1. 1 Alpha 6.5: The Great Moonbuggy Race 2006 Russell Alberts Scott Coll Haison Nguyen Jason Zaloudek Sponsored by: CBU Department of Mechanical Engineering Faculty Advisors: Dr. Bernard Beard, Ph.D. Dr. Paul Shiue, Ph.D. March 18 th, 2006

2. 2 Presentation Overview Race specifics Race specifics Design requirements Design requirements Vehicle improvements Vehicle improvements Testing overview Testing overview Final design evaluation Final design evaluation

3. 3 The Great Moonbuggy Race Entrants must “design a vehicle that addresses a series of engineering problems similar to problems faced by the original Moonbuggy team.” Entrants must “design a vehicle that addresses a series of engineering problems similar to problems faced by the original Moonbuggy team.” Vehicles will be human powered and carry two drivers over a half-mile of simulated lunar terrain including "craters", rocks, "lava" ridges, inclines and "lunar" soil. Vehicles will be human powered and carry two drivers over a half-mile of simulated lunar terrain including "craters", rocks, "lava" ridges, inclines and "lunar" soil.

4. 4 The Course

5. 5 Design Requirements Competition rules provide the design requirements of the vehicle Must fit inside 4’ cube in “stowed” configuration Must fit inside 4’ cube in “stowed” configuration No wider than 4’ in operational configuration No wider than 4’ in operational configuration Maximum turning radius of 15’ Maximum turning radius of 15’ Minimum passenger ground clearance of 15” Minimum passenger ground clearance of 15” Drivers must carry vehicle 20’ unassisted Drivers must carry vehicle 20’ unassisted Must be equipped with simulated mission equipment Must be equipped with simulated mission equipment

6. 6 Alpha 6 Lunar Roving Vehicle Designed as proof-of- concept vehicle to navigate the lunar surface Designed as proof-of- concept vehicle to navigate the lunar surface A human powered vehicle (HPV) A human powered vehicle (HPV) Competed successfully in NASA’s 2005 Great Moonbuggy Race Competed successfully in NASA’s 2005 Great Moonbuggy Race

7. 7 Alpha 6.5 Lunar Roving Vehicle Redesign of the Alpha 6 LRV Redesign of the Alpha 6 LRV Eliminate previous critical design failures Eliminate previous critical design failures Transmission mounting failure Transmission mounting failure Difficult steering design Difficult steering design Compete in the 2006 Great Moonbuggy Race Compete in the 2006 Great Moonbuggy Race

8. 8 Major Design Tasks Steering control Steering control Steering links redesigned Steering links redesigned New driver controls improve ease of operation New driver controls improve ease of operation Drivetrain Drivetrain Stronger design and built to eliminate structural failure Stronger design and built to eliminate structural failure Durability of vehicle drive train improved Durability of vehicle drive train improved Race performance Race performance Suspension system stiffened to improve obstacle maneuverability Suspension system stiffened to improve obstacle maneuverability

9. 9 Overview of Previous Suspension System The front and rear suspension are both independent systems The front and rear suspension are both independent systems Shock and spring combination used for dampening Shock and spring combination used for dampening Front assembly made of Chromoly steel and aluminum Front assembly made of Chromoly steel and aluminum Upper and lower control arm (A-arm) mounts spindle Upper and lower control arm (A-arm) mounts spindle Heim joints and ball joints link suspension components Heim joints and ball joints link suspension components Steering system utilized pushrod mechanism Steering system utilized pushrod mechanism

10. 10 Geometry components of the system reanalyzed Geometry components of the system reanalyzed Camber and toe-out Understeer Affects of loading Improve suspension system stability Improve suspension system stability Unsteady hubs Poor dampening shocks Improve steering control for improved driver interface Improve steering control for improved driver interface Front assembly made of 4130 Chromoly steel and aluminum Front assembly made of 4130 Chromoly steel and aluminum Redesign of Front Suspension

11. 11 Coilovers Improve Race Performance Front suspension stiffened to improve vehicle ability to negotiate obstacles Front suspension stiffened to improve vehicle ability to negotiate obstacles Spring Constant Old: 228 lbf / in Old: 228 lbf / in New: 976 lbf / in New: 976 lbf / in

12. 12 Design of Wheel Hub New design is composed of three components New design is composed of three components Hub is to be sleeved with stainless steel, which serves as the bearing Hub is to be sleeved with stainless steel, which serves as the bearing New hub provides ride stability and precision New hub provides ride stability and precision Solid one-piece design provides high structural integrity Solid one-piece design provides high structural integrity

