6.4 Angle measuring device . . . . . . . . . . . . . E.7 Transitioning from mechanical design to manufacture . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 195 195 195 196 197 198 199 200 201 201 201 203 205 205 206 206 206 207 207 207 207 208 211 211 213 213 213 215 220 220 220 220 224 224 224 226. ix. . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . ..

(12) CONTENTS. CONTENTS. F Structural analysis of load-bearing components F.1 Stress analysis . . . . . . . . . . . . . . . . . F.1.1 About stress analysis . . . . . . . . . F.1.2 Linear static analysis . . . . . . . . . F.1.3 The goal of our analysis . . . . . . . F.2 Front plate . . . . . . . . . . . . . . . . . . . F.2.1 FEA setup . . . . . . . . . . . . . . F.2.2 Results . . . . . . . . . . . . . . . . F.2.3 Stress concentrations . . . . . . . . . F.2.4 Conclusion . . . . . . . . . . . . . . F.3 Reaction base . . . . . . . . . . . . . . . . . F.3.1 Identifying the critical regions . . . . F.3.2 FEA setup . . . . . . . . . . . . . . F.3.3 Results . . . . . . . . . . . . . . . . F.3.4 Sensitivity study of the fillet . . . . . F.3.5 Conclusion . . . . . . . . . . . . . . F.4 Reaction face . . . . . . . . . . . . . . . . . F.4.1 FEA setup . . . . . . . . . . . . . . F.4.2 Results . . . . . . . . . . . . . . . . F.4.3 Conclusion . . . . . . . . . . . . . . F.5 Finite element analysis conclusion . . . . . . F.5.1 Stress concentrations . . . . . . . . . F.5.2 Steel grade choice . . . . . . . . . . F.6 Bolting considerations . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. G Test bench manufacturing process G.1 Acquiring parts and off-the-shelf systems . . . . G.1.1 Torque tool and accessories . . . . . . . G.1.2 Load cells . . . . . . . . . . . . . . . . . G.1.3 Angle encoder . . . . . . . . . . . . . . G.1.4 Mounting hardware . . . . . . . . . . . . G.2 Manufacturing drawings for machined parts . . . G.2.1 Geometric dimensioning and tolerancing G.2.2 Manufacturing drawings . . . . . . . . . G.2.3 Analysis of tolerancing . . . . . . . . . . G.3 Manufacturing tenders . . . . . . . . . . . . . . G.3.1 Local tenders . . . . . . . . . . . . . . . G.3.2 International tenders . . . . . . . . . . . G.3.3 In-house manufacturing considerations . G.3.4 In retrospect . . . . . . . . . . . . . . . G.4 Manufacturing of parts . . . . . . . . . . . . . . G.4.1 Deciding on the machine shop . . . . . . G.4.2 Payment through proforma invoice . . . . G.4.3 Manufacturing process . . . . . . . . . . G.4.4 Logo application . . . . . . . . . . . . . G.4.5 Final pictures before shipment . . . . . . G.4.6 In conclusion . . . . . . . . . . . . . . .. x. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. 227 227 227 228 229 229 229 232 232 232 232 235 235 237 239 243 243 243 243 246 246 246 246 247. . . . . . . . . . . . . . . . . . . . . .. 251 251 251 251 251 251 252 252 254 263 264 264 265 266 267 267 267 267 267 269 269 272.

(13) CONTENTS. CONTENTS. G.5 Initial fitment test and showcase of machined parts . . . . G.5.1 Receival of parts . . . . . . . . . . . . . . . . . . G.5.2 Fitment testing . . . . . . . . . . . . . . . . . . . G.6 Ordering of parts for SL210 setup . . . . . . . . . . . . . G.6.1 Meeting at TechnipFMC . . . . . . . . . . . . . . G.6.2 Fitment issues for SL210 stud setup . . . . . . . . G.6.3 New drawings sent to production . . . . . . . . . . G.6.4 Second order received and socket turning . . . . . G.7 Making the case for the MCM . . . . . . . . . . . . . . . G.7.1 Choice of case . . . . . . . . . . . . . . . . . . . G.7.2 Designing the I/O-panel . . . . . . . . . . . . . . G.7.3 Cutout for humidity and temperature sensor . . . . G.7.4 Designing front panel . . . . . . . . . . . . . . . . G.7.5 Ordering process . . . . . . . . . . . . . . . . . . G.7.6 Creating clear plastic top panel for exhibition . . . G.8 Receival of torque load cells . . . . . . . . . . . . . . . . G.8.1 Calibration values and serial numbers . . . . . . . G.8.2 Fitment issues for reaction faces . . . . . . . . . . G.8.3 Correcting the error . . . . . . . . . . . . . . . . . G.8.4 Milling of reaction faces . . . . . . . . . . . . . . G.8.5 New test fitment . . . . . . . . . . . . . . . . . . G.9 Receival of angle encoder . . . . . . . . . . . . . . . . . . G.10 Ordering process and receival of the AEP 2MN load cell . G.10.1 Placement of order and price update . . . . . . . . G.10.2 First status update . . . . . . . . . . . . . . . . . G.10.3 Second status update . . . . . . . . . . . . . . . . G.10.4 Third status update . . . . . . . . . . . . . . . . . G.10.5 Receiving the load cell . . . . . . . . . . . . . . . G.10.6 Could the time issue have been avoided? . . . . . G.11 Preparing the AEP 2MN load cell for test bench assembly . G.11.1 The day of receival . . . . . . . . . . . . . . . . . G.11.2 Day after receival . . . . . . . . . . . . . . . . . . H Actuation of the Jgun H.1 Emulating the hand . . . . . . . . . . . . . . . . H.2 Direction control . . . . . . . . . . . . . . . . . H.2.1 Back plate fitment testing . . . . . . . . H.2.2 3D-printing of back plate . . . . . . . . . H.2.3 Implementing the servo . . . . . . . . . . H.2.4 Testing the servo function . . . . . . . . H.2.5 Implementing feedback switches . . . . . H.3 First trigger control prototype . . . . . . . . . . . H.3.1 Choice of actuator . . . . . . . . . . . . H.3.2 Safety concerns . . . . . . . . . . . . . . H.3.3 Designing the first trigger pull mechanism H.3.4 Testing the initial trigger pull mechanism H.3.5 Remarks on the first prototype . . . . . .. xi. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 272 272 272 273 277 277 279 282 282 282 284 285 286 286 286 287 290 290 291 291 292 292 294 294 295 296 296 297 297 298 298 299. . . . . . . . . . . . . .. 302 302 303 303 304 304 306 306 307 308 308 309 310 311.

