Final presentation on the mechanical improvements made to the Urban Concept Vehicle Glen Burkhardt Andy Jiang Peter Subosits Kyle Wydock Department of Mechanical and Nuclear Engineering The Pennsylvania State University 12/09/2014 1

OverviewBrakesHingeDoorMCMiscRisk The Shell Eco-marathon annual competition challenges teams to produce efficient and innovative vehicle platforms 2

OverviewBrakesHingeDoorMCMiscRisk The Urban Concept Vehicle competition requires teams to design a fully functional vehicle for urban use 3

OverviewBrakesHingeDoorMCMiscRisk An analytical hierarchy process chart (AHP) was used to weigh each customer need to determine the most important 4 CostAppearanceErgonomicsWeightSafetyDurableEfficiencyTotalWeightingRanking Cost Appearance Ergonomics Weight Safety Durable Efficiency Sum84.31

OverviewBrakesHingeDoorMCMiscRisk The team focused on these four improvements to make to the UCV before competition 5 Brake system Door/Latch Repair Wheel Alignment Motor Controller

OverviewBrakesHingeDoorMCMiscRisk Three brake line configurations were considered to satisfy competition rules and maximize safety 6

OverviewBrakesHingeDoorMCMiscRisk The team chose to use four independent hydraulic brake lines to reduce the risk of total brake failure 7

OverviewBrakesHingeDoorMCMiscRisk The brakes are typically used on mountain bikes and provide a lightweight yet powerful stopping solution 8

OverviewBrakesHingeDoorMCMiscRisk The team tested the brake system on a 20-degree incline to see if it complied with competition specifications 9

OverviewBrakesHingeDoorMCMiscRisk Three hinge concepts were generated to modify the door and secure it to the body 10 A new notch could be machined into the existing vehicle hinge A durable, soft-closing plastic hinge would allow for smooth operation A stainless-steel friction hinge would have 270 degrees of motion and produce a constant force

OverviewBrakesHingeDoorMCMiscRisk Three hinge concepts were generated to modify the door and secure it to the body 10 A new notch could be machined into the existing vehicle hinge A durable, soft-closing plastic hinge would allow for smooth operation A stainless-steel friction hinge would have 270 degrees of motion and produce a constant force

Two hinge plates were designed to mount the hinge to the body and door of the vehicle 11 OverviewBrakesHingeDoorMCMiscRisk

The team used finite element analysis to determine if the mounting plate could withstand the forces created by the door 12 OverviewBrakesHingeDoorMCMiscRisk

A new mounting plate was made for the latch to properly align the door to the vehicle body 13 OverviewBrakesHingeDoorMCMiscRisk

Commercial grade door sealant was applied to the edge to mitigate water intrusion during vehicle operation 14 OverviewBrakesHingeDoorMCMiscRisk

OverviewBrakesHingeDoorMCMiscRisk The motor controller was tested and will be redesigned by a group of electrical engineers next semester 15

OverviewBrakesHingeDoorMCMisc.Risk The team used known adjustment techniques to align the wheels for ideal travel 16

OverviewBrakesHingeDoorMCMiscRisk A Gantt chart was used throughout the semester to prioritize and keep track of major project deadlines 17

OverviewBrakesHingeDoorMCMiscRisk The team spent $ of the initial $1000 allocated budget on project deliverables and materials for next semester 18

OverviewBrakesHingeDoorMCMiscRisk With the help of Gary Neal, the team developed a high level list of tasks needed to send the UCV to competition in April 19

OverviewBrakesHingeDoorMCMiscRisk The team did not face any major issues when it came to risk management throughout the semester. 20 RiskLevelActions to MinimizeFall Back Strategy Schedule delays High use MS Project to track progress and current tasks Add extra time to each task and deliverable System does not function favorably Moderate Construct multiple prototypes and conduct testing Simplify or start with new concepts System unsafe for users or public High All designs will have safety as a priority and will comply with Shell Eco-marathon 2015 Rules Use testing to determine the cause of any dangerous situations and redesign as necessary Delays due to shipping or lead times Moderate Check stock status before purchasing parts and send all needed information to purchasing as soon as possible Manufacture instead of purchasing or search for another vendor

In conclusion, the work done on the Urban Concept vehicle will help future teams qualify for the 2015 Eco-marathon Competition 21 Questions?