MB1 Advisory Committee Review April 27, 2006

Jake Adkins – Frame and Suspension Ya-Chi Chou – Accessories/Seats Adam Dean – Power Train Jay Mansheim – Power Train Saptarshi Mitra – Budget/Accessories Eric Rodgers – Frame and Suspension

Race Day Results  3 rd Place Time of 5:08  Design Competition Winners For best solving the problem of navigating the lunar surface  Most Improved Time First run7:21 Second Run5:08

Aug SeptOctNovDec Concept Design xxxxxxxxxxx Concept Drawings xxxxxxx Final Concept Agreement x Component Research xxxxxxxxxx x x Drawings xxxxxxxxxxxx x xxx Stress Analysis xxxxxx x Component Acquisition xxxxx xx x x Component Fabrication xxxx x x x Testing Clean up Install Instrumentation Instrumentation Testing Buggy Testing

JanFebMarApr Concept Design Concept Drawings Final Concept Agreement Component Research x x xx Drawings x x x x xx x x xx x x Stress Analysis Component Acquisition x x x x xx x xx x x x x Component Fabrication x xx xx x x x x xx xx x x x Testing x x Clean up x Install Instrumentation Instrumentation Testing Buggy Testing x x

Budget

SourceAmount ($) MB One Members600 PSU200 Electronic Systems Grant0 Caterpillar1600 Snorkel InternationalPaint VanBecelaere Machine WorksSteel Total2400 Funding 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,  Weight: 80 lbs (192 lbs actual)  Top Speed of 20 mph  Able to handle 17” obstructions on various types of terrain TEAM

Design Conditions  Reliable for a minimum of 10 miles  Braking from 20 mph to 0 mph in 20 feet TEAM

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

Frame and Suspension

ER Frame (orthoscopic)

ER Frame (top view)

WaterJet files drawn in AutoCad

Shear and Moment Diagrams ER

OPERATION WORK INSTRUCTION Part Number Part Description 101 Frame Beam, Front Created by: ER Checked by:AD Date:11/26/2006Date:11/26/2006 Material:1020 HRSFM:120 Operation # Operation Descript ion Machine Used Tooling/Fixtu re Tolerance Speeds, Feeds 1 Cut Material Horizontal Bandsaw +/ Mill SlotsBridgeport V-blocks, 3/8" End Mill+/ RPM

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

ER/JM Original Chain Path

JM/ER Original Chain Path

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 56/22/34-11/39 Max Speed rpm Max torque 324 ft 350 lbs input  Option 2 56/16/34-11/39 Max Speed rpm Max torque 238 ft 350 lbs input

AD

Simulated Items  Manufactured out of plastic  Vinyl - ABS/PVC Alloy (Density: 0.6 g/cm ³ )  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 Upper Air bag support brackets  MEA (mental element analysis) failed.  Corrective Action: adding cross- sectional area to failed area

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

Questions? PITT THUNDER