Element H

Test 1

Design Requirement #1: The Solution shall be able to sense motion and function accordingly:

Testing Summary:

We will set up our system on the light switch and walk in front of it at 5 different distances to test the functionality of the motion sensor and the reliability the further we are from it.

Purpose:

The purpose of this test is to ensure that our solution will be able to reliably sense motion and create function to its mechanical parts effectively.

Initial Conditions:

The desired room will be empty with no existing motion in the environment.

Materials:

• Prototype

• Tape Measure

• Standard Wall Switch 

• Test Subject

Pass Criteria:

1. The system successfully detects motion at each of the 5 predefined distances.

2. The light switch is activated or triggered by the motion detected at each distance.

Fail Crrteria:

1. The system fails to detect motion at any of the 5 predefined distances.

2. The light switch does not activate or trigger in response to motion at any distance.

Procedures/Safety Considerations:

We will place our prototype on the light switch, powered on. We will then have one test subject walk past the solution once. We will document the results and allow a brief break time in between the next test. The test subject will then walk past at a different distance. Documentation and break period will be repeated. The procedure will be repeated 5 different times.

Test 2 and 8

Design Requirement #2: Fit over existing light switches, and have all mechanical and electrical functionalities remaining inside a 2.75” x 4.5” (width x height rectangular) constraint

#8: Not protrude any more than 3" from the existing light switch plate:

Testing Summary:

We will attempt to place our system over the existing light switch and ensure with a ruler that it does not break the 2.75" x 4.5" perimeter of the standard plate. We will also measure the distance it protrudes from the light switch and ensure it does not reach over 3”.

Purpose:

By testing to see if our system fits within the light switch plate and/or the 2.75” x 4.5” and 3-inch depth constraint, we are able to ensure our solution occupies the least amount of space and will not be an inconvenience for the owner in terms of space.

Initial Conditions:

The light switch and plate will be clear of obstructions, with the plate and switch clean, with the switch able to move freely.

Materials:

• Prototype

• Standard Wall Light Switch with Plate

• Tape Measure

Pass Criteria:

1. The system fits over the existing light switch without exceeding the 2.75" x 4.5" (width x height) constraint.

2. Depth of Solution on the light switch is under 3 inches

3. All mechanical and electrical components of the system are contained within the specified dimensional constraint.

Fail Criteria:

1. The system does not fit over the existing light switch or exceeds the 2.75" x 4.5" (width x height) dimensional constraint.

2. Depth of Solution on the light switch is over 3 inches

3. Any mechanical or electrical components extend beyond the specified perimeter.

Procedures/Safety Considerations:

Turn off the servo/movement of the switch when testing dimensions.

Test 3

Design Requirement #3: Works for both toggle and rocker light switches and not require connection to existing switch wires:

Testing Summary:

We will test the function of our overlay overtop both the rocker and toggle light switches. We will do three trials on rocker and toggle light switches, possibly with them being in different environments/homes.

Purpose:

We need to test the functionality of our mechanism by flipping both the toggle and rocker light switches meeting our universal solution design requirement. 

Initial Conditions:

The switch plate will be clear of obstructions and clean. The switch will be able to be moved without greater resistance compared to other switches. The wiring and space in the wall will be standard.

Materials:

• Prototype

• Standard Wall Rocker Light Switch with Plate

• Standard Wall Toggle Light Switch

Pass Criteria:

1. The overlay functions correctly on both rocker and toggle light switches in all trials.

2. The overlay does not require any physical connection to the existing switch wires for its operation.

Fail Criteria:

1. The overlay fails to function on either the rocker or toggle light switches in any of the trials.

2. The overlay requires a physical connection to the existing switch wires to operate.

Procedures/Safety Considerations:

Ensure testers understand the mechanism and install it properly to guarantee no broken equipment or hurt people.

Test 4

Design Requirement #4: Only require maintenance out of the box, not needing to be extensively interacted with after setting up the first time, aside from battery replacement/recharge or personal settings adjustment, with an assembly/set-up time of under 3 minutes:

Testing Summary:

We will assemble our solution and then time our consumer installation/setup, ensuring it is under three minutes. We will also see if our solution functions without needing to tinker or adjust anything.

Purpose:

The purpose of this test is to determine if our solution, post-manufacturing, is user-friendly enough to be operational in under 3 minutes, making it an efficient and easy solution.

Initial Conditions:

We will have a clean table with only the necessary assembly parts on it.

Materials:

• Prototype

• Test Subject

• Timer (Phone)

• Standard Wall Light Switch and Plate

Pass Criteria:

1. Assembled and set up in < three minutes out of ‘box’

2. After the initial setup, the product functions correctly without the need for additional adjustments, tinkering, or maintenance, not including battery removal or switching

Fail Criteria:

1. Test subject fails to understand how to effectively install the product

2. The test subject does not install in the allotted time

Procedures/Safety Considerations:

We will place all the necessary solution components on a clean table, start a stopwatch, then begin assembling at a moderate speed, stopping the stopwatch once we have assembled and installed.

Test 5

Design Requirement #5: Have all components, materials, and manufacturing prices for a single product add up to below $40, with an MSRP estimation of below $20, in a theoretical mass production:

Testing Summary:

We will take an audit of all the materials and components we used during our first prototype, calculating the total cost of assembly and fabrication, ensuring it is under forty dollars.

Purpose:

By having all components total up to below $40, we are able to justify that our solution was both efficiently built and is affordable to the owner.

Initial Conditions:

We will have a blank Google Sheet in which a blank table will be. We will also have our bill of materials present to provide a reference for calculation. 

