The Design, Construction and Testing of a Human-Powered Moonbuggy Faculty Advisor: Dr. Paul Shiue Industry Advisors: Dr. Paul Shiue Christian Brothers University January 31, 2000 Moon Buggy Squad Katie Baxter Thomas Malone II Teretha Blackburn Rob Hartelust

2 NASA NASA - Authority in Space Research NASA is deeply committed to spreading the unique knowledge that flows from its aeronautics and space research….

3 NASA Sponsors High-school and college students develop a human-powered moonbuggy. Competitors engineer solutions to similar problems faced by NASA with the lunar rover.

4 The Race Is... At Marshall Space Flight Center in Huntsville, Alabama On April 8, 2000 (college division only) 1/2 Mile in Length with 15 obstacles

5 The Course Has 15 Obstacles Around the Space Center

6 Race Conditions Simulate Lunar Surface Course consists of a rocky, dusty terrain with 180 o turns. Surface may include one or more of the following at each obstacle: –“Craters” –“Lava” ridges –Inclines (up to 30 o ) –“Lunar” soil, crushed limestone gravel, sand or grass

7 NASA Presents Design Constraints for Moonbuggy Max dimensions unassembled: 4’ X 4’ X 4’ Lunar Rover Maximum dimensions assembled: 1.) 4’ width 2.) 15” clearance from passenger to ground

8 The Moonbuggy Constraint List Continues Maximum allowable turning radius: 20ft Seat restraints for each passenger No sharp edges or protrusions Features: –Simulated T.V. Camera (2”x3”x6”) –Simulated electronic controls-radio & display console (1 cubic ft combined) –Two simulated batteries (4”x6”x8” each) –2’ satellite dish –U.S. flag –Moon dust abatement device(s)

9 Ergonomics Is Addressed Combined weight of racers = 350 lbs. Max carry capacity per person = 75 lbs. Vehicle weight alone = 150 lbs. max Goal: Max combined weight of moonbuggy + racers = 500 lbs.

10 Scattered Puzzle Pieces Chassis Structure Drivetrain Steering Pedals & Seats

11 Frame and Chassis Must be Simple but Effective Easy to Assemble and Take Apart Gear and Drive Train Protection Maintain Structural Integrity

12 Chassis Material Specified Performed static and dynamic loading on chassis component under highest stress (seat support) Determined that 2” x 2” x 1/4” 6061-T6 aluminum square tube can withstand these stresses with a safety factor of 10

13 Folded Moonbuggy Fits Volumetric Constraint After viewing footage from previous races, the necessity of quick race time construction became apparent. Moonbuggy squad has developed a way for the chassis to fold in two. Caused some design modifications. Will limit race-time construction to unfolding and putting together chains.

14 Internally Geared Hub Chosen Over Derailleur Style Gear Internal Hub –chain length remains constant –housed gears are not exposed to the environment –easier to mount –possible to attach brake to exterior of hub –can shift at a standstill Derailleur system –gears are exposed to environment –chain alignment is very important and difficult to maintain –interferes with ground clearance

15 Total Cost Estimate Parts :$1800 Chassis Material :$300 (6061 T-6 Al) Labor :$50/hr (2hr w/ certified welder) Travel Expenses :$700 Total Cost :$3000

16 Short Term Goals Set Seek more sponsors Continue to acquire parts Finish modeling prototype in ProEngineer Acquire aluminum tubing and begin chassis construction

17 Timeline Is Intact For 2000

18 For Updates on The Moonbuggy Squad Go to the following url: 1.)

19 Any Questions or Suggestions?