(14) CONTENTS. I. CONTENTS. H.4 Second revision of Jgun actuation . . . . . . . . . . . . . . . . H.4.1 Linear actuator for trigger pull . . . . . . . . . . . . . . H.4.2 New limit switches . . . . . . . . . . . . . . . . . . . . H.4.3 Tensioning the wire and emergency stop . . . . . . . . . H.4.4 Mounting the back plate properly . . . . . . . . . . . . H.4.5 Turnbuckles for servo linkage . . . . . . . . . . . . . . H.5 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . H.5.1 Remarks on final mechanism . . . . . . . . . . . . . . . H.5.2 Other applications and market value for this mechanism H.6 Training and setup of the Jgun3 . . . . . . . . . . . . . . . . . . H.6.1 Training session in safe use of the tool . . . . . . . . . . H.6.2 Acquiring the FRL unit . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. 311 311 312 312 313 315 315 315 315 315 316 316. Design of the system controller I.1 Introduction . . . . . . . . . . . . . . . . . . . . I.2 Design parameters . . . . . . . . . . . . . . . . I.3 Checking for existing solutions . . . . . . . . . . I.4 First research prototype . . . . . . . . . . . . . . I.5 First design iteration . . . . . . . . . . . . . . . I.5.1 Load cells . . . . . . . . . . . . . . . . . I.5.2 Actuation of the torque tool . . . . . . . I.5.3 Incremental angular encoder . . . . . . . I.5.4 Communication with PC . . . . . . . . . I.5.5 Conclusion of the first design iteration . . I.6 Second design iteration . . . . . . . . . . . . . . I.6.1 Load cell introduction . . . . . . . . . . I.6.2 Output from the system load cells . . . . I.6.3 Minimum ADC resolution . . . . . . . . I.6.4 The perfect sample rate . . . . . . . . . . I.6.5 Simultaneous sampling . . . . . . . . . I.6.6 Conclusion of the second design iteration I.7 Third design iteration . . . . . . . . . . . . . . . I.7.1 Choosing the optimal ADC . . . . . . . . I.7.2 The SPI interface . . . . . . . . . . . . . I.7.3 Synchronization . . . . . . . . . . . . . I.7.4 Clock distribution . . . . . . . . . . . . . I.7.5 Input filter . . . . . . . . . . . . . . . . I.7.6 Conclusion of the third design iteration . I.8 Forth design iteration - The split . . . . . . . . . I.8.1 Defining the board-to-board interface . . I.8.2 Additional signals . . . . . . . . . . . . I.9 Detailed design of the System Controller modules I.10 Mating of the modules . . . . . . . . . . . . . . I.11 Testing . . . . . . . . . . . . . . . . . . . . . . . I.11.1 Measurement resolution of the load cells I.11.2 Angle encoder . . . . . . . . . . . . . . I.11.3 Actuators . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 318 318 318 318 320 320 321 322 323 324 324 324 324 329 330 331 331 332 332 332 334 335 335 335 335 337 337 337 340 340 341 341 341 341. xii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

