SEC
Saluki Engineering Company
Proposal for:
F-12-32-MOON
SIUC Moonbuggy Team
Submitted:
November 6th, 2012
Members:
Caleb McGee
Dan Rogers
Nick Sager
Dylan Sartin
Ryan Schmidt
Technical Advisor:
Dr. Tsuchin Philip Chu
November 5, 2012
Saluki Engineering Company
Southern Illinois University
Carbondale, IL
618-534-2224
Email: ryanschmidt@siu.edu
Dr. Chu
Manager of Mechanical Engineering Projects
Southern Illinois University
Carbondale, IL
618-452-7003
Email: tchu@siu.edu
Dr. Chu,
In response to your request to create a moonbuggy for competition at NASA’s 2013 Great
Moonbuggy Race, Saluki Engineering Company proposes the following design. Thank you for
considering our design for competition.
The moonbuggy is to be an all new design with a special emphasis on suspension performance
and safety. The overall design consists of a three rail chromoly space frame. Steering will be an
under-seat design with pivotal steering capability. The moonbuggy will be four-wheel drive and
employ a high travel, double wishbone suspension system. Integrated roll bars will aid in driver
safety. In addition, the moonbuggy will meet required size criteria so as to avoid penalties.
This design solves issues which plagued previous year’s moonbuggies while improving upon
those systems which functioned well. Speed will be increased due to a suspension and steering
system which works together over rough terrain to provide predictable performance. Rider
confidence will be increased through the use of roll over protection. A comfortable riding
position will allow riders to apply greater force to the pedals. These improvements will provide
the SIUC moonbuggy with a distinct advantage over competitors in not only the race, but in the
design competition as well.
If there are any questions or concerns with this moonbuggy design, please contact our team by
email at ryanschmidt@siu.edu or by phone (618) 534-2224.
Thank you for reviewing our design proposal and giving us the opportunity to compete at the
2013 Great Moonbuggy Race.
Sincerely,
Ryan Schmidt, PM
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Executive Summary
The Saluki Engineering Company (SEC) proposes to construct a moonbuggy for the purpose of
competing in the 2013 NASA Great Moonbuggy Race in Huntsville, Alabama. The competition
calls for the construction of human powered, off-road vehicles that are ridden by two drivers.
Despite the many requirements for the Moonbuggy as stated in the event rules, the vehicles
allowed in the competition have much variation and design freedom. The proposed moonbuggy
will stand out above the rest by refining design innovations discovered by the SEC in previous
moonbuggy competitions and by implementing new design innovations where major
improvement is needed. Improvements include implementing a more weight efficient frame,
higher travel suspension, a more reliable drivetrain, redesigned steering, ergonomic seats, greater
driver safety, and a lighter overall design. The proposed Moonbuggy will have a target weight of
125 lbs. and time of 4:00 minutes around the competition course in addition to complying with
NASA’s vehicle standards for the competition.
As a result of this proposed work, there are several deliverables that will be supplied to the
consumer by the SEC. The deliverables include CAD renderings of all parts and assemblies for
the 2013 Moonbuggy design, validations for all design choices implemented, physical testing to
demonstrate the outcome of the design, and the final functioning Moonbuggy used in the
competition. The SEC proposes to complete the work detailed in this proposal and deliver the
stated deliverables for the price of $10,000.
The responsibility of designing the moonbuggy was separated among the team members by
creating subsystems consisting of multiple parts. These subsystems were then assigned to each
team member based on expertise and work load. In all, five subsystems were created: frame,
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drivetrain, suspension, steering, and ergonomics and safety. The development of the frame
consists of designing the primary load bearing frame rails, secondary supporting structure, hinge
and latch mechanism for folding, and mounting points to accommodate the other subsystems.
The drivetrain design includes the development of a system to transmit power from the drivers to
the wheels using pedals, transmissions, axels, bearings, axel couplings, and differentials as well
as a braking system. The design of the suspension includes the combination of a-arms, uprights,
shocks, and connecting parts such as push rods or rocker arms. Steering design involves the
control of the buggy from the control surfaces to the turning of the wheels using handles,
linkages, and Heim joints. The ergonomics of the interfaces between driver and buggy include
designing seats, supports, pedal positioning, and control positioning. Finally, the safety of the
riders, included in ergonomics, includes the design of protective seat belts, roll bars, and overall
stability of the buggy.
