Skill for comprehensive mechanical test plan development and execution support
Generates comprehensive mechanical test plans including objectives, instrumentation, procedures, and safety analysis.
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The Test Plan Development skill provides comprehensive capabilities for developing mechanical test plans including objective definition, test configuration, instrumentation planning, and data analysis procedures.
Verification vs Validation
| Type | Question | Purpose |
|---|---|---|
| Verification | Built correctly? | Meets specifications |
| Validation | Built the right thing? | Meets user needs |
Test Categories
Success Criteria
Pass/Fail criteria must be:
- Measurable and quantitative
- Traceable to requirements
- Unambiguous
- Defined before testing
Configuration Control
Pre-Test Condition
Boundary Conditions
Fixture requirements:
- Simulate actual mounting
- Minimize artificial constraints
- Allow access for instrumentation
- Safe for failure modes
Load Introduction
| Type | Application | Accuracy |
|---|---|---|
| Foil gage | General purpose | +/- 1% |
| Rosette | Unknown principal direction | +/- 1% |
| Clip gage | Large strains | +/- 0.5% |
| DIC | Full-field | +/- 2% |
| Type | Range | Accuracy |
|---|---|---|
| LVDT | +/- 50 mm | +/- 0.1% |
| String pot | 0-2000 mm | +/- 0.5% |
| Laser | 0-500 mm | +/- 0.01% |
| Dial indicator | 0-50 mm | +/- 0.02 mm |
Load cell selection:
- Capacity: 1.5-2x expected maximum
- Accuracy: Class 0.1 or better for critical
- Type: Tension, compression, universal
- Environmental: Temperature, humidity range
| Type | Range | Bandwidth |
|---|---|---|
| Piezoelectric | +/- 500 g | 1 Hz - 10 kHz |
| MEMS | +/- 50 g | DC - 1 kHz |
| Capacitive | +/- 10 g | DC - 100 Hz |
Nyquist criterion: f_sample >= 2 * f_max
Practical guideline: f_sample >= 5-10 * f_max
For transient events:
- Sample at 10x highest frequency content
- Include anti-aliasing filter
Channel List
Data Management
1. Scope and applicability
2. Reference documents
3. Safety requirements
4. Equipment and materials
5. Pre-test setup
6. Test execution steps
7. Data recording requirements
8. Post-test procedures
9. Acceptance criteria
10. Reporting requirements
Hazard Analysis
Risk Mitigation
| Data Type | Analysis Method | Output |
|---|---|---|
| Static load-displacement | Linear regression | Stiffness |
| Stress-strain | Offset method | Yield strength |
| Fatigue | S-N curve fit | Life equation |
| Vibration | FFT, modal fit | Frequencies, damping |
Combined uncertainty:
u_c = sqrt(sum(u_i^2))
Expanded uncertainty (95%):
U = k * u_c (k = 2 for 95%)
Sources:
- Calibration uncertainty
- Resolution
- Environmental effects
- Repeatability
{
"test_article": {
"part_number": "string",
"description": "string",
"quantity": "number"
},
"requirements": {
"specifications": "array of requirement IDs",
"success_criteria": "array"
},
"test_type": "development|qualification|acceptance|certification",
"test_conditions": {
"loads": "array of load cases",
"environments": "array of conditions",
"duration": "string"
},
"resources": {
"facility": "string",
"equipment": "array",
"personnel": "array"
}
}
{
"test_plan": {
"document_number": "string",
"revision": "string",
"test_matrix": "array of test cases",
"instrumentation_list": "array",
"schedule": "object"
},
"test_procedures": "array of procedure references",
"safety_analysis": {
"hazards": "array",
"controls": "array",
"approval_required": "boolean"
},
"data_analysis_plan": {
"methods": "array",
"acceptance_criteria": "array"
},
"resource_requirements": {
"cost_estimate": "number",
"duration": "number (days)",
"personnel": "array"
}
}
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