Team 3: TRIumph
TRIumph Team Members
Matt Disselkoen, Amy Newland, Jamison Vande Ree
Outline
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Background
Project Description
Design Process
Build Process
Obstacles
Lessons Learned
Project Assessment
Acknowledgments
Questions
Background
• myTEAM TRIUMPH
▫ Athletic ride-alongs
▫ Triathlons, Marathons, 5k’s
• Stage-specific equipment
▫ Swimming
▫ Bicycling
▫ Running
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Background
• Transition Process
▫ Lost time
▫ Difficult
• Current Equipment
▫ More room for storage
▫ Not enough legroom
• Project Motivation
▫ Help others
▫ Solve problem
Matt Smith & Family
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Current Equipment
Running Chair,
from Advance Mobility™
Bicycle Trailer,
from Cycletote®
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Project Description
• Primary Goals:
▫ Two-in-one: Biking and Running
▫ Increase height and weight capacity
• Secondary Goals:
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Improve seat comfort
Build for easy transportation
Strengthen connection points
Reduce parachute effect
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Product Research
• Existing Products
▫ Some convertible
▫ Low capacity
▫ Not built for
endurance races
Burley® d’lite
Wike® Extra Large
Special Needs Trailer
Chariot Carriers Inc. Corsaire XL
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Research
• Safety/Testing Standards
▫ ASTM
 Bicycle Trailers
 Strollers
• Common Sense
▫ Strength
▫ Pinch points
▫ Access
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Initial Design Components
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Seat
Harness
Shock Absorption
Brakes
Wheels
Windows
Roll Cage
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Initial Design
• Based on mTT bicycle trailer
▫ Larger capacity
▫ Low center-of-gravity
• Decisions needed:
▫ Material
▫ Dimensions
Initial Autodesk Inventor Model
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Design Decisions
• Basic Frame Structure
▫ Material
 Aluminum
 Titanium
 Carbon Fiber
▫ Manufacturing capabilities
• Weight Considerations
Early SolidWorks Model
▫ Lightweight
▫ Current models: 25 – 30 lbs
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Finite Element Analysis
• Objective:
▫ Determine high-stress areas
▫ Ensure prototype strength
▫ Size tubing required
• Process:
▫ Applied loads
▫ Boundary conditions
Algor FEA Results
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
FEA Results
• Results:
▫ Maximum von Mises Stress
 2.9 ksi
▫ Dynamic Stress
 7.25 ksi
▫ Safety Factor: 4
Insert many
different FEA
setups,
results to
show
iterations
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Design Decisions
• Frame Material
▫ Aluminum 6061-T6
 7/8” OD, 16 ga (0.065”)
▫ Aluminum 6061-T6
12’
 3/8” Diameter Solid
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Design Decisions
• Two-in-one
▫ Removable bike attachment
• Seat
▫ Sling-style
▫ Folding seat back
• Frame structure
▫ V-shape design
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Frame Structure
• Tube Bending
▫ Conduit Bender
▫ Hydraulic
▫ CNC Bender
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Frame Structure
• Cutting Tube
▫ Fish-mouth slot
 Mill
 Hole Saw
▫ Mate surfaces
for welding
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Frame Structure
• Welding
▫ MIG
▫ TIG
• Issues
▫ Welding Aluminum
▫ Thin-walled tube
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Frame Structure
Upper seat
pivot point
Lower seat
attachment point
7/8” Dia. Tube
3/8” Dia. Round
Superb weld
quality
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Frame Features
• Wheel mounts
▫ Forces axle into mount
• Seat mount plates
▫ Two separate pieces
▫ Reduced weight
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Seat Design
• Two piece, sling style
▫ No cross tube
▫ Increased comfort
• Seat Back
▫ Folding
▫ Locking
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Roll Cage
• Aluminum tube shell
▫ Strong connections
▫ Pinned/clamped in place
• Foldable
▫ Unpin joints
▫ Loosen clamps
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Fabric Components
• PVC-Lined Polyester Shell
Retractable
Polyester roof
▫ Water-resistant
▫ One piece
• Vinyl Seat
▫ Padded inserts
• Iterative Design
▫ Four miles of thread
▫ Perfect fit
Polyester shell
Vinyl seat
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Roll Cage Covering
• Vinyl to Mesh
▫ Better airflow
▫ Allows sunlight
• Mesh airflow panels
▫ Decreased drag
• Windows
▫ Increased visibility
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Hand Controls
• Brakes
▫ Caliper brakes
▫ Locking levers
▫ Cable + housing
• Front swivel pin
▫ Waiting on part
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Bicycle Attachment
• Similar to current design
▫ Bent tubes
▫ Ball joint
• Removable tubes
▫ Two pins
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Running Attachment
• Sliding tube-in-tube design
Pins
▫ Pin in place
• Steel fork and plate
▫ Balanced weight
▫ Reduced wobble
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Obstacles
• Design vs. Build
• Make vs. Buy
vs.
• Machining Skills
• Manufacturing Capabilities
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Valuable Lessons
• Concurrent Engineering
▫ Redesign time
• Teamwork
▫ Task Delegation
• Scheduling
▫ Step by step goals
▫ Realistic
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Project Assessment
• Success?
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Convertible prototype
Increased capacity
Foldable for transportation
Metal connection points
Improved seat comfort
Decreased parachute effect ? /
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Acknowledgments
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myTEAM Triumph
Phil Jasperse
Senior Design Professors
Progressive Technologies
Rapid-Line
Highlight Industries
Kenneth Haan Jr.
Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks
Questions?