(15) CONTENTS. CONTENTS. I.12 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342 J. Design of the Control Module J.1 Introduction . . . . . . . . . . . . . . . . . J.2 Design specification . . . . . . . . . . . . . J.3 Interface . . . . . . . . . . . . . . . . . . . J.4 Main system components . . . . . . . . . . J.5 Component selection . . . . . . . . . . . . J.5.1 Microcontroller . . . . . . . . . . . J.5.2 USB interface . . . . . . . . . . . . J.5.3 Digital isolator . . . . . . . . . . . J.6 Schematic design . . . . . . . . . . . . . . J.6.1 Introduction . . . . . . . . . . . . . J.6.2 PCB Design package . . . . . . . . J.6.3 Hierarchical design . . . . . . . . . J.6.4 TMS320F28035 Microcontroller . . J.6.5 USB transceiver and digital isolator J.6.6 Power supply layout . . . . . . . . J.6.7 3.3V Voltage regulator . . . . . . . J.6.8 ESD Protection . . . . . . . . . . . J.6.9 Conclusion . . . . . . . . . . . . . J.7 Schematic - Revision 1 . . . . . . . . . . . J.8 PCB layout . . . . . . . . . . . . . . . . . J.8.1 Stack-up . . . . . . . . . . . . . . J.8.2 Trace impedance . . . . . . . . . . J.8.3 USB section . . . . . . . . . . . . J.8.4 Voltage regulator . . . . . . . . . . J.8.5 Final layout design . . . . . . . . . J.9 3D Visualization . . . . . . . . . . . . . . J.10 Component management . . . . . . . . . . J.11 PCB production . . . . . . . . . . . . . . . J.12 Assembly . . . . . . . . . . . . . . . . . . J.13 Testing . . . . . . . . . . . . . . . . . . . . J.13.1 Test points . . . . . . . . . . . . . J.13.2 Functional testing . . . . . . . . . . J.13.3 Voltage rails . . . . . . . . . . . . J.13.4 Current draw . . . . . . . . . . . . J.13.5 Temperature measurements . . . . J.13.6 Power and efficiency . . . . . . . . J.13.7 Oscillator clock . . . . . . . . . . . J.14 Improvements . . . . . . . . . . . . . . . . J.15 Conclusion . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 348 348 348 348 350 352 352 354 354 356 356 356 356 357 358 360 361 363 363 363 368 368 369 370 371 371 382 382 385 386 386 387 389 389 389 391 391 392 392 393. K Design of the Measurement Module 394 K.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 K.2 Design specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 K.3 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394. xiii.

(16) CONTENTS. K.4 K.5. K.6 K.7. K.8 K.9 K.10 K.11 K.12 K.13 K.14 K.15. CONTENTS. K.3.1 Power . . . . . . . . . . . . . . . . . K.3.2 Control Module . . . . . . . . . . . . K.3.3 Load cells . . . . . . . . . . . . . . . K.3.4 Actuators . . . . . . . . . . . . . . . K.3.5 Encoder . . . . . . . . . . . . . . . . Main system components . . . . . . . . . . . Analog front-end . . . . . . . . . . . . . . . K.5.1 Input protection . . . . . . . . . . . . K.5.2 Input filter . . . . . . . . . . . . . . K.5.3 Noise contribution from front-end . . K.5.4 Noise contribution from load cells . . K.5.5 Total noise before ADC . . . . . . . K.5.6 Non-linearity due to leakage currents Amplification and ADC . . . . . . . . . . . . K.6.1 Sample rate . . . . . . . . . . . . . . Power supply . . . . . . . . . . . . . . . . . K.7.1 Power input . . . . . . . . . . . . . . K.7.2 Fuse . . . . . . . . . . . . . . . . . . K.7.3 5V Analog supply . . . . . . . . . . K.7.4 5V Digital supply . . . . . . . . . . . K.7.5 3.3 V Digital supply . . . . . . . . . K.7.6 Input protection controller . . . . . . K.7.7 6V Main step-down converter . . . . Clock generation . . . . . . . . . . . . . . . Final schematic . . . . . . . . . . . . . . . . PCB layout . . . . . . . . . . . . . . . . . . Bill of materials (BOM) . . . . . . . . . . . . PCB Production . . . . . . . . . . . . . . . . PCB Assembly . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . Conclusion . . . . . . . . . . . . . . . . . .. L MCM Firmware L.1 Code composer studio . L.2 Code documentation . L.3 Modules . . . . . . . . L.4 Conclusion . . . . . .. . . . .. . . . .. . . . .. . . . .. M ADS1231 Development board M.1 Introduction . . . . . . . . . . M.2 The ADS1231 . . . . . . . . . M.2.1 Schematic . . . . . . . M.2.2 Board pin descriptions M.2.3 Clock select jumper . . M.3 Board layout and production . M.4 Testing . . . . . . . . . . . . . M.4.1 Electrical testing . . .. . . . .. . . . . . . . .. . . . .. . . . . . . . .. . . . .. . . . . . . . .. . . . .. . . . . . . . .. xiv. . . . .. . . . . . . . .. . . . .. . . . . . . . .. . . . .. . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 394 394 394 397 397 397 398 398 400 401 402 403 403 404 404 404 404 404 404 406 406 406 407 413 413 430 440 440 440 444 444. . . . .. 445 445 445 445 448. . . . . . . . .. 449 449 449 449 451 451 451 453 453.

