ADJUSTABLE UNIVERSAL GOLD MEDAL SAILING SEAT Andrew Sulik Timothy Slattery Marion Paredes Pages Derek Topper Detailed Design Review 2/8/13, 3:30 pm

Agenda Meeting Purpose Overview of Project Review Customer Needs & Eng. Specifications Review Decomposition of System Detailed Design Test Plan Review Project Plan Review Risk Assessment Conclusions 2

Project Goals Make system comfortable and adjustable to multiple users Allow enough room for the use of a jib transfer bench Increase and/or maintain the functionality already available Adapt for any C4-5 quadriplegic user such as Richard Ramos on a 3 person Sonar keel boat that meets all IFDS regulations 3

Customer Needs Recap *1=Most important 4 Customer Need # Importance Level* 1 DescriptionComments/Status CN11Designed specifically to fit SONAR sailboat CN21Adjustable foot rests CN31Seat Mobility (up/down) CN41Hand crank Adjustability (up/down) CN51Mechanical Advantage6.4x CN61Corrosion ResistancePowder Coat CN71Seat Locking mechanism (2 Positions around arc) CN81Cost$3,000 CN91Allows space for jib transfer bench CN101Safe system to operate for long periods4 years minimum CN111Portable, non-permanent installationno damage to boats CN121Fits on 1 pallet to ship CN131Emergency quick release for rudder control CN141System Controls Rudder CN151Crank Geometry fits multiple usersProduct for range of users, ie. Yacht club CN162System weight CN172Better Functioning 'Fast Pin' systemAll fast pin locations CN182Crew Safety CN192Enlarge Track Platform CN202Improved harness CN212Interchangeable seats CN223Grab Handle at top of seat CN233Fit to multiple boats CN243Easy to assemble & install

Engineering Specs Recap *1 For importance level 1 is must have, 2 is nice to have, 3 is preference only 5 Engineering Specification # Importance* 1 SourceSpecification Unit of Measure Marginal ValueIdeal ValueComment/Status ES11CN1, CN11Secure to Sonar with non-permanent attachmentsBinary Yes ES21CN2Adjustable Foot Restsin 4< ES31CN3Seat Adjustment (up/down)in 3< ES41CN4Hand Crank Adjustmentin 4< ES51CN5Percentage Amplification of User Force Input%3rev/ 90° Tiller 4rev/ 90° Tiller ES61CN6Corrosion resistanceBinary YesMaterial Selection ES71CN7Seat locks into position anywhere in travelBinary Yes ES81CN8Cost of components manufactured for MSD$ 3000> ES91CN9 Entire seating system is moved aft from previous iterationin0<3< ES101CN10Minimum FOS of critical elements found via analysis#2≤3< ES111CN13Steps required to release rudder in emergency#3>1 ES121CN14Degree of movement of rudder from centerline of boatdegrees40<90< ES131CN14Backlash in lines controlling rudderin1>0.5> ES141CN15Distance between hand attachment pointsin18±218±0.5 ES152CN22Grab handle(s) to assist seat movementBinary Yes ES162CN17Time required to attach or detach handss30<15< ES172CN18System has limited number of sharp corners or edges#10>0 ES182CN19Pinch points created by track platform#2>0 ES192CN20Steps required to release from harness#3>1 ES203CN21System fits multiple seats# 2< ES212CN11, CN21Time to fit system in SONAR sailboatminutes60>30> ES222CN11, CN21Time to adjust system for new userminutes60>30> ES232CN24Time to assemble systemminutes60>30> ES241CN3Seat Adjusetmenyt (fore/aft)in 3<

Functional Decomposition 6

Anthropometry 7

Ergonomics & Adjustability 95 th Percentile Males – 5 th Percentile Females Accommodate 90% of the population Backrest Proper back support Minimum 10° rearward tilt ✓ Handles/Hand Grips Neutral wrist position Interchangeable for C5 gloves and regular grips 30° angle 8 30°

Adjustability – Detailed Design 9 Considerations: Distance from shoulders Shoulder-forward Shoulder-down Distance from knees Distance between legs Rotation effects and distance 3 in 7 in 3 in 30º

Adjustability – Detail Design 10 Crank Up/Down Below shoulder Accommodate user’s preference

Adjustability – Detailed Design 11 Seat Up/Down Height Comfort Seat Back/Forth Distance from crank Foot Rests Up/Down Leg length Detachable Foot Rests Angle Comfort/Disability

Material Selection Selection criteria Good corrosion resistance Good strength Readily available Easy to weld Ideal Material Aluminum 6061-T6 Yield Strength 40 ksi Tensile Ultimate 45 ksi Young’s Modulus 10 ksi 12