13. 13 Analysis of Front Hub Static load multiplied by a factor of 3

14. 14 New Steering System Old system uses a rotating T- plate connected to solid links and a lever Old system uses a rotating T- plate connected to solid links and a lever Wire steering creates a system that uses cables instead of rods or shafts Wire steering creates a system that uses cables instead of rods or shafts steering system utilizes Heim joints on all linkages steering system utilizes Heim joints on all linkages Heim joints are multidirectional and more precise Implementing steering wheel provides more intuitive control Implementing steering wheel provides more intuitive control Flexible wire cables adapt easily to folding frame Flexible wire cables adapt easily to folding frame

15. 15 Additional Modifications New driveshafts manufactured due to wear and tear of old parts New driveshafts manufactured due to wear and tear of old parts CNC-machined out of heat treated stainless steel and TIG welded CNC-machined out of heat treated stainless steel and TIG welded

16. 16 Additional Modifications Continued Previous cantilever support for seats show signs of deflection Previous cantilever support for seats show signs of deflection Modified circular cross section and moment arm designed to increase safety factor Modified circular cross section and moment arm designed to increase safety factor

17. 17 Drive Train Reconstructed for Improved Durability 21 speed transmission 21 speed transmission Low Gear Torque: 357 ft lb Speed: 2.0 mph High Gear Torque: 19 ft lb Speed: 16.5 mph Critical drive train failure prevented completion of 1 heat in last year’s race Critical drive train failure prevented completion of 1 heat in last year’s race Transmission mounting plate redesigned Transmission mounting plate redesigned Expected loading: 88.5 ft lb

18. 18 Test Plan Alpha 6.5 will be more extensively tested than past entries Alpha 6.5 will be more extensively tested than past entries Improved testing sequence provides: Improved testing sequence provides: Additional time for redesign Additional time for redesign Reconstruction before competition Reconstruction before competition Testing will explore Testing will explore Vehicle frame strength Maximum sustainable and operational speeds Control during obstacle negotiation

19. 19 Design Verification – The “Drop” Test LRV designed to survive a 12” drop while fully loaded LRV designed to survive a 12” drop while fully loaded Vehicle will be subjected to a fall of equivalent force Vehicle will be subjected to a fall of equivalent force Verifies frame designed and manufactured strength Verifies frame designed and manufactured strength Verifies vehicle meets race guidelines for driver ground clearance Verifies vehicle meets race guidelines for driver ground clearance

20. 20 Design Verification – Operational Speed Test LRV designed with a maximum sustainable speed of 16 mph LRV designed with a maximum sustainable speed of 16 mph Design based on average human capability Design based on average human capability Must be verified with selected drivers Must be verified with selected drivers Maximum sustained speed over smooth terrain Maximum sustained speed over smooth terrain Operational speed over rough terrain Operational speed over rough terrain

21. 21 Design Verification – Extreme Situations The “Stair Flight” Test The “Stair Flight” Test Verify vehicle control and strength during a trip down CBU’s library front staircase Verify vehicle control and strength during a trip down CBU’s library front staircase The “Sand Pit” Test The “Sand Pit” Test Will determine ability of vehicle to maneuver out of the CBU volleyball court Will determine ability of vehicle to maneuver out of the CBU volleyball court The “Lazy Driver” Test The “Lazy Driver” Test Test transmission mounting Test transmission mounting

22. 22 Design Verification - Race Ultimate success will be determined by performance in the 13 th Annual Great Moonbuggy Ultimate success will be determined by performance in the 13 th Annual Great Moonbuggy Moonbuggy designed to give drivers the best opportunity to win Moonbuggy designed to give drivers the best opportunity to win Race is held on April 8, 2006 at U.S. Space and Rocket Center in Huntsville Race is held on April 8, 2006 at U.S. Space and Rocket Center in Huntsville Come support us; you will be glad you did Come support us; you will be glad you did

23. 23 Project Goals Remaining Complete assembly of Alpha 6.5 transmission Complete assembly of Alpha 6.5 transmission Test vehicle Test vehicle Increase driver familiarity with vehicle operation under race conditions Increase driver familiarity with vehicle operation under race conditions Win 2006 Great Moonbuggy Race Win 2006 Great Moonbuggy Race

24. 24 Questions