(17) CONTENTS. CONTENTS. M.4.2 Noise floor testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 M.4.3 Minimum measurement resolution (50 N loadcell) . . . . . . . . . . . 453 M.4.4 Minimum measurement resolution (TC4 2 MN) . . . . . . . . . . . . . 454 N IF-2 - PC to MCM interface N.1 Description . . . . . . . . . . . . . . . . . . . . N.2 Physical interface . . . . . . . . . . . . . . . . . N.3 Messaging protocol . . . . . . . . . . . . . . . . N.3.1 Cyclic Redundancy Check - CRC . . . . N.3.2 Run test cycle . . . . . . . . . . . . . . . N.3.3 Stop test cycle . . . . . . . . . . . . . . N.3.4 Request a single measurement . . . . . . N.3.5 Automated measurements . . . . . . . . N.3.6 Manual control . . . . . . . . . . . . . . N.3.7 Change LCD display on MCM closure . N.3.8 Change system controller settings (MCM) N.4 Error messages . . . . . . . . . . . . . . . . . . N.4.1 Stop messages . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. 457 457 457 457 457 459 459 460 460 460 460 461 461 461. O System simulation 462 O.1 Simulation model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462 P Sensors and load cell research P.1 Sensors of the test bench . . . . . . . . . . . . . . . . P.1.1 AEP Transducers 2MN load cell . . . . . . . . P.1.2 Calibration report . . . . . . . . . . . . . . . . P.1.3 ARL 6t shim load cells . . . . . . . . . . . . . P.1.4 British Encoders TR3 industrial rotary encoder P.1.5 Miscellaneous sensors . . . . . . . . . . . . . P.2 Torque load cell calibration testing . . . . . . . . . . . P.2.1 Test setup . . . . . . . . . . . . . . . . . . . . P.2.2 Test data . . . . . . . . . . . . . . . . . . . . P.2.3 Processing the data . . . . . . . . . . . . . . . P.2.4 Conclusion . . . . . . . . . . . . . . . . . . . P.3 Shop press calibration of the cells . . . . . . . . . . . P.3.1 Calculating the correction factor . . . . . . . . P.3.2 New graphs with correction factor . . . . . . . P.3.3 Conclusion . . . . . . . . . . . . . . . . . . . P.4 Verification of calibration factor . . . . . . . . . . . . P.4.1 Test setup . . . . . . . . . . . . . . . . . . . . P.4.2 Combinations of load cells . . . . . . . . . . . P.4.3 Test data . . . . . . . . . . . . . . . . . . . . P.4.4 Visualizing the result . . . . . . . . . . . . . . P.4.5 Conclusion . . . . . . . . . . . . . . . . . . . P.5 Calibrating the load cells . . . . . . . . . . . . . . . . P.5.1 Test setup . . . . . . . . . . . . . . . . . . . . P.5.2 Results . . . . . . . . . . . . . . . . . . . . .. xv. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. 468 468 468 468 468 472 472 472 473 473 475 480 482 482 483 483 485 485 485 486 486 486 489 489 490.

(18) CONTENTS. P.5.3 P.5.4. CONTENTS. Creating calibration factors . . . . . . . . . . . . . . . . . . . . . . . . 490 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493. Q Assembly and initial testing of test bench Q.1 Initial assembly of test bench . . . . . Q.1.1 Assembly of test cell . . . . . Q.1.2 Assembly process evaluation . Q.2 Initial testing . . . . . . . . . . . . . Q.2.1 First test . . . . . . . . . . . . Q.2.2 First test with actuation . . . . Q.2.3 Results from test . . . . . . . Q.2.4 Performance of the test bench 10 References. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. 494 494 494 494 496 496 496 496 496 499. xvi.

(19) CONTENTS. CONTENTS. Abbreviations AC ADC AH AUX CAD CNC Comport CRC CSV DC DPI DRC EDA EDP EEPROM EG EMI ERC ESR FEA FoS FRL FTA GAN GND GNDD GPL GUI HSE I/O IC ID ISO LDO LED LGPL LRP MCM MCU MM MN MOSFET Obs OD. Alternating Current Analog-to-Digital Converter Andreas Hansen Auxiliary Computer Aided Design Computer Numerical Control Communication Port Cyclic Redundancy Check Comma-Separated Values Direct Current Dots per Inch Design Rule Checking Electronic Design Automation Emergency Disconnect Package Electrically Erasable Programmable Read-Only Memory Espen Grønlie Electromagnetic Interference Electrical Rule Checking Equivalent Series Resistance Finite Element Analysis Factor of Safety Filter Regulator Lubricator Fault Tree Analysis Georg Aarnes Nisja Ground Digital ground GNU General Public License Graphical User Interface Health Safety and Environment Input/Output Integrated Circuit Inner Diameter International Organization for Standardization Low Dropout Light Emitting Diode GNU Lesser General Public License Lower Riser Package Measurement & Control Module Measurement Control Unit Measurement Module Mega Newton Metal–Oxide–Semiconductor Field-Effect Transistor Obsolete Outer Diameter. xvii.

