Introduction: ECO BIKE TEST PLAN DOCUMENT Traffic jams have always been one of the major global issues, which can have negative impacts on the environment and the human. Nowadays, commuters have had a hard time to avoid traffic jams especially during rush hours to arrive to their workplace or school. One of the solutions of this problem is using alternative transportation such as bicycling. Therefore, by designing and building up ECO BIKE project, it will encourage the commuters to increase the efficiency of using the bicycle for transportation needs and decrease amount of private car uses. Thus, the ECO BIKE will allow the user to use his/her energy or the motor to ride the bicycle. What will make the product practical is that the user can charge the battery of the motor during bicycling process or using any power supply outlet. It also has adjustable assistance levels that can help the user to mount up a hill or to accelerate. Using push button and toggle switches for power and assistance level selections can achieve all these functions. The main subsystems of this project are power supply, motor throttle, generation mode circuit, DC DC converter, and LCD display. Each of the project s subsystem will be tested individually to accomplish all desired tasks and requirements. Essentially, the main purpose of arranging a testing plan is to ensure the ability of demonstrating the desired performances of our overall project system. Therefore, this document will include all of the subsystems/system tests along with some design and testing details to illustrate the process of the testing plan. Data collection plan, Sampling plan The plan of data collection and sampling of the project is going to be the measurements of the inputs and outputs of the system to perform certain analysis after the test. The data collection will also include current, voltage, RPM, and the temperature with/without weight added to the system. Thus, all the measurement data will be collected and analysed to determine the criteria of pass/fail. Measurement capability /equipment The measurement equipment that will be used for the ECO Bike system are the laboratory equipment and software provided on campus for the engineering students. Also, the system has internal sensors that allow us to collect certain data for current, voltage, and temperature. Test Procedure, Work Breakdown Structure, Schedule. The testing procedure will start off simulating all subsystems circuits involved in the ECO Bike using computer software such as Pspice. Some of the circuits will be simulated individually such as DC DC converter and voltage regulator. Also, the arduino microcontroller which acts as a brain of the whole system will be programmed to make sure that the system is functioning properly as we desired. Then all measurements and data will be
collected to ensure the output of the system is satisfying our specifications. After that, the team will begin to connect all subsystems together and test it. Since all circuits will be simulated prior building them on the actual hardware, the test of the overall system should be done in one or two days. Contingencies/mitigation for preliminary or insufficient results If the team obtain insufficient results from the system during the testing process especially with the power supply, the team is going to make some changes in the design. In case of the power supply, if the power is not efficient using a 12V battery and DC DC boost converter to reach the maximum power of 24V to the motor, we will need to add a 12V battery to the system or apply some changes in DC DC converter design. Also, if the temperature is too high of some components such as MOSFET s in the system, we will need to attach some heatsinks to these component to prevent any braking circuit or burning in the system. Test risks and assumptions During the testing process, there are various risks and assumptions that must be taken in consideration in order to have an effective and successful plan. Most of the collected data from the testing and simulations will be followed according to the specifications in the devices /components datasheets. The assumption that must be considered from the team is that all the information in the datasheets are provided from the manufacturer are accurate and precise. In case of the team gets any inaccurate measurements we will need to adjust the contingencies plan to resolve the issue. System Tests: TEST CASE FOR POWER SUPPLY SUBSYSTEM: The power supply test will be used to verify the operation of motor and arduino power supplies. A 12 volt battery will be connected in series to DC DC converter in order to achieve 24 volts for our DC motor. A 9 Volt battery will also be used in order to separately power the Arduino Mega Microcontroller. It is important to verify that the 9 Volt battery supply is correct and is properly connected to the Arduino Board as it can be sensitive to having too much or too little power supplied to the board. All the voltages will be verified using a digital multi meter and computer software. 1 Verify the motor power supply 24 volts (when connected together in series) 2 Verify Arduino Mega power supply 7 12 V
