1. Engineering Design II Senior Project NASA Moon Buggy Team Members: Rawad Abougahnem Bryan Delong Sean McIntosh Steve Thiede Faculty Advisor: Dr. Quamrul Mazumder Engineering Science University of Michigan-Flint

2. Steve Thiede Sean McIntosh Bryan Delong Rawad Abougahnem Dr. Quamrul Mazumder May 1, 2007

3. Project Scope Statement Design a four-wheeled human powered vehicle to compete in NASA’s MoonBuggy Race. Design, Manufacturing, and Testing must be completed by 3/20/2007. Total cost must not exceed $750 (Design, Part and Supplies, Manufacturing, Testing).

4. Project Schedule

6. Weekly Progress Reports

7. Moonbuggy Teams- each moonbuggy must be the work of a student team of a high school or an accredited institution of higher learning. A group of high schools may also work in collaboration toward building a moonbuggy entry. Propulsion System- human powered (one or both passengers); energy storage devices- such as springs, flywheels or others- are not allowed. Un-Assembled Dimensions- Prior to course testing, assembly judging is conducted the morning of the race, prior to the first run. The un-assembled vehicle must fit (or be collapsible) to fit in a volume of maximum dimension 4'x 4'x 4'. A container of this dimension will be placed over the collapsed or un-assembled moonbuggy for verification. Weight- the vehicle must be lifted and carried 20 feet by the two passengers, without aid of any sort (e.g., no wheels) in the unassembled 4'x 4'x 4' volume. Design Requirements

8. Assembled Dimensions- the maximum width of the assembled vehicle is four (4) feet, including wheels. There are no constraints for height and length of the assembled vehicle. Other than the stated configuration requirements, no constraints are imposed regarding materials and design. Vehicles, or parts of vehicles not constructed by the entering team are not acceptable. Vehicles that have been previously entered should contain major modifications that attempt to improve on design and performance.. No constraints are imposed in the means of contact between the buggy and the simulated lunar surface. We encourage creativity and participants are open to using wheels, belts, treads, etc. Design Requirements (Contd)

9. Requirments Cont… No body part of either passenger may be closer than 15" to the flat surface on which the vehicle is supported. The vehicle must have a turning radius of 15 feet or less. For safety reasons, it is recommended that the center of gravity of the "vehicle plus passengers" be low enough to safely handle slopes of 30 degrees forward and sideways. Any moonbuggy exhibiting handling characteristics or other vehicle dynamics that are deemed unsafe or unstable by the judges will be disqualified from the competition. This determination will be made by inspection of the assembled moonbuggies prior to course testing. Each vehicle must have seat restraints for each of the two passengers. The restraints must be worn during runs of the course.

10. All sharp edges and protrusions must be eliminated (i.e. padded) or guarded as necessary to the satisfaction of the judges. The vehicle must be equipped with the following elements: simulated TV camera (approximately 2" x 3" x 6"), simulated high gain antenna (minimum diameter of reflector: 2'), two simulated batteries (each approximately 4"x 6"x 8"), moon dust abatement devices (aka fenders) over each wheel, simulated electronic controls- radio and display console (total combined minimum size 1 cubic foot) and national or school flag. These items (and their sizes) will be checked prior to, and after, each course run. Backing up is not required, but may be useful. Vehicles that do not satisfy the intent of the moonbuggy competition can be disqualified. Requirments Cont…

11. Passenger Rules Moonbuggy Passengers- two (2) student team members (one female and one male) Eye protection (e.g. goggles or face shield), head protection (a bicycle helmet), and appropriate clothing (gloves WITH fingers, long pants, socks, shoes, short or long sleeved upper garment covering the torso) must be worn during operation of the moonbuggy. No appendages such as stilts may be used on the feet of the moonbuggy passengers. Pushing the moonbuggy with a pole or other implement is not allowed. The consumption of alcoholic beverages or controlled substances by any team member at any time during the event is strictly prohibited and is grounds for disqualification of the team.

12. Component Design Frame Assembly Pedal Assembly Front fork and support assembly

13. Components Design Rear Pivot Axle Rear Pivot Axle Bracket 24 inch bicycle wheels Steering Column

14. Component Design Frame Assembly Pedal Assembly Front fork and support assembly

15. Final Assembly

16. CAD Drawings Cont... Top Assembly View

17. Manufacture and Assembly

18. Final Assembly of Moon Buggy

19. Competition Rules Obstacle (1-15) penalties, full/0 of standard penalty Passenger/ground, course contact penalties, full/0 of standard penalty (One passenger/ground contact penalty will be incurred if there is ground, rope or railing contact in an "obstacle judging area". An obstacle judging area is defined as the area from the previous obstacle to the "current" obstacle. Maximum of 1 penalty in each obstacle judging area). Standard Penalty: 1 minute. Post/Pre Race: Final Condition- seven items (Fenders, US flag, simulated: 1st battery, 2nd battery, high gain antenna, tv camera, radio and display console)- 0:30 seconds ea.

20. Disqualification: Passenger requirement (1 male, 1 female) Missing an obstacle Safety Disqualification (judges discretion) 10 minute late start Penalty Appeals: The scoring decisions of the judges are considered to be final. Only in extraordinary circumstances should appeals of penalties be proposed. If the appeals process is chosen, the advisor/instructor or the team leader must submit the appeal of the penalty. Appeals must be submitted in writing to the scoring tent within 1/2 hour of the posting of the score in question. The team risks forfeiting 1 standard penalty if the appeal is rejected. The final decision of the Great Moonbuggy Race Director shall prevail.

21. Summary and Conclusion The design phase is the most important part of any design project. Designing a good product from the beginning reduces the amount of hurdles and problems and eliminates the need for redesigning major components. This brings us to realize that there is a real need to have team members work well together and be very open minded to good ideas which helps us in the early design phase. This has a ripple effect on the project as a whole.

22. Summary and Conclusion Productivity becomes an issue when there are negative factors that contribute to high levels of tension between group members. On the other hand money availability gets in the way of having an instant buying power which makes it harder to get certain parts in time efficient completion of component manufacturing and fabrication. The project as a whole was a good experience for all of us on the team, especially on project design and management, and dealing with different types of people in a group setting.