(20) CONTENTS. PCB PDF PI PLC PO PPR PWM QCP QML RMS RPM SL SL SNT SPI SPICE SS SSTB SW SysML TPI UART UI UML UN USB USN UTS VAT VCC VXT. CONTENTS. Printed Circuit Board Portable Document Format Proforma Invoice Programmable Logic Controller Purchase Order Pulses per Revolution Pulse Width Modulation QCustomPlot Qt Modeling Language Root Mean Square Revolutions Per Minute Speedloc Steffen Lurås Sondre Nyhus Tyssen Serial Peripheral Interface Simulation Program with Integrated Circuit Emphasis Stainless Steel Speedloc Stud Test Bench SolidWorks Systems Modeling Language Threads per Inch Universal Asynchronous Receiver-Transmitter User Interface Unified Modeling Language Unified (thread standard) Universal Serial Bus University of South-Eastern Norway Ultimate Tensile Strength Value Added Tax Common Collector Voltage Vertical Christmas Tree. Glossary AD rate Sample rate. C++ Popular high-level programming language. Elastic deformation Non-permanent deformation of materials. When releasing the applied load the material returns to its initial shape. Flange For piping: A plate or a ring at the end of a pipe to form a connection interface to connect several pipes together. FRL unit Filter, regulator and lubricator unit used for pneumatic tools. It dries the air, regulates the pressure and introduces an oil mist to the air supply. G-code Numerical control programming language. Used in many CNC mills to specify the tool paths necessary to create a part.. xviii.

(21) CONTENTS. GitHub Grip length. KiCad EDA LATEX Load cell Major diameter MatLab Minor diameter MySQL Overleaf PayPal Thread pitch Pitch diameter Preload Protocol PTFE. PUGH matrix Qt Riser. Setpoint Simulink SL210/SL222 SolidWorks SW Simulation Speedloc STEP-file Stud Vector graphic. Workover. CONTENTS. Web hosting service for version control. Mostly used for computer code. The length of a bolt or stud between the bearing surface and where it is threaded into a hole or a nut. It is this length that stretches and controls the stiffness of bolt specimen during tightening. Free software for electrical design automation. A document preparation system. Markup tagging is used to stylize documents. A sensor which measures force applied to it. Usually calibrated in kilogram-force or newtons. Largest (outside) diameter of a thread form. Maths program with its own programming language based on C. Diameter of thread form measured at the root of each side. Data base administration system. Online LATEX editor often used to collaborate on the same project. American payment service. Widely used as a money transfer service internationally. The distance between adjacent crests or roots of the thread form. Imagined half way point between the thread form’s crest and root diameter. The force which a tightened bolt clamps a bolted joint together with. Correct preload is important for joint integrity. A set of rules determined to define how data is transmitted. Polytetrafluoroethylene. Group of synthetic coatings used in for example cookware and threaded joints. Teflon is maybe one of the most widely known PTFE coatings. Xylan is used for the Speedloc studs. A tool to help determine which solutions will be best given some evaluation criteria. A cross-platform, C++ based, application development framework for desktop, embedded and mobile. Temporary extension of a subsea oil well to a surface drilling or maintenance facility. Used during drilling, maintenance, repairs, commissioning or decommissioning. A desired or target value for a variable or measurement data of a system. A graphical programming environment for modeling, simulating and analyzing dynamical systems. Different models of the Speedloc. The 222 Speedloc is larger than the 210 and utilizes different studs. Popular CAD system. Finite element analysis module within SolidWorks. A special type of flange for connecting riser segments together. A CAD file format used to share models between different CAD systems. A threaded rod similar to a bolt, but without the head and just the threaded portion. Images which are made by specifying the paths of the shapes it consists of and not the pixels directly. This makes them infinitely scalable and robust. Intervention of subsea hydrocarbon wells for maintenance or repairs.. xix.

(22) Actors AEP Transducers Biltema British Encoder Company Hytorc Norge AS. Products. Kolberg Caspary Lautom as Mouser Electronics PCBWAY Schaeffer AG TechnipFMC TESS. Texas Instruments Tools University of South-Eastern Norway Vetek Weighing AB Wayken Rapid Manufacturing. Manufacturer of load cells and weighing solutions, located in Modena, Italy. Retailer specializing in inexpensive tools, parts and hardware. Encoder supplier and manufacturer. Norwegian sub-department of Hytorc which offers industrial bolting solutions. Industrial tools and parts retailer, located in Asker. Electronic components distributor located in Texas, USA. PCB manufacturing company located in Shenzhen, China. Company specializing in custom front panel manufacture, located in Berlin, Germany. The company we are doing our bachelor’s thesis for. Global leader within project life cycle services in the energy industry. Retailer specializing in hoses and hose accessories. The larger part orders for the project were made through TESS by TechnipFMC. Global semiconductor design & manufacturing company. Tool and fastener retailer. The university we are writing our thesis at. Swedish load cell supplier. Rapid prototyping and CNC machining company located in Shenzhen, China..

(23) Introduction. 1. Introduction. 1.1. About us. Sondre Nyhus Tyssen Computer engineering - Project leader - Web responsible. Espen Grønlie Computer engineering - Software lead - Test responsible. Georg Aarnes Nisja Mechanical engineering - Mechanical lead - Documentation responsible. Andreas Hansen Electrical engineering - Electrical lead - Requirement responsible. 1.2 1.2.1. Steffen Lurås Computer engineering - UML lead - Risk responsible. Problem description TechnipFMC’s problem. TechnipFMC have given us the mission of analyzing the studs used in Speedloc flanges. A render of the Speedloc flange is shown in figure 1.1. Speedloc flanges are used during subsea workover Subsea workover happens on completion, maintenance and repair of existing subsea hydrocar-. 1/502.

