Rascals- Final Design Review. Matt Badman Cathy Foscolo Zac Manson Tyler Wallace

Transcription

1 Rascals- Final Design Review Matt Badman Cathy Foscolo Zac Manson Tyler Wallace

2 Overview Prototype Design Changes Competition Results Final Design Changes Final Cost and Weight

3 Design Criteria Fits within 36 x24 x18 box Carry a 250lbs rider Weighs less than 40lbs including packaging Cost less than $600 in lots of 1000 Govern to 10mph Drop from 3ft and assemble in 15 min. Complete one mile in under 7.5 min. without going over 10mph Complete assembly and maneuverability test

4 Transmission Selection Belt / Direct Drive Tensioning Testing 1 Pivot / 1 set of Turnbuckles Simplest approach 2 Backup Ideas 2 Pivots /2 Turnbuckles 1 Pivot / Slots allowing Engine to Slide

5 Prototype Transmission

6 Packaging Polyethylene Foam Light weight Shatter proof Cost effective Excellent buoyancy Super strength and tear resistance High shock absorption Flexibility Superior chemical and grease resistance Price: $23 for 2 x 54 x 24 Weight: 5 lbs Longevity 8 10 years

7 Packaging Fits within 36 x24 x18 box

8 Bag to Carry Foam When Riding Light weight Easy to Carry Price: $ Similar to what is shown in picture

9 Safety Rider Safety Gear Gloves, Helmet, Eye Glasses Reflective Tape Additional visibility, although night riding is discouraged Handle Bar Caps Sheet metal Cover over moving belt and pulleys

10 Safety (continued) Warning Stickers Hot Do Not Touch Wear Safety Gear Deck grip tape Reduces shoe slip Handlebar Grips Reduces Hand fatigue Gives better grip

11 Qualification Results Complete one mile in less than 7:30 Keep speed under 10mph Official time: 6:28(9.3mph)

12 Competition Results Drop test and assembly were successful But parts were damaged Weight: 40lb Time of course: 2:50 Two penalties assessed: 45sec Two tries on rumble strips One missed cone Official time with penalties: 3:35

13 Final Design Changes Solder all electrical connections If deck is changed to 1/8 weight will be reduced by 1.2lbs Add more foam to rear to protect dropouts(see photo on next slide)

14 Dropout Damage

15 Final Design Change Rear Tire Less aggressive tire Reduce transmission vibration Reduce force between tire and shaft

16 Design Changes Investigated Shorten frame? Assembly time would be much quicker Rider would have less room to stand Final decision: Do not shorten frame.

17 Governing Clutch housing (green) Clutch mounting bracket(steel color)

18 Final Decision on governing Scooter never went over 11mph during test rides Friction in transmission acts as a brake Weight of governing system would put scooter over weight

19 Weight/Cost Subsystem Weight (lbs) Structure 22.4 Steering 1.8 Powerplant 9.35 Transmission 4.65 Safety/Protection 0.55 Assembly (Tools) 0.95 Total 39.7 Subsystem Cost Structure Steering Powerplant Transmission Safety/Protection 5.23 Assembly (Tools) Manufacturing Total 500.7

20 Any Questions?

21 Back Up Slides

22 Back up Cost/Weight 1 Structure Part (Frame) Material Dimensions lbs/foot Cost/Foot Amount Required (Foot) Weight (lbs) Cost Rec. Tube Al 6063 T52 2"x1.5"x.125" Rec. Tube Al 6063 T52 1.5"x3"x Sq. Tube Al 6063 T52 1"x Round Tube Al 6063 T "x.125" Angle Al 6063 T "x1.25"x.25" Part (Fork) Material Dimensions lbs/foot Cost/Foot Amount Required (Foot) Weight (lbs) Cost Round Tube Al 6061 T "x.875"x.125" Rec. Tube Al 6063 T52 2"x1.5"x.125" Plate Al 6061 T6 18"x8"x Part (Steering Column) Material Dimensions lbs/foot Cost/Foot Amount Required (Foot) Weight (lbs) Cost Round Tube Al 6061 T "x1.259"x.058" Round Tube Al 6061 T6 1.50"x1.384"x.058" Part (Transmission) Material Dimensions lbs/foot Cost/Foot Amount Required (Foot) Weight (lbs) Cost Angle Al 6061 T6 2"x2"x.25" Rectangular Bar Al 6061 T6 1"x.25" Part (Deck) Material Dimensions lbs/sq. F Cost/sq. F Amount Required (sq. F) Weight (lbs) Cost Plate Al 6061 T6 18"x7.66"x Total Structure Cost Total Structure Weight 22.4

23 Back up Cost/Weight 2 Steering Part Weight Cost Vendor Part # Front Wheel (5") Athens Bicycle none Handle Bars Athens Bicycle none Grips Athens Bicycle none Orbit Threadless Headset Pricepoint.com none LX V-Brake Levers Pricepoint.com none Cables/Housing 0.2 Included with Brake Levers Steering Clamp Athens Bicycle none Total Steering Cost Total Steering Weight Powerplant Part Weight Cost Vendor Part # Honda GX 31 Engine 7.5 ##### Honda none Centrifugal Clutch Housing Small Engine W none Wire Quick Disconnects C&E True Valu none Kill Switch Wireing C&E True Valu none Kill Switch C&E True Valu GSW-125B Total Powerplant Cost otal Powerplant Weight

24 Back up Cost/Weight 3 Transmission Part Weight Cost Vendor Part # Brake Spring C&E True Valu none 7" AX-Section V-Belt Pulley McMaster-Carr 6245K52 2" AX-Section V-Belt Pulley McMaster-Carr 6245K15 AX27 Vbelt McMaster-Carr 6054K104 Rear Wheel (12") Athens Bicycle none 2 Stainless Steel Turnbucke McMaster-Carr 30125T203 2" Knurled Al Roller OnlineMetals.co Mounted Ball Bearings Grainger 4X727 Keyed Aluminum Shaft McMaster-Carr570K42REC otal Transmission Cost l Transmission Weight Safety/Protection Parts Part Weight Cost Vendor Part # Griptape C&E True Valu none Foam Foam Factory WP2X2X5 Reflective Tape identi-tape.com sr105 Safety/Protection Cost fety/protection Weight Assembly Parts Part Weight Cost Vendor Part # 5mm hex wrench Tandemseast.c none 15mm wrench Sears.com /16" wrench Sears.com Backpack Target.com al Assembly Parts Cost Assembly Parts Weight

25 Manufacturing Cost Manufacturing Costs (Based on Volumetric Removal Handout From Dr. Halliday) Subsystem Holes (in dia) / Cut Volumetric Removal (incost/(in 3 ) Operation Cost Steering 2 1/4" " Cuts Frame Cuts Dick 2 Cuts Engine Mount 8 1/4" Cuts Transmission 14 1/4" Cuts Subsyestm Operation Cost Per Hour Hours Required Operation Cost All Welding All Assembly Total Manufacturing Cost

26 Ergonomics Comfortable standing position Steering Column can be raised or lowered Damage/Grooves

27 Governing Centrifugal Clutch from gokartsupply.com Cost: $25.50 Engages: about 2000 rpm (added to the direct drive shaft, will engage around 9mph) 3/4 shaft- requires reducer