FINAL PRESENTATION UNIVERSITY OF CINCINNATI MUTHAR AL-UBAIDI, PHD 04/20/17

Agenda Team Introductions Problem Statement Project Objectives Design and FEA Analysis Fabrication Hydraulic Circuit Hydraulic Components Testing Cost Analysis Lessons Learned Conclusion

Muthar Al-Ubaidi, PhD Team Advisor

Dorian Durant

Ray Frank

Bill Hayes

Tyler Tavalero

Paige Weaver

Problem Statement Design, build, and test a human powered vehicle utilizing hydraulics as a means of power transmission. The vehicle will compete in three events: Sprint Race Durability Race Efficiency Challenge   The following design parameters must be observed: Must accommodate a single rider who can enter and operate the vehicle unassisted Comply with all appropriate safety codes Vehicle cannot leak any hydraulic fluid Vehicle must have multiple, fully active, independent brakes Guards must be used to protect the rider from unsafe moving components No chains or belts can be utilized in the design Dorian

Project Objectives   Reduce the overall weight relative to the 2016 prototype Eliminate electronic components Shorten hose lengths as much as possible Minimize number of fittings Change the input gear ratio leading into the pump Use a two-wheeled bicycle frame Paige

Design and FEA Analysis Design Variables Values Units Weight Rider 180 lb Weight Bike 100 Weight Total 280 Incline Grade 0.05 % Incline 2.86 Degree Rolling Resistance Factor 0.008 Rough Paved Asphalt Total Resistance 16.22 Tire Diameter 24 in Tire Radius 1 ft Torque ftlb Pressure 2200 psi Displacement Motor (90% Eff) 0.62 in3/rev Velocity 12.5 mi/hr RPM 175 Rev/min Flow Rate (95% Eff) 0.49 gal/min Power 0.63 hp Size Hose 0.25 Velocity of Oil 3.21 ft/s Pedal RPM 250 Displacement Pump (95% Eff Pump & Motor) 0.50 Pump Displacement (cc) 8.26 cc/rev Motor Displacement (cc) 10.12 Tyler

Design and FEA Analysis Two wheeled 2.3L Reservoir inside bike frame geometry 1:3 Gear ratio 1L Accumulator Bill

Design and FEA Analysis Cont’d 200lb Rider 4,978psi Max 50,000psi Yield strength .005” Max displacement Bill

Design and FEA Analysis Cont’d 200lb Force 9,270psi Max 51,000psi Yield strength .0003” Max displacement Bill

Hydraulic Circuit 2 Phase Ball Valve Actuated Pressure Relief Valve Charging accumulator Accumulator discharge & direct drive Ball Valve Actuated Pressure Relief Valve Ray

Hydraulic Components Parker 1 liter, 4000 PSI piston accumulator Pump: ACNAL02ACA0040000000000A 26002-LZD 8.2 cc 3/4" keyed shaft Rear Ports Motor: ADMAR04ACA0100000000000A 10.2 cc 5/8" keyed shaft Side Ports Parker 1 liter, 4000 PSI piston accumulator Prince RV4H 3000 PSI Pressure Relief Valve Set to 2800 PSI Anchor AE2 3000 PSI Hydraulic Ball Valve Tyler

Fabrication 19 Fabricated parts 4 Subassemblies Plasma cut Welding Milling Lathe Explain rear shaft, pedal shaft, reservoir fabrication, Paige

Testing Initial Testing Tested at Different Gas Pressures No nitrogen charge Ran at lower pressures than anticipated Tested at Different Gas Pressures Between 2000 PSI Nitrogen and 500 Lowered pressure in 100 PSI increments Tested to find optimal balance between charged volume and direct drive capability 1000 PSI performed best on smooth, level concrete Tyler

Cost Analysis Parameters were put in place as a guide through the costs for the overall fabrication of the bicycle. They are listed below: Labor: $60/hr Average Cost of Steel: $4.00/lb Efficiency of Production: 95% Yearly production: 500 units Life Volume: 5000 units The total cost of the 2017 University of Cincinnati’s prototype was $1012.09. Including labor costs, the total cost of the prototype is $40,012. Ray

Cost Analysis (cont.) Dorian

Lessons Learned Practical Hydraulics Applications RPMs are important Small components are surprisingly capable Design with Manufacturing in Mind Multiple Ways to Approach Machining The Simplest Solution is Often Best Rely on Your Team

Conclusion Design Goals Achieved Possible Improvements Weight Reduction to 100 Pounds Maximum Reliable Circuit Performance Consistent Speeds and Take-offs Build Quality Possible Improvements Regenerative Braking Lower Fluid Requirements Precharge Stability Lower Center of Gravity