(24) Introduction. Problem description. Figure 1.1: Render of Speedloc connection. The orange parts are the segments and inside them you see the Speedloc stud and nut in red. bon wells. To access the subsea well a riser tube is installed to create a path from the platform and vessel down to the well. With the riser installed one can guide tools and parts down to the well. The workover stackup is shown in figure 1.2. The riser tube acts as an extension of the subsea well up to a surface platform or vessel. The riser can be quite long and is therefore made up by several tube segments. Each of these segments are connected by Speedloc flanges. The benefit of Speedloc flanges compared to a conventional flange is that the Speedloc connection involves no loose parts which can be lost and it is much faster to make and break. The Speedloc with a single element exploded is shown in figure 1.3. During makeup of the connection the stud (SL stud) gets preloaded by tightening the nut. This creates a clamping force which clamps the riser sections tightly together and creates a water-tight and strong seal. This is important because speedloc flanges has to carry large loads from lowering and landing subsea equipment as well as contain high pressures. The cross section of the Speedloc is shown in figure 1.4. There you can see more clearly how each of the segments engage the inner hub and makes the seal. When tightening the nut you stretch the stud. As the material in the stud wants to remain in its original shape this creates a preload force which clamps the segment tightly onto the inner hub. This stretching is known as elastic deformation of the stud. Elastic deformation is analogous to stretching and holding a spring or a rubber band. You will experience a force which tries to pull your hands together. The clamp force (preload) in a bolted connection is not applied directly, but induced from the torque you apply to the nut. It is often impractical or impossible to measure the preload directly. 2/502.

(25) Introduction. Problem description. Figure 1.2: Workover of a subsea well.. SL Washer SL Nut. SL Stud. Figure 1.3: Speedloc with one segment exploded. You can see the Speedloc stud, washer and nut annotated.. 3/502.

(26) Introduction. Problem description. Figure 1.4: Cross section of Speedloc connection. Each segment has slanted surfaces which bears on the inner hub and clamps it once the nuts get tightened. in a bolted connection. To know the preload we have to know the relationship between torque applied and preload achieved. There are multiple variables controlling this relationship. The variables are torque applied, thread geometry and friction coefficient of the contacting surfaces. This can be expressed as a pseudo-function Stud preload = f (torque applied, friction coefficient, thread geometry) The thread geometry is a set of constants defined by the thread specification. The torque applied is easily measured. The only unknown variable here is therefore the coefficient of friction. When TechnipFMC designs the Speedloc they design them with the bolt preload in mind. This means that for the Speedloc flange to act as expected you need the correct preload. Since we only determine which torque we apply when assembling the Speedloc we need to know the coefficient of friction to predict what torque is necessary. The studs are coated in a PTFE coating called Xylan to make the coefficient of friction lower and protect the bolted joints from corrosion. In their lifetime the Speedloc is made and broken apart many times. This introduces a wear factor to the system. The degradation of the coating raises the coefficient of friction causing the preload to be harder to predict. How the coating wear affects the frictional characteristics for this bolted connection is essentially TechnipFMC’s problem. During makeup and operation of the speedloc flange they have discovered that they know less about the frictional characteristics of these studs than they initially thought. They need a way to predict what friction coefficient you will get with a certain lubrication, coating type and degree of coating wear. 1.2.2. Ways to solve the problem. TechnipFMC’s problem does not have a single solution that is inherently the best or the obvious one to apply. There are several ways to attack or solve this problem. Figure 1.5 show visually different paths one can take to attempt to solve this problem.. 4/502.

(27) Introduction. Problem description. Ultrasonic measurement. Loadcell under each bolt Map events. Simulations Direct measurement in the field Research. Correct stud preload. Characterize friction. Redesign speedloc Test coating only. Avoid problem. Test bolted joint. New studs each time Testbench. Small scale. Full scale. Figure 1.5: Different paths to solve the problem of incorrect or unknown preload. The goal is shown in the middle and the red circle indicates our mission.. 5/502.

(28) Introduction. System context. As an example a simple, but very costly way would be to replace the Speedloc studs every time between make and break cycles. This would ensure that the friction was known since no wear effects would be present and every make-up of the Speedloc would have identical initial conditions. This is obviously not a feasible solution since it would create a lot of additional costs to replace perfectly fine studs that were only used once. This problem is on such a small-detail-level that TechnipFMC have had several bachelor’s projects on this case. Earlier there have been attempts at both doing simulations of the system to attempt to make predictions of preload and there have been some research on the possibility to implement ultrasonic probes in impact sockets to measure the preload during tightening. These projects gave TechnipFMC new information, but did not give the endgame solution where they had full confidence in the bolted joint. Considering this they decided to “order” a full scale test bench which could be used in research to characterize the friction of the joint. 1.2.3. Our mission. Our mission is to design and manufacture a full scale automatic test bench capable of running torque-up tests on the actual Speedloc studs, seen in Fig. 1.6. They want this test bench to gain new knowledge on the behaviour of this exact bolted joint. They want to investigate how changing the initial conditions with lubrication and coating choice for the bolted connection affects test results. This knowledge can be used to adjust mounting procedures or coating/lubrication specifications. The test bench should be able to tighten the studs to a desired setpoint while measuring preload induced, torque applied and angle of tightening. The data from the sensors should be recorded and stored for later analysis. TechnipFMC wants to run cycle-testing which means you must be able to set up and define a comprehensive test from an application. This test should then run automatically with a push of a button. 1.3. System context. The system context diagram of our system can be seen in Fig. 1.7. The diagram shows all actors that interact with our system. The first and most important actor is TechnipFMC, the system owner. TechnipFMC will supply studs and bolts for testing and analysis. The return value is increased safety and reliability of their workover operations, due to correct preload in the speedloc mounting studs. In addition, the cost of workover operations might be reduced if the studs can be reused more than the current number of cycles. The next actor is TechnipFMC’s test engineers. They can characterize and verify the friction and preload in their bolted connections, and therefor remove any doubts concerning the design and mounting process. Furthermore, the knowledge gained from the testing can be applied to future projects. The operator, is the actor which will interact directly with our system. The operator receives the test sample from the test engineer, and run the desired tests. When the test has been completed, the results are returned to the test engineer. Since the operator work directly with the system,. 6/502.