Non-Disclosure Statement
The information provided in or for this proposal is the confidential, proprietary property of the
Saluki Engineering Company of Carbondale, Illinois, USA. Such information may be used
solely by the party to whom this proposal has been submitted by Saluki Engineering Company
and solely for the purpose of evaluating this proposal. The submittal of this proposal confers no
right in, or license to use, or right to disclose to others for any purpose, the subject matter, or
such information and data, nor confers the right to reproduce, or offer such information for sale.
All drawings, specifications, and other writings supplied with this proposal are to be returned to
Saluki Engineering Company promptly upon request. The use of this information, other than for
the purpose of evaluating this proposal, is subject to the terms of an agreement under which
services are to be performed pursuant to this proposal.
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Table of Contents
Executive Summary CM .............................................................................................................. 3-1
Non-Disclosure Statement ........................................................................................................... 4-1
Introduction DS ............................................................................................................................... 1
Literature Review............................................................................................................................ 2
Introduction ................................................................................................................................. 2
Frame CM ................................................................................................................................... 2
Drivetrain DR .............................................................................................................................. 5
Suspension RS ............................................................................................................................. 8
Steering NS ............................................................................................................................... 15
Braking NS ................................................................................................................................ 18
Seating DS ................................................................................................................................. 20
Safety DS................................................................................................................................... 23
Conclusion................................................................................................................................. 25
Overall Project Description DR .................................................................................................... 26
Basis of Design DR ....................................................................................................................... 28
Specifications RS .......................................................................................................................... 28
Technical Description ................................................................................................................... 30
Frame CM ................................................................................................................................. 30
Suspension RS ........................................................................................................................... 31
Drivetrain DR ............................................................................................................................ 32
Steering NS ............................................................................................................................... 35
Ergonomics DS ......................................................................................................................... 36
Contract Pricing NS ...................................................................................................................... 37
Resources and Parts List RS ......................................................................................................... 38
Validity Statement ........................................................................................................................ 39
Project Organization Chart CM .................................................................................................... 40
Action Item List RS ...................................................................................................................... 41
Timeline DS .................................................................................................................................. 42
References ..................................................................................................................................... 43
Appendix A ................................................................................................................................... 45
Resumes DR .............................................................................................................................. 45
Appendix B ................................................................................................................................... 50
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Competition Rules DS............................................................................................................... 51
Appendix C ................................................................................................................................... 59
Block Diagram NS .................................................................................................................... 59
Appendix D ................................................................................................................................... 60
Request for Proposal ................................................................................................................. 60
Figures
Figure 1. Moonbuggy Course Map ................................................................................................. 1
Figure 2. 2012 SIU Moonbuggy with Single Rail Frame ............................................................... 4
Figure 3. 2010 SIU Moonbuggy with Three Rail Frame ................................................................ 5
Figure 4. HammerSchmidt Crank ................................................................................................... 6
Figure 5. Rohloff Transmission ...................................................................................................... 6
Figure 6. Tricycle Differential ........................................................................................................ 7
Figure 7. Spline Shaft with Male and Female Couplers ................................................................. 8
Figure 8. Suspension Overview ...................................................................................................... 9
Figure 9. Suspension Performance ................................................................................................. 9
Figure 10. Single A-arm Suspension ............................................................................................ 10
Figure 11. McPherson Strut .......................................................................................................... 11
Figure 12. Double Wishbone Suspension ..................................................................................... 12
Figure 13. Pushrod Suspension ..................................................................................................... 13
Figure 14. Rod Ends in Bending and Single Shear ....................................................................... 14
Figure 15. Spherical Bearing ........................................................................................................ 14
