Formal Design Review

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MB1 Advisory Committee Review April 27, 2006
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• Jake Adkins Frame and Suspension
• Ya-Chi Chou Accessories/Seats
• Adam Dean Power Train
• Jay Mansheim Power Train
• Saptarshi Mitra Budget/Accessories
• Eric Rodgers Frame and Suspension

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Race Day Results

• 3rd Place
• Time of 508
• Design Competition Winners
• For best solving the problem of navigating the
  lunar surface
• Most Improved Time
• First run 721
• Second Run 508

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Aug Aug Sept Sept Sept Sept Oct Oct Oct Oct Oct Nov Nov Nov Nov Dec Dec Dec Dec
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Concept Design x x x x x x x x x x x                
Concept Drawings         x x x x x x x                
Final Concept Agreement                       x              
Component Research               x x x x x x x x x x  x  x 
Drawings       x x x x x x x x x x x x  x  x x x 
Stress Analysis                     x x x x x x  x     
Component Acquisition                     x x x x x  x x  x  x 
Component Fabrication                         x x x x  x  x  x 
Testing                                      
Clean up                                      
Install Instrumentation                                      
Instrumentation Testing                                      
Buggy Testing                                      
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Jan Jan Jan Jan Jan Feb Feb Feb Feb Mar Mar Mar Mar Apr Apr Apr
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Concept Design                                
Concept Drawings                                
Final Concept Agreement                                
Component Research x   x  x x                         
Drawings x  x  x   x  x x   x  x  x x  x   x        
Stress Analysis                                
Component Acquisition x  x  x  x   x x  x   x x  x  x  x   x      
Component Fabrication x   x x   x x  x  x   x  x  x x  x x  x  x  x 
Testing                             x  x 
Clean up                                x
Install Instrumentation                                
Instrumentation Testing                                
Buggy Testing                              x  x
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Budget
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Funding
Source Amount ()

MB One Members 600
PSU 200
Electronic Systems Grant 0
Caterpillar 1600
Snorkel International Paint
VanBecelaere Machine Works Steel
Total 2400
TEAM
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Expense Report
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Grand Total
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Design Conditions

• Complies with all rules set forth to compete in
  the NASA competition in Huntsville, Alabama on
  April 13-14, 2007.
• Weight 80 lbs (192 lbs actual)
• Top Speed of 20 mph
• Able to handle 17 obstructions on various types
  of terrain

TEAM
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Design Conditions

• Reliable for a minimum of 10 miles
• Braking from 20 mph to 0 mph in 20 feet

TEAM
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Safety Factor

• General 2
• Critical Weight 1.5
• High Dynamic loading (suspension) 4

JM
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Frame and Suspension
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Frame (orthoscopic)
ER
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Frame (top view)
ER
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WaterJet files drawn in AutoCad
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Shear and Moment Diagrams
ER
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OPERATION WORK INSTRUCTION OPERATION WORK INSTRUCTION OPERATION WORK INSTRUCTION OPERATION WORK INSTRUCTION OPERATION WORK INSTRUCTION OPERATION WORK INSTRUCTION OPERATION WORK INSTRUCTION OPERATION WORK INSTRUCTION
Part Number Part Number Part Number Part Description Part Description Part Description
101 101 101 Frame Beam, Front Frame Beam, Front Frame Beam, Front

Created by ER Checked by AD
Date 11/26/2006 Date 11/26/2006

Material 1020 HR SFM 120

Operation Operation Description Machine Used Tooling/Fixture Tolerance Speeds, Feeds
Operation Operation Description Machine Used Tooling/Fixture Tolerance Speeds, Feeds
1 Cut Material Horizontal Bandsaw   /- .030  
2 Mill Slots Bridgeport V-blocks, 3/8" End Mill /-.003 1222 RPM
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ER/JA
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ER/JA
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ER
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Frame Hinge Assembly
JA
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Drive Train
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Design Considerations

• Both riders power one output
• Chain tension constant during setup
• Differential
• Differential Placement/Drive shafts
• Usable 7 speed gear range
• Quality Components/adjustment
• Wheels/tires

AD/JM
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Original Chain Path
ER/JM
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Original Chain Path
JM/ER
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Modified Chain Path
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Target Gear Ratios

• High gear ratio of 2.21
• Low gear ratio of .81
• Have a useable range of gears spaced in between
  to have a total of 7 speeds

AD
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Gearing Options

• Option 1
• 56/22/34-11/39
• Max Speed 13.8 mph _at_ 80 rpm
• Max torque 324 ft lbs _at_ 350 lbs input
• Option 2
• 56/16/34-11/39
• Max Speed 18.9 mph _at_ 80 rpm
• Max torque 238 ft lbs _at_ 350 lbs input

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AD
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Simulated Items

• Manufactured out of plastic
• Vinyl - ABS/PVC Alloy (Density 0.6 g/cm³)
• Console, Battery box, TV box, Fender, some
  simulated items will use this material

SM/Y-CC
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Problems Encountered
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Failure to fit in 4x4x4 box

• Best solution would be to be a total redesign.
• Corrective Action installed a hinge on the front
  pedal tower.

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Rear Upper Air bag support brackets

• MEA (mental element analysis) failed.
• Corrective Action adding cross-sectional area to
  failed area

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Rear A-arms

• Rear A-arms were bent after testing on obstacles.
• Corrective Action added gussets to high stress
  points on rear lower A-arms.

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Driveshaft pin connection

• Pins were sheared multiple times on rear inboard
  Universal Joints
• Corrective Action Welded it
• Jammed an Allen wrench into it and broke it off

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Chain breaking

• Chain was catching on sprocket mounting bolts.
• Corrective Action countersunk bolt heads

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Back of rear seat

• Rear seat back broke
• Corrective Action welded it.

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Fenders

• Fender mounts failed
• when bent three times
• Corrective Action Redesign of fender mounts.
• Problem was fixed for the race by simply
  removing the fenders.

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Things we would have done different.

• More emphasis on handlebars and rider ergonomics.
• Try to stick closer to manufacturing timeline.
• Limit weight

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Questions?
PITT THUNDER
Questions?