Fastener Material Selection Fastener Material 316 Stainless Steel Limited Galvanic Corrosion Cheap and readily available Yield Strength 34 ksi Tensile Ultimate 79 ksi Galvanic Corrosion Reduced by material selection Reduced by Delrin washers at all bolts 13

Seat & Footrest Adjustability 14

Hand Crank Adjustability 15

States of Loading Worst Case (P12031) 170 lb applied horizontally to hand crank 150 lb applied downward on collection barrel 1349 lb impact force applied to end of track 16

Detailed Design-Track Platform Similar to original design – ½” thick marine fir Aluminum L-beam (underneath) adds support to track platform Added 2 detachable pieces in the front Secured using dovetail tabs Drilled holes in plates on allow for the adjustment of handle locks Rubber plugs are used to eliminate sharp edges and corners on the handle locks 17

Track Platform Analysis Max deflection = in 18 Track deflection with load Max deflection = in

Track Platform Analysis Stress on bolts during impact of 1349 lb (worst case. From P12031.) Shear strength = psi ¼”-20 aluminum bolts – Stainless Steel bolts to be used 19

Detailed Design-Pedestal Base Clamping fixture same as P12031 Platform extended aft 3 in to accommodate Jib Transfer Bench Support Ribs contoured to boat deck 20

Detailed Design-Pedestal 21 Swivel plate provides rotation and deceleration Pedestal will interface with swivel via welded plate or bolt pattern Maximum loading parameters determined by manufacturer

Pedestal Forces M A =M B = lb*in R B =260 lb Specified at 750lb compression (Trendler) Specified moment of 9000 lb*in (Trendler) in

Detailed Design-User Support Seat support frame from P12031 Main support arm fixed to top of swivel plate 23

Main Support Arm δ yA = 0.29 in M = (in*lbs) σ = psi σ y for 6061-T6 Aluminum is 45,000 psi. FOS =

Detailed Design-Hand Crank Centered pulley system allows individual barrels Telescoping tube allows vertical adjustment Center pivot allows space for user entry Adjustable tensioner allows for easy set up 25

Detailed Design-Crank Support Arms Case 1 (worst case) Fa=170 lb Mb= lbin/arm σ= psi/arm σy=45 ksi (6061-T6) FOS=

Detailed Design-Crank Support Arms Case 2 (normal conditions) Fa=20 lb Mb=98.76 lbin/arm σ= psi/arm σy=45 ksi (6061-T6) FOS=

Detailed Design-Rotation Pin Since bearing cannot apply moment, need pin to lock crank arm into place These calculations still need to be completed 28

Detailed Design-Hand Crank Lower pulley axle Aluminum 6061-T6 Yield strength:45000 psi 29

Detailed Design-Hand Crank Upper pulley axle Same properties as before 30

Hand Crank Fatigue From quadsailor.com, we found evidence of 3 hour trips Assuming a 5 month season, 1 tack every 5 minutes, and 4 cranks per tack we get 8460 rev/season Based on a life of 8 years you get a lifetime use of 69,120 revolutions Due to this low number, fatigue analysis on these axles is unnecessary 31

Hand Crank Gearing Goal: 4 cranks for 90 degree tiller movement Want to keep 4” load pulley Based on current system, where 3 cranks give 90 degree tiller movement, we have a 1.25 pulley ratio To get 4 cranks, need pulley ratio of Requires 3.75” drive pulley – Not Readily Available Using 1 pulley ratio need 3.75 cranks for 90 degree tiller movement 32

Hand Crank Gearing Options for gearing 1. Keep current gear ratio with 3 cranks per 90 degree tiller rotation 2. Use decreased gear ratio with 3.75 cranks per 90 degree tiller rotation Options to be given to Richard Ramos 33

Detailed Design-Hand Crank Grips System designed to mimic C5 grips Detent pin to keep hands in place Detent pin axial pull out force needs to be acquired 34

Bearing Specifications Max Dynamic Load 2110Lb Max Static Load 966Lb Max Axial Load 966Lb Sealed bearings to last in elements Able to withstand larger loads than applied Cheap to replace if needed 35

Tiller Strut Same structure as P12031 Hasp fitting connection removed Replaced with clamp Clamp geometry has not been determined 36

Emergency Tiller Release Cam cleat concept has not been fully developed Requires testing of cam cleats (on Skip’s boat) 37

Preliminary Test Plan 38 MSDII Test Plan See Excel Spread Sheet

Project Plan MSDI final Project Plan See.pdf Files %20Plan%20/Project%20Plan%20MDSI%201_4.pdf %20Plan%20/Project%20Plan%20MDSI%201_4.pdf 39

Risk Assessment Overall assessment of risks See Excel Spreadsheet 40

Questions? 41