(29) Introduction. System context. Figure 1.6: Xylan coated SL222 stud.. 7/502.

(30) Project model. Chain of command. the user safety is of utmost importance. Furthermore, since there will be bystanders and fellow workers in the workshop, we need to take into account both the noise level and bystander safety of the system. Lastly, the system has an environmental value. Since, the bolted connections will have correct preload force, the already minuscule chance of environmental disaster is reduced even further. In addition, the reused studs will lead to less material usage in production. 1.4. Chain of command. The chain of command diagram can be seen in Fig. 1.8. The diagram shows the flow of information between the actors in our system.. 2. Project model. An important tool for achieving the desired result is a good project model. In a project like a bachelor thesis time is a big constraint and the final deadline is not forgiving. It’s therefore important to choose a project model that is forgiving, one that allows for us to make some mistakes along the way without it meaning the end of the project. Our project needed a quick start to the mechanical design. Because of this we first tried our hand at Scrum with its very aggressive approach to problem solving. This proved problematic however, as it didn’t give us any help in communicating across our three disciplines. We needed systems engineering tools to create models that everyone could understand and create interfaces between the modules of the system. This made us end up on choosing Rational Unified Process as our model instead. It originally has a slightly less aggressive beginning than Scrum, but we could easily modify this to fit our purpose. The project model diagram is shown in figure 2.1. 2.1. Rational Unified Process. This is an iterative and incremental process divided into four phases. Throughout the project the tasks are categorized into six different main disciplines that each get a different amount of focus depending on where you are in the project cycle[49]. The phases are again divided into iterations. The iterations are what makes this model incremental. With each iteration there is added or improved functionality to the system. In figure 2.1 the phases are shown at the top with the iterations in them. On the left side are the disciplines, and a rough draft of how much attention each discipline gets is shown in the graph. 2.1.1. The inception phase. This phase is about getting the project started in the right direction. The scope of the project is defined and the requirements are established through use case models. It is also established risks, a cost estimate and a time estimate of the project. There really isn’t need for more than one iteration at this stage.. 8/502.

(31) Figure 1.7: System context diagram.. 9/502. Enviroment. Operator. System owner. Reduced material usage. Enviromental safety. User safety. Verification. Get results System. Uncertanty about friction. Noise. Bystander safety. Run test. Reduced cost. Workover safety and reliability. Supply studs for testing. System context. Engineer. Bystander. Project model Rational Unified Process.

(32) Project model. The elaboration phase. Chain of command System owner Supply test sample Engineer Valuable research data. Request test. Operator. Test data. Run test. System. Save data. Figure 1.8: System chain of command 2.2. The elaboration phase. The goal of the elaboration phase is about creating a collective understanding of the problem domain. We also need to identify the risks of the project, develop a project plan and work out an architectural framework for out system. In our case we have used a lot of UML to model our system. 2.2.1. The construction phase. In the construction phase the focus is on the system design, programming, manufacturing and testing. At the end of this phase we should have a working and usable system. 2.2.2. The transition phase. In this phase the goal is to ready the system for delivery to the customer. All documentation should be completed and manuals created that the customer might need to use the system. Minor fixes and tweaks can also be done, but all major issues should have already be worked out in the former phases. This phase may often be neglected, but is equally important to the rest of the phases as this phase ensures that the customer receives a product of value to them.. 10/502.

(33) 11/502. Figure 2.1: Unified Process. Deployment. Testing. Implementation. Analysis and design. Requirements. Business modelling. I1. Inception E1. E2. Elaboration C1. C2. Construction C3. C4. T1. Transition T2. Project model The elaboration phase.

