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 (see *Listing 1*). Inside this directory you will find a directory holding the Arduino code, and one holding the Processing (PC-side) code. There is a file named @ShepardDCS_Arduino.ino@ inside the @ShepardDCS_Arduino@ directory. You open this file with the Arduino IDE and compile/upload it to the Arduino Uno. The @ShepardDCS_Processing@ directory includes the @ShepardDCS_Processing.pde@ file, which you open and run with the Processing IDE on your PC to display the data dashboard for Shepard.

*Listing 1*

<pre>

├── branches

├── tags

└── trunk

    ├── libraries

    │   └── controlP5

    └── ShepardDCS

        ├── ShepardDCS_Arduino

        └── ShepardDCS_Processing

</pre>

You'll notice that there is a @libraries@ directory at the same level as the @ShepardDCS@ directory. @libraries@ contains the ControlP5 library which provides the graphical elements for the ShepardDCS user interface. In order for this library to be found, you will either need to move the @libraries@ directory into the already configured Processing sketchbook directory, or you'll have to reconfigure the sketchbook directory to point to the @trunk@ directory. This option is found under File -> Preferences in the Processing IDE (*Figure 1* and *Figure 2*).

*Figure 1*

!Preferences_Location.png!

*Figure 2*

!Arduino_Processing_Preferences.png!

Once you're connected the PC to the Arduino Uno with a USB cable, open and run the @ShepardDCS_Arduino.ino@ file from the Arduino IDE first. This will load and start the program on the Uno. When the Arduino program is running and ready to transmit data, the TX LED for the serial port will be lighted continuously.

Start the Processing application and the TX LED on the Arduino Uno should start to flash. If you have the sensors attached, you should be able to apply pressure to the thrust sensor to change the "CUR" (current thrust value) slide on the user interface as a simple test. To check temperature monitoring, you can hold the thermocouple between your thumb and index finger to see if the "CUR" value for the temperature rises.

There are several components of the user interface, and those are numbered for reference in *Figure 3*.

*Figure 3*

!Shepard_DCS_Overview.png!

# TODO: Call out each item and describe it here.