| name | test-planning |
| description | Skill for comprehensive mechanical test plan development and execution support |
| allowed-tools | ["Read","Write","Glob","Grep","Bash"] |
| metadata | {"specialization":"mechanical-engineering","domain":"science","category":"testing-validation","priority":"high","phase":4,"tools-libraries":["LabVIEW","NI DAQ systems","Test management tools"]} |
| graph | {"domains":["domain:mechanical-engineering"],"skillAreas":["skill-area:physics-simulation","skill-area:mathematical-reasoning","skill-area:motion-planning"],"roles":["role:systems-integration-engineer","role:research-engineer"]} |
Test Plan Development Skill
Purpose
The Test Plan Development skill provides comprehensive capabilities for developing mechanical test plans including objective definition, test configuration, instrumentation planning, and data analysis procedures.
Capabilities
- Test objective and success criteria definition
- Test configuration specification
- Instrumentation and data acquisition planning
- Load and environmental condition specification
- Safety analysis and risk assessment
- Test procedure development
- Data analysis plan creation
- Test report template generation
Usage Guidelines
Test Planning Framework
Test Objective Definition
-
Verification vs Validation
| Type | Question | Purpose |
|---|
| Verification | Built correctly? | Meets specifications |
| Validation | Built the right thing? | Meets user needs |
-
Test Categories
- Development testing (design iteration)
- Qualification testing (design approval)
- Acceptance testing (production verification)
- Certification testing (regulatory compliance)
-
Success Criteria
Pass/Fail criteria must be:
- Measurable and quantitative
- Traceable to requirements
- Unambiguous
- Defined before testing
Test Configuration
Test Article Definition
-
Configuration Control
- Part number and revision
- Serial number
- Manufacturing records
- Deviations from design
-
Pre-Test Condition
- Dimensional verification
- Surface condition
- Prior test history
- Environmental exposure
Test Setup
-
Boundary Conditions
Fixture requirements:
- Simulate actual mounting
- Minimize artificial constraints
- Allow access for instrumentation
- Safe for failure modes
-
Load Introduction
- Point loads vs distributed
- Static vs dynamic
- Load path verification
- Fixture compliance effects
Instrumentation Planning
Strain Measurement
| Type | Application | Accuracy |
|---|
| Foil gage | General purpose | +/- 1% |
| Rosette | Unknown principal direction | +/- 1% |
| Clip gage | Large strains | +/- 0.5% |
| DIC | Full-field | +/- 2% |
Displacement Measurement
| 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 |
Force/Load Measurement
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
Acceleration Measurement
| Type | Range | Bandwidth |
|---|
| Piezoelectric | +/- 500 g | 1 Hz - 10 kHz |
| MEMS | +/- 50 g | DC - 1 kHz |
| Capacitive | +/- 10 g | DC - 100 Hz |
Data Acquisition
Sampling Requirements
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 Planning
-
Channel List
- Channel ID
- Measurement type
- Sensor type
- Location
- Expected range
- Calibration requirements
-
Data Management
- File naming convention
- Storage requirements
- Backup procedures
- Archive policy
Test Procedures
Procedure Structure
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
Safety Considerations
-
Hazard Analysis
- Energy sources
- Failure modes
- Personnel exposure
- Environmental impact
-
Risk Mitigation
- Barriers and shields
- Emergency stops
- Warning systems
- PPE requirements
Data Analysis Plan
Analysis Methods
| 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 |
Uncertainty Analysis
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
Process Integration
- ME-021: Test Plan Development
Input Schema
{
"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",
Output Schema
{
"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"
}
Best Practices
- Define success criteria before testing
- Verify instrumentation calibration
- Document all deviations from plan
- Include margin in load capacity
- Plan for potential failure modes
- Review procedures with test team
Integration Points
- Connects with Requirements Flowdown for test requirements
- Feeds into Test Correlation for model validation
- Supports Design Review for verification evidence
- Integrates with FAI Inspection for first article
