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Module 5 — Test & Iterate

Objective: prove durability and performance, then feed fixes back to design.

Prereqs: Assembled subsystem.

Steps

  • Run stress and endurance tests; track heat, slip, stall, deformation.
  • Log failures and suspected causes; apply fixes (tension, wrap, bracing, ratios).
  • Re-test and update documentation and CAD as needed.
  • Check fasteners post-test for loosening; reapply threadlocker if needed.
  • Validate that changes still clear bumpers, frame perimeter, and wiring paths.

Deliverables

  • Test report with pass/fail, fixes applied, and approved revisions for CAD/build.
  • Updated spares list and maintenance schedule based on failures seen.

Resources

  • Reuse drivetrain/mechanism calculators for any ratio changes.

Instructions (numbered)

  1. Plan tests (stress/endurance); measure heat, slip, stall, deformation.
  2. Run tests; log failures and suspected causes with data/photos.
  3. Apply fixes (tension, wrap, bracing, ratios); re-test and compare results.
  4. Check fasteners after testing; reapply threadlocker if needed.
  5. Verify rules/clearances (bumpers/frame/wiring) after changes; update CAD/docs/spares.

Example

  • Arm test: overheated at 50% duty after 2 min; fix by increasing gear ratio and adding vent holes; retest shows stable temps.

Best practices

  • Instrument tests (temp, current, video) to capture evidence.
  • Test longer than match duration to catch endurance issues.
  • Update spares and maintenance based on observed failures.

Common mistakes

  • Short tests that miss endurance failures.
  • Not retesting after fixes; not checking fasteners afterward.
  • Forgetting to update CAD/docs/spares.

Checklist

  • Test plan defined
  • Data captured (temps, current, video)
  • Failures logged
  • Fixes applied and retested
  • Rules/clearances rechecked
  • Docs/CAD/spares updated

Recommended tools

  • IR thermometer or temp sensors, current logging, camera, torque tools, checklists.

Sample log (template)

  • Date:
  • Test type:
  • Observations/data:
  • Fixes applied:
  • Retest results:
  • Updates made:

Photos/diagrams

  • [Placeholder: test setup and plots before/after]