1. EDGE™ Final Project Plan P08210/11 – Ruggedization of a Data Recorder for a Forklift Truck Shadle Stewart ME Rick Chadwick ME

2. EDGE™ Concept Level Project Plan Project Name –Ruggedized Vehicle Data Recorder for a Forklift Truck Project Number –P08210/P08211 Project Family –Robotic Platform Family Track –Vehicle Systems Technology Track Start Term –2007-2 planned academic quarter for MSD1 End Term –2007-3 planned academic quarter for MSD2 Faculty Guide –George Slack (EE dept) Faculty Consultant –EE & ME Dept, TBD Primary Customer –Raymond Corporation

3. EDGE™ Phase 0: Planning Mission Statement Product Description The product is a data recorder which will be used to determine the speed and acceleration of a forklift truck. The P08210 team will design a non-ground contact device along with a data recording system. The P08211 team will design a ground contacting rolling wheel device along with a remote real time display. Key Business Goals The primary business goals of this product are to Document performance of test vehicles and verify performance of production vehicles, Provide a more useful and ergonomic tool than what is currently used Primary Market The primary market for this project is Raymond Corp Secondary Market Secondary markets for the data recorder could include any industry requiring low speed data recording. Stakeholders Stakeholders in the design of our product include the following: Raymond Corp. RIT faculty, staff and students

4. EDGE™ Phase 0: Planning Difference Between the Two Project Teams P08210 Team: –Non-ground contact measurement system –Modular data recording system P08211 Team: –Ground contacting rolling wheel measurement system –Modular real-time wireless display Together: –Common output –Data recording system from P08210 can be used with P08211 measurement system –Real-time wireless display from P08211 can be used with P08210 measurement system

5. EDGE™ Phase 0: Planning Staffing Requirements for Project P08210 Mechanical Engineers 1 Will act as the team leader and be responsible for designing the enclosure for the recorder and the system for mounting it to the lift truck, will also ensure adequate heat transfer out of the enclosure. Electrical Engineers 2 One will focus on the sensor and interpreting the sensor data, the other will focus on the data recording and power aspects of the project Industrial and Systems Engineers 1 Will act as an interface between the two teams in the areas that need to be consistent and help define important aspects of the operating environment

6. EDGE™ P08210 Preliminary Work Breakdown Structure PersonWeek 0->1 Tasks (7 Dec 07) Week 1->2 Tasks (14 Dec 07) Week 2->3 Tasks (21 Dec 07) ME Team Introductions Meet with other team, Benchmarking Brainstorming on solutions Identify possible sensor solutions Discuss findings Participate in choosing sensor Determine physical size and mounting specs for sensor, heat characteristics of sensor Possible trip to sponsor Meet with other team Determine physical size, mounting, and heat needs for data storage, sensor interpretation EE Student #1 Team Introductions Meet with other team, Benchmarking Brainstorming on solutions Identify possible sensor solutions Discuss findings Participate in choosing sensor Identify possible methods to interpret sensor data Possible trip to sponsor Meet with other team Choose method of interpreting data, discuss with IE EE Student #2 Team Introductions Meet with other team, Benchmarking Brainstorming on solutions Identify possible sensor solutions Discuss findings Participate in choosing sensor Identify possible data storage options Possible trip to sponsor Meet with other team Discuss preferred Data storage with IE ISE Student Team Introductions Meet with other team, Benchmarking Brainstorming on solutions Gather information on testing environment Discuss findings Participate in choosing sensor Meet with other team IE to discuss preferred and possible commonalities Possible trip to sponsor Meet with other team Determine with other team’s IE what the commonalities will be, communicate with team

7. EDGE™ Phase 0: Planning Staffing Requirements for P08211 Team ME Student #1: This student will be responsible for project management and interfacing with Team #1 and Team #1's project manager. They will also be responsible for the mechanical design of the mounting system and the overall layout of the parts of the device and its enclosure. ME Student #2: This student will be responsible for the mechanical design of the actual ground contact measurement part (i.e. wheel), and the interfacing with the electrical sensor that will be measuring it. They will also assist with the manipulation of the data into desired output. EE Student #1: This student will be responsible for the selection and interfacing of the sensor that will be used to collect the data (Tachgen, Optical, or other). This student will be responsible for how the data is being remotely sent to the stationary data collection device. EE Student #2: This student will be responsible for the real-time measurement display system and interfacing it with the measurement being taken. They will also be responsible for how the data is being remotely recieved by the stationary data collection device. ISE Student: This student will be responsible for assuring that the specific parts that should be modular to fit with Team #1's design interface correctly. They will also be responsible for how the data collected will be manipulated once it is on the computer (i.e. Labview Software).

