A key element of a design project.
You are (nearly) here
Product Evaluation Test
Planning and Testing
The TEST PLAN…
 Defines Goals of the test sequence.
 Identifies the specific test procedures,
 Lists the data to be acquired,
 Specifies the schedule, and sequence, of testing
 Specifies Testing Equipment, Facilities to be used
 Measurement Equipment:
 Computer-controlled DAQ?
 Sensors, Transducers; Power source? Accuracy/Resolution?
 Jigs, Fixtures, and Tools; Availability? Skill required for
operation?
Product Evaluation Test
Planning and Testing
The TEST PLAN…
 Is designed to guide the Validation of both the
prototypes components (shape, size, mass etc.), and
the performance of the test article
 Should be able to identify configuration and
performance differences (e.g. shortcomings?)
between what was envisioned/specified and the
fabricated result
 Provides a direct link from Level 1 Requirements, thru
specifications, to actual prototype configuration, and
prototype performance.
What the Client wanted
How the Client
explained it
How the project
manager understood it
How the Engineer
visualized it
How the Engineers
designed it
How Health & Safety
wanted it
How the Contractor
built it
When it was delivered
What the Client paid for
What the Client received
What the client really needed
Types of Testing encountered in an
industrial setting…
1. Component or system
VALIDATION TESTING
 Testing to verify ANALYSIS predictions
 Confirm (or invalidate?) assumptions
Provide confidence in analysis procedures
 Determine if further design work is
warranted
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Types of Testing encountered in an
industrial setting… (continued)
2.
Testing as s COMPANION to ANALYSIS
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Provide required inputs for (future) analysis
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Dimensional data?
Material Properties?
Subsystem Performance?
Reverse Engineering?
Baseline characteristics of new or unique products,
systems, materials must be found in order to support
analysis steps leading to an ultimate solution.
Types of Testing encountered in an
industrial setting…(continued)
3. Testing IN LIEU OF ANALYSIS  Some engineering designs are too complex to be adequately or
completely analyzed
 Inadequate modeling capability?
 Inadequate budget?
 Lack of time?
 Complex or Indeterminate structures often cannot be effectively
modeled
 Often, system performance cannot be fully anticipated
 Testing can establish likely results prior to full engineering
implementation: (e.g. Osprey Test)
 Typical for novel experiments, one-off prototypes, some basic
research projects
Types of Testing , continued
4. ACCEPTANCE TESTING
 Often used to verify performance of fabricated or purchased
parts
 Major function of a Quality Assurance department
 Can also refer to performance of built or assembled delivered
system or design
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Dimensions, Weight, Materials recorded
Kinematics & Dynamic Performance observed, recorded
Results compared to performance specifications to determine if product
performs within required bounds
Destructive/Nondestructive testing, sampling
Types of Testing, continued
5. SYSTEM - LEVEL VERIFICATION & VALIDATION
 Comprehensive testing to verify conformance to specifications,
interfaces, user requirements
 Subsets
 Functional Performance Testing
 e.g. Climatic Testing to extreme environmental limits… MIL-STD-810
(humidity, high/low temp, salt spray, etc.)
 Barge Shock
 Reliability Testing
 e.g. Repeatability, Cyclic fatigue
 Compliance Testing
 Conformance to third-party specs or regulatory rules
e.g. UL or CE testing
Examples of System-Level tests:
Automotive crash testing
Endurance testing of transportation
systems, vehicles
Vibration Acceptance Testing
 http://www.youtube.com/watch?v=MH0okmOnfVo&f
eature=related (Vibe table component test)
 http://www.youtube.com/watch?v=Q5LbFdfVDqE&fe
ature=related (Vibe table computer test)
MSU Student-Accessible Resources
 M&IE Test Facilities
 Materials Testing Laboratory
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Instron Tensile/Compressive Testers, Drop Tower (Impact)
 MSU Subzero Test Facility, ICAL, etc.
 Instrumentation Lab
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Sensors, Transducers, DAQ Hardware
 Machine Shop Inspection Equipment
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Standard QA Equipment – Surface Plates, Gage Blocks, Height Gages,
Calipers
CIM Lab Micro-scribe
 Sponsor’s Facilities, 3rd – Party Shop
 Instructor or Advisor Assistance
Documentation Discussion
Prototype testing provides one of the best opportunities to
DOCUMENT your achievements, and to demonstrate that you’ve met
your “Level 1 contractual requirements: To do so, be absolutely sure to
TAKE PHOTOS/VIDEOS of tests in progress and of test results.
Many groups will utilize MSU Data acquisition equipment and
transducers to record signals (pressures, strains, forces, velocities,
temperatures, etc. In those cases, it is important to capture the
LabVIEW (or other) programming, and to clearly document any postprocessing of data.
Also be sure to record identification of all components, provide info
on sensors (range/resolution/accuracy) names of data files, computer
and software ID, etc. This ensures repeatability (if necessary.)
Specific TEST PLANNING
Documentation Requirements
Test Plan – Due to drop box by 5:00 PM FRIDAY
1.
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A well-written plan documenting the specific procedures that will be used to
inspect and test your prototype components, assembly
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Include schedule and location of testing
Include equipment to be utilized
Include the specific DATA to be acquired
Each test plan MUST include the groups assessment of any and all safety
concerns related to testing, operation.
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The plan must specify the means you’ll utilize to mitigate or eliminate any
safety-related issues.
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Safety is the one issue we cannot ignore – your health and well-being is paramount.
Watch out for existing or unanticipated hot/sharp surfaces, high pressures, dangerous
forces, risk of explosions or catastrophic failures, etc. This is a critical element. EVERY
GROUP should solicit the advice/opinion of their MSU Advisor prior to undertaking
any testing, as a means to ensure that adequate Safety Protocols are in-place.
Include discussion of how your data will be Processed and Presented
Specific TEST PLANNING
Documentation Requirements
2. Technical Addendum – Due at end of term

Test plan documents including procedures, protocol, and results
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A) acceptance testing details for your tests & measurements of fabricated or
purchased parts, assemblies must be included in the final technical addendum
B) functional testing procedures and results must also be included in the final
technical addendum
Formatting of Technical Addendum includes other elements, but test
procedures and RESULTS are one of the highlights
A well written and well-executed test plan supports and helps to
highlight project success.