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 and run 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@ 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 configured Arduino/Processing sketchbook directory, or you'll have to reconfigure the sketchbook directory to point to the @trunk@ directory.