8. EDGE™ P08211 Preliminary Work Breakdown Structure PersonWeek 0->1 Tasks (7 Dec 07) Week 1->2 Tasks (14 Dec 07) Week 2->3 Tasks (21 Dec 07) ME Student #1 Attend meeting with P08210 team to become familiar with project and interfacing issues, plan ahead and lead team meetings Participate in making team decisions and consider how they will affect mounting and enclosure design, plan ahead and lead team meetings Possible visit to Raymond’s test facilities, plan ahead and lead team meetings, discuss possible mounting, device layout, and enclosure designs with team and determine what parts need to be obtained ME Student #2 Attend meeting with P08210 team to become familiar with project and interfacing issues, begin to consider what type of measurement wheel system is needed and discuss with EE Student #1 Discuss with team and decide on a measurement wheel solution and determine what parts need to be obtained Possible visit to Raymond’s test facilities, work with ME Student #1 on mounting, device layout, and enclosure designs, possibly begin assembling measurement wheel parts EE Student #1 Attend meeting with P08210 team to become familiar with project and interfacing issues, begin to consider different solutions to sensors required for wheel speed measurement Discuss with team and decide on a type of sensor solution and determine exactly what will need to be obtained Possible visit to Raymond’s test facilities, begin circuit design for data to go from sensor to wireless transmission EE Student #2 Attend meeting with P08210 team to become familiar with project and interfacing issues, begin to consider different parts needed for real-time wireless display Discuss with team and decide on what parts will be needed for the real- time wireless display Possible visit to Raymond’s test facilities, discuss how interfacing with other team’s design will take place with ISE Student and P08210 team students ISE Student Attend meeting with P08210 team to become familiar with project and interfacing issues Participate in making team decisions, review previous experience in use of LabView Possible visit to Raymond’s test facilities, discuss how interfacing with other team’s design will take place with EE Student #2 and P08210 team students

9. EDGE™ Phase 0: Planning Resource Requirements People Team Guide: George Slack (EE dept.) Raymond Corp. - Analysis and Test Manager: Shane Storman - Engineer: Gabe Clune [Developed Current 5th wheel] - Engineer: Keith Galbraith [Explored alternative designs] Environment Dedicated working space here at RIT. Raymond Corp has offered the possibility of testing on forklift(s) Equipment Computers Basic Hand Tools Oscilloscope / Multimeter Materials P08210 - Non-ground contact measurement sensor (Laser, Doppler, Optical, etc.) Electrical components for data recording system Parts for housing and enclosure Power supply P08211 - Rolling Wheel along with some type of sensor to measure speed of wheel Electrical components for interface with data recording system Electrical components for real-time wireless display Parts for housing and enclosure Power Supply

10. EDGE™ Phase 1: Concept Development Identify Customer Needs - Interviews Primary Customer(s) We have had a brief discussion with Michael Skube about the needs for the project. On Friday 10/12 we had a teleconference with a group of Raymond Employees involved with use of the device. This helped to define the needs more closely and find out background information about what alternative technologies have involved. The conversation was taped for future reference. Other Stakeholder(s) We have recruited George Slack (EE) as the faculty guide for both projects. We still need to interview faculty members to confirm our faculty consultants and to discuss what students from their department would be able to bring to the project. Past Senior Design Team(s) There were not any closely related SD projects.

11. EDGE™ Phase 1: Concept Development Identify Customer Needs - Benchmarking Previous designs and attempts at measurement devices –Previous project at BU to calculate speed based on pixels from a stationary camera mounted on the test area ceiling –Optical sensors Doesn’t obstruct movement – Non Contact Previous technologies limited by sensitivity to height above the floor 8-24 in. Very sensitive to fluorescent light in lab –Doppler Radar sensors Cost is drawback Doesn’t obstruct movement – Non Contact Previous technologies limited by sensitivity to height above the floor 8-24 in. –Laser sensor Stationary that points at lift to measure distance Lift has to drove in straight line which is sometimes hard to accomplish Used for measuring lift velocity now –Wheels Currently used Do not go around corners Hang off 18 in. - 2 ft Measure Tach-gen Voltage Long setup time

12. EDGE™ Phase 1: Concept Development Identify Customer Needs - Interpret Needs Statements: 1.The recorder must acquire (and store) data which can be used to determine velocity and acceleration. 2.The recorder will be effective within a range of 0-15 MPH with an accuracy of +/-0.10 MPH 3.The recorder must contain its own power supply. 4.The recorder will operate at 100hz or greater. 5.The recorder will not hinder lift truck maneuverability during testing and benchmarking. 6.The recorder will be usable on Raymond’s and competitor’s lift trucks. 7.The recorder will interface with a Sony EC 204 data recorder (P08211 team) or record a spreadsheet/text file (P08210 team). 8.The output voltage will match the speed of the vehicle, 1V = 1Mph, or a real time display of speed/acceleration will be provided (P08211 team). 9.The recorder will not require ground contact (P08210 team) or will not need adjustment while lift truck is turning (P08211 team). 10.The mounting and set up time of the recorder will be less than 10 minutes.

13. EDGE™ Needs Importance: 1. Acquire data for speed, accelerationCritical 2. Operate 0-15 Mph +/- 0.10 MphCritical 3. Self PoweredCritical 4. Operate over 100hzCritical 5. Will not hinder maneuverabilityCritical 6. Set up time in less than 10 minutesPreferred 7. Will operate on Raymond’s and competitors’ Lift trucksCritical 8. Output voltage matches speed 1V= 1MphPreferred Common Needs: P08210: P08211 Will not require ground contactWill not need adjustment while vehicle is turning Critical Will store data in an easily transferable and usable format Will interface with Sony data recorderCritical Will display speed real time on a wireless display Preferred

14. EDGE™ Grading Scheme A On time delivery of a design that meets specified criteria including the commonality and modularity with the other project. B On time delivery that meets the specified criteria with commonality, but lacking modularity. C On time delivery that is functional, but does not share commonality or modularity with the other project.

15. EDGE™ Areas of Risk and Concern Sponsor participation and funding are in question. Unsure of possible environment issues within the testing facility For project P08210, It may be determined that the sensor may be out of the scope of the project

16. EDGE™ Future Plan Where do you go from here? Moving Forward: - Verify Raymond Corp participation - Find team members - Identify faculty consultants