TEST CASE FOR MOTOR ASSISTANCE/THROTTLE SUBSYSTEM: The motor assistance level test will be done by verifying that the code we have supplied to the arduino mega board supplies the motor with the correct PWM duty cycle based on how far the throttle is being turned. The throttle will be acting as a potentiometer and have a range of 0 127 points on the Arduino which will correlate with the amount the throttle is turned and then supply the motor the current voltage. We will measure the output current and voltage levels using a digital multi meter and adjust our code as needed to meet the required values. (Test description/condition) 1 Throttle must supply the arduino with the proper value in order to get correct arduino output to motor (Done with the use of a potentiometer) 2 Throttle will be able to supply between 0 100% of the power supply voltage 3 Communicates effectively with the Arduino Mega board 0 5 V (All points from throttle to the Arduino are associated with the appropriate RPM range) 0V 24 V Pass : 0 cases of missing data (Steady operating conditions with no delays for an hour of ride time) TEST CASE FOR GENERATION MODE: The generation mode test will be completed by 1st verifying that when we select the generation mode the polarity of the motor is switched by the H Bridge and it begins to act as a generator rather than a motor. We can verify this by switching into generation mode and spin the motor then measure the current value being supplied back to the battery from the motor. 1 Blocking diode successfully prevents current from going from battery to motor. This will be measured using a multimeter. 2 Switch must be able to put bike in generation mode by reversing motor polarities 3 Full wave rectifier works efficiently Current = 0 A > 0 V Getting an efficient full rectified wave when voltage is applied
TEST CASE FOR DC DC CONVERTER SUBSYSTEM: The DC DC Converter subsystem test will first be done by verifying that our Pspice circuit simulation design works as desired. After it is verified we will build and test out our circuit design that will be physically built and then will be connected between the motor and the battery supply. (Test description/condition) 1 Input Voltage Range: This can be described as the voltage supplied by the battery pack at the minimum and maximum states of charge in which the system can safely operate, as well as the nominal state of charge. 2 Nominal Output Voltage: Maximum voltage rating of the motor 3 Maximum Output Current:: Determined by the motor ratings, as well as by the battery source 4 Estimated Efficiency: Efficiency of the converted is estimated from how much power is lost through switch on resistance and other impedances throughout the system V battmin = 10 V V battmax = 14.7 V V batt = 12 V V motor = 24 V I out =19.9A 78% TEST CASE FOR LCD DISPLAY SUBSYSTEM: The LCD Display test will be completed by verifying that all functions of the display work properly. We must verify that the motor on/off button, assistance level buttons, and generation mode button are all wired into the correct pins of the arduino and operate correctly. We must also verify that the LCD properly reads and displays the battery voltage level as well as mode selected. 1 Correctly and accurately display battery charge level Shows the battery charge in the form of a percentage accurately on the display
2 Correctly and accurately display bicycle speed 4 Correctly and accurately displays the temperature of the system RPM and MPH should be accurately displayed The temperature is accurately shown on the display TEST CASE FOR OVERALL ECO BIKE SYSTEM: 1 Able to be rode in both assist and generation modes safely 2 Temperature of all components are within a specified range. This data will be collected by the Arduino from a temperature probe. > 1 hour of ride time 4 F 105 F 3 Speed of the Bicycle 0 15 MPH 4 System Interface Integrity is the reliability of the Eco Bike subsystems to reliably communicate with associated components. This will be tested by taking samples of data collected by the microcontroller 0 cases of missing data in 1 hour of ride time Test s Matrix: Req # Function Test Method 1 EE Controller Test & Analysis Brief Test description Programs simulations to SME /Facul ty Revie wed / Appr oved
1.1 EE/Circuit Design 1.2 EE/Circuit Design 2 Software/ Hardware Motor portion of the controller should complete all necessary functions and safety requirements. Battery charger portion of the controller should be designed to properly charge the ECO Bike battery Test Test achieve all desired tasks. Ensure that the motor controller properly performs all necessary tasks Ensure that the charge controller properly performs all necessary tasks User friendly display Test Test all pushbuttons and ensure display is easy to read 3 Mechanical Motor functions properly Demonst ration Put motor through the various assistance levels and generation mode 4 Simple Functional Display Batteries Inspectio n Monitor voltages of batteries while using bike in generation mode. Conclusion: When the Eco Bike system meets the testing requirements set forth in this document, this version of the system will be considered complete. Eco Bike will be developed enough to perform in normal weather conditions (32 104 F). The bike should be able to ridden without too much extra stress when the battery is depleted and charge up the battery when operated in this mode (generation). When the battery has been sufficiently charged, the bike should be able to switch the other available mode (assist) and be ridden without pedaling for a desired distance while using the throttle to control speed for approximately one hour. The charge level and temperature of the battery should be properly displayed on the LCD as well as the calculations associated with speed (RPM and MPH).