Figure 16. SIUC Moonbuggy Tank Style Steering, 2012 ............................................................. 15
Figure 17. SIUC Moonbuggy Joystick, 2000 ............................................................................... 16
Figure 18. Under Seat Steering ..................................................................................................... 17
Figure 19. Pivotal Steering ........................................................................................................... 18
Figure 20. Avid Rim Brakes ......................................................................................................... 19
Figure 21. Avid BB7 Disc Brakes ................................................................................................ 19
Figure 22. SIUC Moonbuggy, 2012 ............................................................................................. 20
Figure 23. Recumbent Seating Position ........................................................................................ 21
Figure 24. Rhode Island School of Design Seats .......................................................................... 22
Figure 25. Recumbent Mesh Seat ................................................................................................. 22
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Figure 26. Moonbuggy Crash ....................................................................................................... 23
Figure 27. Moonbuggy Rollover................................................................................................... 24
Figure 28. Crushed Riders ............................................................................................................ 24
Figure 29. 2013 Moonbuggy Frame ............................................................................................. 26
Figure 30. 2013 Moonbuggy Suspension ..................................................................................... 27
Figure 31. Project Organization Chart .......................................................................................... 40
Figure 32 Block Diagram.............................................................................................................. 59
Tables
Table 1. Material Properties ............................................................................................................ 3
Table 2. Coil-over Shock Comparison.......................................................................................... 13
Table 3. Brakes Comparison ......................................................................................................... 19
Table 4. Basis of Design ............................................................................................................... 28
Table 5. Frame Elements .............................................................................................................. 30
Table 6. Suspension Elements ...................................................................................................... 32
Table 7. Transmission Comparison .............................................................................................. 33
Table 8. Drivetrain Elements ........................................................................................................ 34
Table 9. Steering Elements ........................................................................................................... 35
Table 10. Ergonomics Elements ................................................................................................... 37
Table 11. Cost Proposal ................................................................................................................ 38
Table 12. Action Item List ............................................................................................................ 41
Table 13. Timeline ........................................................................................................................ 42
7-1
Introduction
The moonbuggy is to be built to compete in NASA’s Great Moonbuggy Race; an event which
enables engineers to compete in a way which pays tribute to the design challenges faced by those
who designed the original Lunar Rover Vehicle. An event that has been held annually for twenty
years, the Great Moonbuggy Race is a 0.7 mile race in which a moonbuggy must be built to
navigate obstacles which replicate those on the moon. The purpose for teams is not only to
design and construct a moonbuggy to withstand these conditions, but also to do it in the fastest
time. The moonbuggy with the fastest time is declared the champion and can be seen as the best
moonbuggy for that course.
Figure 1. Moonbuggy Course Map
1
The 2013 Moonbuggy Team is comprised of five mechanical engineers who wish to create the
best moonbuggy ever sent to competition by SIUC. This moonbuggy will be made to win the
design competition and the race; a feat yet to be accomplished by SIUC.
Literature Review
Introduction
The Great Moonbuggy Race is a NASA sponsored event held at the Space and Rocket Center in
Huntsville, Alabama. The project is held to pay homage to the Lunar Roving Vehicle which was
used during Apollo 15, 16, and 17 missions to the moon. Engineers who designed the Lunar
Rover had to create a vehicle which was light weight, could navigate lunar terrain, but still fold
into a small space on the Lunar Module. The rules set forth for The Great Moonbuggy Race are
such that contestants will face similar challenges when designing a moonbuggy.
The moonbuggy is comprised of five subsystems: frame, drivetrain and brakes, suspension,
steering, and ergonomics and safety. Each subsystem must be designed so that it is optimized to
work with all other subsystems.
Frame
The frame of the moonbuggy acts as the foundation for all of the other systems on the buggy and
requires many design considerations. The frame consists of the supporting structure that runs the
length of the buggy, hinge mechanism to allow the buggy to fold, and mounting points for
attachment of the other systems. Further, materials selection is a very important part of
designing the frame. The frame needs to be rigid and strong to prevent bending or failure when
2
the buggy is subjected to high loads on the course, all while being as light as possible to increase
the speed and acceleration of the buggy.
Research shows that there are many possible materials that would be suitable for constructing the
frame. Considerations when choosing the frame materials include strength, weight, elasticity,
required tooling, and cost.
Table 1. Material Properties [1]
Yield
Strength
(kpsi)
36
50-63.3
35-40
Tooling
Cost ($ per foot of 1”
tubing)
0.284
0.283
0.098
Mod. of
Elasticity
(Mpsi)
29-30
30
10
Weld
Weld
TIG Weld
$3.38 (0.120” Wall)
$6.55 (0.083” Wall)
$5.72 (0.250” Wall)
0.05-0.067
~22
120-175
Adhesive
$25.45 (0.031” Wall)
Material
Density
(lb/in3)
Steel A36
Steel 4130
Aluminum
6061
Carbon Fiber
The data for structural steel (A36), chromoly steel (4130), multi-purpose aluminum (6061), and
carbon fiber show a wide variety of material properties leading to various advantages and
disadvantages for each material. The data shows that A36 steel is the most flexible and the
cheapest of all the materials, but its density is higher than all the other suitable materials and its
yield strength is relatively low. When chromium and molybdenum are added to produce 4130
steel (chromoly), the yield strength nearly doubles. The elasticity and density are nearly the
same as in structural steel, but there is also a cost increase. 6061 aluminum is another alternative
with advantages such as a lower price than chromoly and a much lower density than steels while
maintaining a similar yield strength to A36. However, aluminum is not nearly as ductile as steel
and requires special welding techniques and equipment to use it in manufacturing. Finally, the
most expensive option is carbon fiber. The primary advantages of carbon fiber are a very high
3
yield strength and low density. However, carbon fiber is brittle, requires different manufacturing
methods than metals, and is much more expensive.
