1. The Auto Crash Case Study #3 The Egg Mobile “Ted and Angelina’s Eggsellent Adventure” Northern Highlands Regional High School Applied Technology Department Real World Engineering List Design/Build Engineering Team Members Name of Engineering Firm Date Instructor- Mr. Mugno

2. Scenario The national Automobile Underwriter’s Insurance Association is very concerned about the number of accidents that are occurring and the amount of money the insurance companies must payout to their policy holders for bodily injuries received during automobile accidents The automobile manufacturers are now forced to design and build a safer vehicle and have asked engineering firms to submit prototypes for improving auto safety. Your engineering firm is required to design a better energy absorbing crumple zone system and a better seat restraint system for protecting the occupants in the vehicle.

3. Statement of the Problem The problem we had to solve was to design, build and test an energy absorbing crumple zone and seat restraint system in a vehicle that would allow the occupants to survive without injury in the event of a head on collision.

4. Design Criteria Build a test vehicle that will remain intact during a head on crash. Develop and build a crumple zone system that will absorb enough energy to allow occupants to survive a head on crash without injury. The crumple zone will increase the time that the vehicle is moving until it reaches a complete stop. The crumple zone will absorb energy and reduce the force of some impact to the occupants. Develop and build a seat restraint system that will keep the occupants in their seat and uninjured during a head on crash. The test vehicles design should simulate a real automobile as much as possible. The test vehicle must hold two occupants The occupants will be two fresh large, Grade A, raw chicken eggs. The seats and seat restraint safety system must be designed so that the occupants can be placed in and removed easily.

5. Design Constraints You must use only the materials supplied by the teacher to construct the test vehicles frame, Top (body). You will build 3 car frames to specs and test each on the ramp. Supplies for the seat restraint systems and crumple zone systems must be brought in by group members. The energy absorbing crumple zone system may not extend out in front of the test vehicle’s body It must be contained within the dimensions of the test vehicles body (cannot be longer than 8”). All safety systems must be constructed by the design build team. The test vehicles occupants must have clear visibility out of all windows (180 degrees from left to right). You may not stuff the interior with material All safety systems must be constructed in the interior of the test vehicle’s body (shell). The occupants cannot be altered in any way. The occupants cannot be glued into their seats.

6. Possible Solutions Energy Absorbing Crumple Zone System Hypothesis -How it will work?Tested Results (Discuss how the system works and how it will absorb the impact force.)(Explain what did you observe when it was tested?) 1) 2) 3)

7. Crumple Zone Solution#1 2 views Front and underside

8. Crumple Zone Solution#2 2 views Front and underside

9. Crumple Zone Solution#3 2 views Front and underside

10. Final Solution to Auto Energy Absorbing Crumple Zone

11. Possible Solutions Seat Restraint Safety System Hypothesis How it will workTested Results (Discuss how the system works and how it will absorb the impact force.)(Explain what did you observe when it was tested?) 1) 2) 3)

12. Seat Restraint Solution#1 2 views Front and Top

13. Seat Restraint Solution#2 2 views Front and Top

14. Seat Restraint Solution#3 2 views Front and Top

15. Final Solution to Seat Restraint System

16. Egg Mobile Test Vehicle Frame Construction

17. Egg Mobile Design Solution 3-D Isometric Drawing – for those who have completed any of the CAD courses

18. Test Results and Conclusions Describe in detailed discussion what you observed when your vehicle was tested for each area. Copy into Word and answer the questions there and then attach to Power point print out.  1. Condition of car body and frame.  2. Performance of Crumple Zone (explain in applied physics terms – impact force, absorb, reaction force etc.)  3. Performance of Seat Constraints (explain in applied physics terms)  4. Condition of Passengers  5. The time of the vehicle  6. Speed of the vehicle.  7. Weight of vehicle  8. Mathematical calculation of the force. (F=ma)  9. Each person write a 2 paragraph evaluation about the project – likes, dislikes, was it interesting, worthwhile, what changes would do you think should be made to the problem, process, time constraints, materials. Please explain your responses and attach the evaluation. One-paragraph Conclusion: What would you do to improve your vehicle – crumple zone & seat restraint systems? Be detailed in your explanation. CAD drawing of your vehicle– orthographic projection (multi-view drawing) with crumple zone and seat restraint designs due 4 class meetings after documentation due date.

19. GRADING Possible Solution Sketches of Crumple Zone and Seat Restraints with detailed applied physics explanations of how they will work– 15% Frame construction, foam, crumple zone and seat retsraint systems due dates – all Pass/Fail grades – 10% Testing of three test vehicles and their documentation of each – 12% Final Prototype – 40% (20% for each the seat restraint and crumple zone systems) Documentation Report – 35% Presentation – 10% CAD Drawing – 10%

20. The End Begin Case Study #4 and FINAL EXAM “AVIATION”