mb1 advisory committee review april 27, 2006. jake adkins – frame and suspension ya-chi chou –...

MB1Advisory Committee Review

April 27, 2006

Jake Adkins – Frame and SuspensionYa-Chi Chou – Accessories/Seats

Adam Dean – Power TrainJay Mansheim – Power Train

Saptarshi Mitra – Budget/AccessoriesEric Rodgers – Frame and Suspension

Race Day Results

3rd Place Time of 5:08

Design Competition Winners For best solving the problem of

navigating the lunar surface Most Improved Time

First run 7:21 Second Run 5:08

Aug Sept Oct Nov Dec

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

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                                      

Jan Feb Mar Apr

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

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

Budget

Source Amount ($)

MB One Members 600

PSU 200

Electronic Systems Grant 0

Caterpillar 1600

Snorkel International Paint

VanBecelaere Machine Works Steel

Total 2400

Funding

TEAM

Expense Report

Grand Total

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

Design Conditions

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

feet

TEAM

Safety Factor

General 2 Critical Weight 1.5 High Dynamic loading (suspension)

4+

JM

Frame and Suspension

ER

Frame (orthoscopic)

ER

Frame (top view)

WaterJet files drawn in AutoCad

Shear and Moment Diagrams

ER

OPERATION WORK INSTRUCTION

Part NumberPart Description

101 Frame Beam, Front

Created by:

ERChecked by: AD

Date: 11/26/2006 Date: 11/26/2006

Material: 1020 HR SFM: 120

Operation #

Operation Descript

ionMachine

UsedTooling/

FixtureTolerance

Speeds, Feeds

1Cut Material

Horizontal Bandsa

w   +/- .030  

2 Mill Slots Bridgeport

V-blocks, 3/8"

End Mill +/-.0031222

RPM

ER/JA

ER/JA

ER

Frame Hinge Assembly

JA

Drive Train

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

ER/JM

Original Chain Path

JM/ER

Original Chain Path

Modified Chain Path

Target Gear Ratios

High gear ratio of 2.2:1 Low gear ratio of .8:1 Have a useable range of gears spaced

in between to have a total of 7 speeds

AD

Gearing Options

Option 1 56/22/34-11/39 Max Speed 13.8 mph @ 80 rpm Max torque 324 ft lbs @ 350 lbs input

Option 2 56/16/34-11/39 Max Speed 18.9 mph @ 80 rpm Max torque 238 ft lbs @ 350 lbs input

Item QTY Make/Have Price ea. Totals

Bottom Bracket Case 2 0 $7 $14Bottom Bracket 2 2 $24 $0Plastic BB seal 2 0 $1 $2Crank Set 2 2 $30 $0Chainrings / Freewheels 6 0 $15 $90Cage Pedal Set 2 1 $15 $157 Speed Cassette 1 0 $25 $25Output Shaft/ Bearings 1 x $10 $10Derailer 1 0 $70 $70Shifter / Cables 1 0 $50 $50Differential 1 1 $0 $0Differential Drive Gear 1 0 $15 $15Universal Joints 4 0 $20 $80Driveshafts 2 x $10 $20Diff. Bracket / Bearings 2 2 $0 $0Chain ( 5ft ) 4 0 $25 $100Misc. brackets / etc. 1 x $25 $25

$516

Wheels 4 0 $30 $120Tires / Tubes (26x2.5+) 4 0 $35 $140Wheel Bearings 4 0 $5 $20

$280

Hydraulic Brake System 1 0 $125 $125Hyd. Cable ( 8ft ) 1 0 $20 $20

$145

$941

Sub Total =

Sub Total =

GRAND TOTAL (Drive Train, Wheels, Brakes) =

POWER TRAIN BUDGET

Sub Total =

AD

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

Problems Encountered

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.

Rear Upper Air bag support brackets

MEA (mental element analysis) failed.

Corrective Action: adding cross-sectional area to failed area

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.

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

Chain breaking Chain was catching

on sprocket mounting bolts.

Corrective Action: countersunk bolt heads

Back of rear seat Rear seat back

broke

Corrective Action: welded it.

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.

Things we would have done different.

More emphasis on handlebars and rider ergonomics.

Try to stick closer to manufacturing timeline.

Limit weight

Questions?

Questions?

PITT THUNDER