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Objective
The objective of design validation plan is to ensure the all components used in our Go-kart are on
good quality and perform their respective function to the needed standards and meet required
specification. The most important function of DVP is to identify and rectify potential problems in
mountings and the design itself. The secondary purpose of the DVP is to ensure that we meet the
OEM requirements for various components purchased and that we do not use any substandard
parts on the Go-kart.
IN Scope
The following tests are in scope of this design validation plan:
1)
2)
3)
4)
5)
6)
Mechanical tests
Metrological inspection
Visual inspection
Computer simulation
Performance tests
Electrical circuit testing
Mechanical tests
Mechanical tests like strength under torsional, shear and bending are in scope of testing
Metrological inspection
All components that are going to be fitted on the Go-kart will undergo a metrological inspection
where they will be accepted only if they are within the tolerance limit set for the specific part.
Visual inspection
A thorough visual inspection of all parts will take place for finding cracks, bends, surface abrasion
and any other imperfections.
Computer simulation
Project report/DVP
Performance tests
The performance of the engines and brakes can be tested.
OUT of Scope
Testing methods such as Ultrasound and eddy current testing are out of scope due to unavailability
of the required setup.
Validation strategy
The DVP is divided based on subsystem
1) Chassis frame
2) Engine and Transmission
3) Brake
4) Steering
5) Safety
6) Maintenance
The validation process will give higher priority to the validation of the chassis frame by simulation.
Then the priority will shift to the testing and the validation of the tube steel that is to be used as it
is the paramount if we intend to stick to the fabrication timeline. All parts that are bought will first
undergo a thorough visual inspection in the store before buying the component.
Project report/DVP
DVR
The Design Validation Report will be prepared on each and every component validation and every
iteration of testing if there are more than one required. The design validation report will be
prepared with a fixed format as given below. The final DVR for the chassis structure is given after
the sample DVR.
Project report/DVP
Test conducted:
Equipment used:
(date)
(subsystem)
(part)
(revision no)
(name)
(signature)
(title)
Validation plan for the XYZ component
Test parameters:
Test results:
Diagnosis (if any):
Supervisors signature.
Project report/DVP
DVP by subsystem
Chassis frame: the design validation for the frame is done in a two pronged system where
first the frame is analysed using computer simulation for different working stresses such a static
load and impact load. And then the material is tested using for its mechanical properties by
conducting material tests.
The tests conducted on the chassis are:
Computer simulations under following load
Static load
Impact loads(front and side)
Torsion loads
Tension loads
Bending loads
Torsional loads
ANSYS software
Universal Testing Machine
Torsional test setup
The computer simulations for the frame have been done at the CAD lab of NMAM Institute of
Technology. The design was redesigned and modified until the factor of safety was up to the mark.
The design was analysed using ANSYS15 and the above mentioned simulations were conducted
All the material strength tests are going to be conducted in the material testing laboratory in the
NMAM institute of technology campus.
The material tests are going to be conducted once the material is available to work with.
Project report/DVP
Project report/DVP