Module 6 — Iterate with Testing
Objective: close the loop from tests to design updates.
Prereqs: Prototype/build test data.
Steps
- Capture failures (slip, deflection, jams, heat); quantify when possible.
- Adjust belt/chain wrap, ratios, structure; lighten or reinforce as needed.
- Re-test and log deltas; update decision records if a major change.
- Verify changes against rules (weight, extension, bumper gaps) before releasing.
- Update maintenance docs and spare parts lists based on failures seen.
Instructions (numbered)
- Test and log failures (what/expected/actual); measure where possible.
- Identify fixes (wrap, ratios, bracing, materials) and implement.
- Re-test, compare results, and log deltas; update decision records if significant.
- Recheck rules (weight, extension, bumpers) after changes.
- Update maintenance docs and spares list based on issues found.
Example
- Intake jammed at 70% speed; fix by increasing compression 0.1 in and adding flare; re-test shows no jams over 20 cycles.
Best practices
- Change one variable at a time and log results.
- Keep before/after photos and data.
- Update CAD/notes promptly to avoid divergence.
Common mistakes
- Fixing without measuring; not logging changes.
- Forgetting to re-verify rules after mods.
- Skipping maintenance/spares updates.
Checklist
- Failure logged with data
- Fix applied and retested
- Results compared and recorded
- Rules rechecked post-change
- Maintenance/spares updated
Recommended tools
- Test log template, camera for photos, scale/tape for measurements, checklist for rules.
Sample log (template)
- Date:
- Failure observed:
- Fix applied:
- Test results (before/after):
- Rule check status:
- Updates to maintenance/spares:
Photos/diagrams
- [Placeholder: before/after images of mechanism and data plots]
Deliverables
- Change log tied to test results with before/after notes.
- Approved revisions handed back to CAD/build.
Resources
- Field tours for geometry checks: youtube.com/playlist?list=PLZT9pIgNOV6b3g0-QYDz7eW8lTqrsaprb