Materials:

• Prototype

• Calculator (Phone)

• Team’s Bill of Materials

Pass Criteria:

1. All of the materials used in our prototype total to under $40

Fail Criteria:

1. Our total cost of materials and assembly exceeds the $40 limit

Procedures/Safety Considerations:

We will have our prototype present, pull up our bill of materials, along with Google for any other retail references, and begin to add together the cost of each component used in our prototype, documenting and totaling all of it.

Test 6

Design Requirement  #6: Include a manual override button that allows users to override the automatic features so that the usual use of the light switch can still be used:

Testing Summary:

We will place our system in its correct position, press the pre-installed button 5 times, and evaluate whether it functions and overrides the motion at the current moment all five times.

Purpose:

Guarantee logical function of our light switch.

Initial Conditions:

Both the sensor activated and sensor deactivated, must be tested with different combinations of conditions.

Materials:

• Prototype

• Test Subject

• Standard Wall Light Switch and Plate

Pass Criteria:

1. This functionality works correctly all five times it is tested, under various conditions, demonstrating the effective operation of the manual override feature.

Fail Criteria:

1. The prototype fails to allow for manual override of the automatic features when the pre-installed button is pressed at least once out of the five attempts, indicating inconsistency or malfunction in the override system.

Procedures/Safety Considerations:

First test off of the light switch and then test on the light switch to ensure proper and safe function of the switch before resistance is added.

Test 9

Design Requirement  #9: Contain no sharp edges or exposed wiring that may cause harm to the user:

Testing Summary:

We will determine whether all edges of our solution are either clean or have negligible danger to the owner, along with ensuring any hardware or wiring stays contained within to reduce the risk of danger.

Purpose:

This will determine whether our solution is safe for the user to use and handle.

Initial Conditions:

The prototype is fully assembled and functional.

Materials:

• Prototype

• Test Subject

Pass Criteria:

1. Test subject is able to touch and interact with the prototype without cutting or harming themselves

Fail Criteria:

1. Any uncomfortableness or hurt when examining the prototype

Procedures/Safety Considerations:

First, inspect using eyes to find any exposed wires or sharp edges. Then run hands across to find any dangerous parts that were not located via visual inspections. Possibly wear a protective glove to protect hands from any damage from the prototype.

Test 10

Design Requirement #10: Have a total weight of no more than 4 lbs:

Testing Summary:

Once fully assembled, we will weigh our prototype on a simple scale, ensuring it weighs less than 4 pounds.

Purpose:

To confirm our product will be able to be held onto the panel using our adhesive.

Initial Conditions:

The product will be in its entirety (all components and pieces), and the scale will be zeroed.

Materials:

• Prototype

• Scale

Pass Criteria:

1. The prototype weighs < 4 lbs

Fail Criteria:

1. The prototype exceeds 4 lbs

Procedures/Safety Considerations:

Zero scale and then weigh the prototype.

Test 11

Design Requirement #11: Contain a shell that will house the components of a motor, micro-controller, and power source, along with the mechanical features, and will be 3D Printed in a PLA or PETG filament material to protect and streamline function:

Testing Summary:

We will ensure every component fits inside of our 3d printed shell and that it is sturdy enough for functionality.

Purpose:

By testing if everything fits within the shell, is protected, and can still function, ensures that the material and switch will hold up while being used in homes across America.

Initial Conditions:

The prototype is assembled.

Materials:

• Prototype

Pass Criteria:

1. All components, including the motor, microcontroller, and power source, along with the mechanical features, are securely housed within the 3D-printed shell. There should be no misfits or components protruding outside the shell.

2. The shell, made of PLA or PETG filament, maintains its structural integrity and does not crack, break, or deform under the stress tests of dropping, kicking, and bumping into it, ensuring durability.

3. The prototype remains fully functional after the stress tests, with the switch operating as intended without any loss of performance or damage to the components inside the shell.

Fail Criteria:

1. Any of the essential components do not fit properly inside the 3D printed shell, or there are gaps that expose the components, failing to provide the necessary protection or containment.

2. The shell exhibits cracks, breaks, or significant deformations after being subjected to dropping, kicking, and bumping, indicating that the material chosen (PLA or PETG) is not durable enough for the intended use.

3. The prototype failed to operate correctly after the stress tests, indicating that the shell did not adequately protect the components from the impacts, or the mechanical features were impaired due to the stress tests.

Procedures/Safety Considerations:

‘Rough up’ the overlay via dropping, kicking, and bumping into it.

Carefully check the switch is functional and with no breaks after each test.

Test 12

Design Requirement #12: Remain minimalistic, and neutrally colored, such as white or light gray, so as to not distract from an existing appealing room through unnecessary unattractive features:

Testing Summary:

We will install our solution and survey up to 10 people, asking them to rank on a scale of 1-5 on appearance. We will ask them to score based on how neutral it seems in the room, whether it drastically distracts in an unappealing way, along how sleek the design looks.

Purpose:

The purpose of this test is to determine whether our exterior aesthetic design is subtle and neutral enough that it does not draw from the room, or presents itself as unappealing.

Initial Conditions:

The solution will be placed over the existing light switch.

Materials:

• Prototype

• 10 Test Subjects

Pass Criteria:

1. Over 60% of Test Subjects believe our solution is appealing or does not distract in an unwarranted way.

Fail Criteria:

1. Over 40% of Test Subjects believe our solution is not appealing or distracts in an unwarranted way.

Procedures/Safety Considerations:

We will place our solution on the existing light switch and ask 10 unbiased test subjects to rate on a scale from 1 to 5 as to how appealing or distracting they think our solution is, with 1 or 2 being unattractive, and 3 to 5 being attractive.