(34) Project model. 2.3. Our implementation. Our implementation. All projects must adjust their model to fit their project and we were no exception. As our desired result is to deliver a complete and working test bench, we needed a very aggressive start to our project. Therefore we decided to give analysis, design and implementation more focus in the beginning of the project. This is because a lot of the parts that needs to be ordered are not typical ”off the shelf” items and must in some cases be custom made. These parts are both expensive and often has a long delivery time. We must be absolutely certain that we order the correct parts and this is why early design and implementation is key. Safety is also a requirement that TechnipFMC clearly specified to be an important one. When working with the high pressure and momentum that is applied on these studs the possible damages to both humans and equipment must be given adequate attention. For this reason we also increased the focus on testing towards the end of the project to ensure that the machine will be completely safe to use. Our focus when we have created models has been that anyone who reads the models can understand them. Therefore we haven’t been too strict on the proper semantics as not everyone in the group has learned either UML or SysML. We regard the progress of the project as the most important issue and will for this reason not spend too much time on getting all semantics correct when the model is understandable. 2.4. Gantt chart. To ensure that our project is on schedule we have created a Gantt chart, shown in figure 2.2, with all the iterations. We had initially set 2 weeks for each iteration but with the exam period and some delay from suppliers we needed to make some changes along the way. We chose to put a pause before the third construction iteration to give ourselves a chance to study for our exams and we also extended it to finish our goals for the iteration. We also had planned two transition iterations but we ended up merging them into one. There is more information about the iterations in the iterations section in this report.. 12/502.

(35) Project model. Gantt chart. Figure 2.2: Gantt. 13/502.

(36) Project model. 2.5. System modeling. System modeling. In a multidisciplinary project like the one we have at hand it is important that the different disciplines are able to communicate with one another. We need a governing language that everyone can understand and give us the opportunity to understand what is going on in every part of our project without necessarily understanding every technical aspect of every diagram. We have chosen to use the Systems Modeling Language (SysML) as our top level modeling language of the entire SSTB system. SysML is an extension of the Unified Modeling Language (UML) which we have some previous experience using and is also what we are using to model the software application part of the system. While UML is intended for software development the SysML extension is meant for multidisciplinary use. Much of the grammar and vocabulary of SysML is however very similar to the one of UML which was advantageous to us as we didn’t have to learn a completely new language to use it for our project [16]. At the beginning of a multidisciplinary project one is often tempted to split the designing of the system into the different disciplines that are involved. While this approach may work in some cases it would not suit the problem we have at hand where the disciplines are quite interdependent on each other. As our group consists of members from three different engineering disciplines there is a risk of communication difficulties within the group. This is where the systems modeling will come into play and help us achieving a better understanding of the behaviour of our entire system. To give a thorough description of the behaviour of the components is also very important when we hand off our system to our employer. They may be using our system for some time after we are finished and as this is only a student project we will not be available for any customer support after delivery date. They may also want to make improvements on or change the system, and this will be a difficult task without good documentation that isn’t properly organized.. <<block>> SysML. <<block>> Behavior Diagram. <<block>> Activity Diagram. <<block>> Requirements Diagram. <<block>> State Machine Diagram. <<block>> Use Case Diagram. <<block>> Block Definition Diagram. <<block>> Structure Diagram. <<block>> Internal Block Diagram. <<block>> Package Diagram. <<block>> Parametric Diagram. <<block>> Sequence Diagram. Figure 2.3: The diagram hierarchy of SysML As shown in figure 2.3 the diagrams of SysML can be divided into three main categories: behavior diagrams, structure diagrams and requirement diagrams [16, p. 15]. With the limited. 14/502.

(37) Project model. Time report. time we have at hand we have decided to not use SysML to its full extent, as this would require a lot of research, and rather focused on learning and using the diagrams that would help our project the most. We had already organized our requirements before we started using SysML and therefore decided to not do that work again with SysML. Then we were left with behaviour diagrams and structure diagrams. Our group consists of only one mechanical engineer and one electrical engineer that in turn made us feel that the mechanical and electrical structure didn’t need much help in the designing process. Thus we chose only to use the structure diagrams to a limited extend to give us a superficial overview of the components in our system. In the software part of the system all three of the computer engineering students were from previous courses experienced with UML which was then used heavily for most of what it could offer. The behaviour of the components on the other hand needed more help, as this was important for how one component communicated with another. It also gives people of different disciplines the opportunity to understand how things work without necessarily knowing much about the engineering field in itself. 2.5.1. Implementation. In appendix A are the diagrams we have created to help us design our system. As previously mentioned we have not used all the diagrams included in the SysML language. Of the nine diagrams to choose from we have used the following four: Use case diagrams are used to present the different use cases that a system performs. They can be viewed as black boxes where they only explain what the system can do, and not how it’s done. In our project the use case diagrams have been heavily used in the design process of the software application. As we had created Scrum user stories before we started with SysML we saw no reason to redo the work we had done in words with diagrams instead. Block definition diagrams are used to display the components of the system in a hierarchy. In our project we have used it to create clear overview of the entire system. Activity diagrams are used to describe the behaviour of the system with focus on the flow of control. We have used activity diagrams in the software application and also to describe the work of the MCM. Sequence diagrams are used to describe the behaviour of the system with focus on how the components communicate with each other. We have used sequence diagrams to describe both the software application and how it communicates with the MCM and test bench. 2.6. Time report. We used Google Spreadsheet to log hours worked on the project. Activity codes were specified to be able to categorize the hours by working activity. Our final time-sheet can be seen in Table 2.1. The table is a summary of all the hours worked on the project, categorized by team member and activity. The total hours worked on the project was 3220.. 15/502.

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