SOAP February 27, 2014 Armstrong Hall of Engineering 1 SOAP

Presentation Overview  Project Identification/Development  Body Team  Braking Team  Steering Team 2 SOAP

Project Objectives  To empower kids  To provide engaging experience  Make car available as a kit 3 SOAP

Indianapolis Soap Box Derby  Hosts Super Kids Race 

Super Kids Race 5

Specifications 6 Number of Children100 Weight of Child and Adult pounds Height of drivers4 – 6.5 feet Number turns per child2 – 3 per day Height of Hill40 feet Max Speed35 mph Max Turning Radius15 feet Length of Track1500 feet Cost$1000 Braking Distance300 feet SOAP

Survey Results – Customer Priorities 7 SOAP

Survey Results - Cost SOAP 8

Budget Breakdown  Budget for year - $1500  Budget remaining - $  Current Cost of Prototype - $  Target cost for car – $1000  Future Expenses Front wheel breaks Rear steering system with override Rear axle mounting system SOAP 9

Cost of Prototype 2013 Expenses Toward PrototypePrice Seats200 Seatbelts49.98 Brake pads36.71 ODYSSEY brake cable ” x 4” x 8’ boards15.54 ½” 4 x 8 plywood99.80 Spray paint24.72 Wood Filler11.58 Steering system Wheels Expenses Toward PrototypePrice Axles20.00 Seating Housing

Design Evolution SOAP 11 Prototype IV Prototype I Prototype II & III

Design Process: Where are we? 12 SOAP Body Team Brake Team Steering Team

SOAP Team Breakdown 13 SOAP Body Team: Nick F, Lakshya G, Alexandra M. Brake Team: Jake S, Rachel P, Justin S Steering Team: Nick L, Alan G, Pulkit P

Body Team 14 SOAP

Team Members:  Nicholas Farley (team leader)  Alexandra Milat  Lakshya Gupta

16 Questions/Comments

Braking Team

Team Members  Jake Schramm - Project Leader  Justin Sohn -Webmaster  Rachel Pauley - Team Liaison 18

Semester Progress  Determined exact location of brake pedal  Decided to buy new brakes parts as opposed to transferring old ones  Visited Go-Kart and Bike Shops to research new parts  Research prices

Semester Progress  Created Decision Matrix on Emergency Brake System  Traveled to stores  Matching tires on car  Purchased Brake Parts  Started assembling braking system  Planning and collaborating on brake assembly with Steering Team

Gantt Chart

Emergency Brake System

Challenge with Tires  Original tires would not work with our brakes  Two Options Buy 4 New tires Purchase 2 new tires for back wheels

Purchased Parts 24

Purchased Parts 25

Purchased Parts

Brake System Assembly  (Pictures)

Attachment of Brakes on Car  Planning Stage  Collaborated with steering team Axle Welding of Parts

End of Semester  Prepare sketches for brake system  Plan on how to apply brakes for next semester  Prepare transitional document

31 Questions/Comments

Steering Team 32 SOAP

Steering Housing  Calculated the location of the steering housing-14” tall 12” from front  Based off the angle of the steering shaft, location of the front seat and height of the car

Steering Housing  4x4 piece of wood drilled into the floor of the car  Hood of the car rests on top of the housing  Attached steering wheel to steering shaft

Steering Housing  Drilled hole in the floor for the steering shaft  This allows the shaft to be attached to the linkage on the front axle

Underside of the Body  Consisted of a combination of our original design and a bedframe design  Decided on this after a brainstorming activity

Underside of the Body  Used 2x2 pieces of wood and L- brackets  Will test deflection with the same test plan that was used on the old underside of the body

Axle Test Step 1: We placed our front axle with the steering linkage fully assembled inside a clamp to support it

Axle Test Step 2: Going by increments of 10 pounds, we slowly added weight to each spindle until the axle started to break

Axle Test Step 3: At 160 pounds the screws on either side of the wood started to rip out of the wood

Solutions  Change axle material  Brackets  Change orientation of U-bracket 41

42 Questions/Comments

DFMEA (Separate into Teams)  Steering System – 720/1000 RPN Improper slip clutch setting  Durability of Brakes – 200/1000 RPN Must function properly during all day race  Wheels  Axle 43 SOAP