Shepard Test Stand

h1. Operating Manual v1.0

{{toc}}

h2. Hardware Operation

h3. Unpacking After Transport

# Check shipping container(s) for:

## Test stand

## Concrete block

## Box of accessories

### Launch controller

### D motor spacer ring

### Motor mount adapters (A, B, and C to D/E size)

### Thermocouple attachment tape (high temp)

## Computer and USB cable

## Motors to test (with igniters and igniter plugs)

## Fire extinguisher and maybe a bucket for water

h3. Test Stand Setup

# Place concrete block in location where test stand will be operated

# Set test stand on concrete block

# Create the safety perimeter.

## Delineate no stand zone for both proximity and positions

### Use length of cord for the igniter (radius of operations)

### Exclusion zones exist behind where exhaust escapes (30 degree cone), and in front on each side of the exhaust T (30 degree cone on each side)

# Set up the management area for test.

## Igniter

### Clip the igniter to a part of the test stand and deploy the cable to its full length and place it where the test(s) will be run from

## Computer

### Set up computer

### Boot computer

### Run USB cable from computer to test stand

### Connect Arduino-based DAQ system to USB cable at test stand

### Start the Test Stand App

### Ensure DAQ system and Computer are both running and connected

h3. Prepare For Test*

# Check the following areas of the test stand for fatigue damage and good fit.

## Motor mount

## Zip ties holding motor mount

## Linear guide rail system

# Clear any debris from linear guide rail system and ejection charge exhaust ports

# Test sensors

## Push on thrust sensor and confirm current value slider responds

## Put fingers around thermocouple(s) (after ensuring it is not hot) and confirm plot responds

# Install motor in test stand

## A-C Motors

### Attach thermocouple(s)

### Insert igniter into motor and cap with igniter plug, making sure to space leads

### Install the motor in an adapter

### Insert D spacer ring into the motor mount

### Insert the motor assembly into the motor mount so a notch from the adapter lines up with the clip on the motor mount so it clicks into place

## D Motors

### Attach thermocouple(s)

### Insert igniter into motor and cap with igniter plug, making sure to space leads

### Insert D spacer ring into the motor mount

### Insert the motor into the motor mount, pushing it all the way into the the motor mount, note the clip should close

## E Motors

### Attach thermocouple(s)

### Insert igniter into motor and cap with igniter plug, making sure to space leads

### Insert the motor into the motor mount, pushing it all the way into the the motor mount, note the clip should close

# Double check that the range is actually clear

# Set up igniter

## Make sure the firing pin is not in place

## Connect alligator clips from Launch Controller to the igniter (one to each lead)

### At this point the range is hot (ready to fire)

h3. Perform Test (Fire Motor and Take Data)*

# Hit button to enable recording

# Insert firing pin into Launch Controller

# Check for continuity by pressing on firing pin (light will turn on)

# Count down

# Press ignition button (may have to hold it down for a second)

# At the end of the firing, remove the firing pin from the Launch Controller

h3. Post Test Duties*

# Remove motor and prepare for disposal

## Wait several minutes before removing the motor to allow it to cool down to a safe handling temperature

## Remember to also remove the D space ring if the motor was D size or smaller

## Remember to find the igniter (it should still be attached to the alligator clips) so it can be properly disposed

## For C size motors and smaller, be sure to recover the motor adapter

## Store spent motors away from flammable material during future tests

# Check to make sure that data was autosaved to the "data" directory.

h3. Post Operations Duties (After Firing All Motors)

# Dispose of motor(s), being careful to observe all state, federal, and local guidelines.

## Rinse motors in water to ensure they are completely cooled before disposal

## Throw the motors away according the manufacturer’s recommendation

# Pack up the accessories

# Pack up the computer

# Pack up the test stand and block

*Note:* If performing multiple tests during the same setup, repeat the steps with an asterisk (*) for each test.

h2. Software Operation

For instructions on how to download and install the Shepard data acquisition (DAQ) software, please see the "Software Source Code":https://opendesignengine.net/projects/shepard-ts/wiki/Software_Source_Code_v1_0 section of the wiki.

When you've downloaded the source code via subversion, you descend through the directory tree until you end up in the ShepardDCS directory (shepard-ts/trunk/ShepardDCS). Inside this directory you will find a directory holding the Arduino code, and one holding the Processing (PC-side) code. The @ShepardDCS_Arduino@ directory