Team 3: TRIumph TRIumph Team Members Matt Disselkoen, Amy Newland, Jamison Vande Ree Outline • • • • • • • • • 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: ▫ ▫ ▫ ▫ 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 • • • • • • • 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? ▫ ▫ ▫ ▫ ▫ ▫ 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 • • • • • • • 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?