ISR - MOONBUGGY Advisory Committee Review BRHS/CS MONROE 2012-2013

MOONBUGGY ASSIGNMENTS - BRHS NAMES?– Frame and Suspension NAMES?–– Accessories/Seats NAMES?–– Power Train NAMES?–– Budget/Accessories NAMES?–– Frame and Suspension

Race Day Results ? Place Design Competition Winners Most Improved Time Time of ? Design Competition Winners For best solving the problem of navigating the lunar surface? Most Improved Time First run ? Second Run ?

Sept Oct Nov Dec Aug Concept Design Concept Drawings 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Concept Design x   Concept Drawings Final Concept Agreement Component Research x  Drawings  x Stress Analysis Component Acquisition Component Fabrication Testing Clean up Install Instrumentation Instrumentation Testing Buggy Testing

Jan Feb Mar Apr Concept Design Concept Drawings 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 Drawings Stress Analysis Component Acquisition Component Fabrication x Testing Clean up Install Instrumentation Instrumentation Testing Buggy Testing

Budget

Funding TEAM Source Amount ($) SAIC 500 ORBITAL 2000 STEM LOCKHEED MARTIN 1600 BILLY BOB’S BEARING EMPORIUM BEARINGS SALLY SUE’S CYCLE SHOP GEARS Total 6100 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, 2013. Weight: ? lbs (? lbs actual) Top Speed of ? mph Able to handle ?” obstructions on various types of terrain TEAM

Design Conditions Reliable for a minimum of ? miles Braking from 20 mph to 0 mph in ? feet TEAM

Safety Factor General 2 Critical Weight 1.5 High Dynamic loading (suspension) 4+ JM

Frame and Suspension

Frame (orthoscopic) ER

Frame (top view) ER

Operation Description OPERATION WORK INSTRUCTION Part Number Part Description 101 Frame Beam, Front Created by: ER Checked by: AD Date: 11/26/2006 Material: 1020 HR SFM: 120 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

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

Original Chain Path ER/JM

Original Chain Path JM/ER

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 Option 2 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

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 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