Another important aspect in designing a moonbuggy is the frame layout. In years past,
successful teams have used two primary designs: single rail and triple rail. The 2012 SIU
moonbuggy utilized the simplicity of a single rail design to become the lightest SIU moonbuggy
to ever complete the competition. The simplicity allowed for the fastest assembly time of any
SIU moonbuggy, but made mounting subsystems complicated. The three railed design, like that
used in 2010 by SIU (6th place) and the 2012 Huntsville team (1st), is more complicated, but its
triangular shape provides greater rigidity and facilitates easier mounting of necessary parts to the
frame.
Figure 2. 2012 SIU Moonbuggy with Single Rail Frame.
Photo credit: Lisa Dohn
4
Figure 3. 2010 SIU Moonbuggy with Three Rail Frame
Photo credit: Lisa Dohn
Drivetrain
The drivetrain system of the moonbuggy consists of every part to convert human force on the
pedals to the rotational movement of the wheels. The main parts of the drivetrain include pedals,
transmission, differentials, axles, u-joints, wheels, and tires. All are equally important due to the
fact that if one subsystem fails the entire drivetrain becomes useless.
There are many options for transmissions that other teams and past buggies have used. Many
teams use Shimano Nexus hubs or Rohloff hubs which are both internal hub gear transmissions
used in racing bicycles. The Shimano Nexus hub comes with many options for gearing from 3
speeds to 22 speeds [2]. The Rohloff hub comes in just 14 speeds but is made with much better
quality than the Shimano Nexus hub [3]. A third option is a two speed crank/transmission
combination made by HammerSchmidt. This transmission is a system of planetary gears
contained within the sealed housing which yields either a 1:1 or a 1.6:1 overdrive gear ratio [4].
5
With this change in gear ratio, a 22T chainring delivers 22/36T versatility and a 24T ring
provides the same range as a 24/38T. The HammerSchmidt can shift gears while under pedaling
load, unlike the Shimano or Rohloff hubs in which load must be reduced to allow for shifting.
The 2011 and 2012 moonbuggies used a Shimano transmission, both of which failed during
competition and limited the buggy to only one usable gear. The 2012 Rhode Island School of
Design moonbuggy used HammerSchmidt pedals which did not fail.
Figure 4. HammerSchmidt Crank [4]
Figure 5. Rohloff Transmission [3]
The purpose of a differential is to adjust power between two wheels. While going around a
corner, the differential prevents the inner wheel from spinning and/or the outer wheel dragging.
If the inner and outer wheels were rigidly connected, the results would be unpredictable
handling, damage to the tires, and strain on the drivetrain. Previous SIUC moonbuggies have
6
used modified golf cart differentials. They are heavy, and if one wheel loses traction, the other
wheel will not rotate leading to a loss of forward motion. Another differential design, used by the
Rhode Island School of Design, is a tricycle differential. It consists of two BMX freewheels
bound together with a drive gear between them. The gears of the free wheels are turned by the
center gear but the axles are allowed to rotate independent of each other. This differential is a
locking type, which means both wheels will spin at the same speed, even if one of the wheels
does not have traction [5].
Figure 6. Tricycle Differential
Photo credit: Ryan Schmidt
The purpose of the axle is to transmit rotational power from the crank through the differential
and finally to the wheels. The driveshaft must telescope due to suspension design. Options for
the drive shafts include hexagonal, pipe, or spline shaft. Hexagonal and spline shafts telescope
easily by using male and female connections. A standard pipe axle requires a key or another
object to be attached to allow telescoping but prevent torsional failure between parts [6]. The
splined drive shafts of previous SIUC moonbuggies have proven to be reliable.
7
Figure 7. Spline Shaft with Male and Female Couplers [6]
Suspension
The suspension system of a vehicle must accomplish multiple objectives. Firstly, it must reduce
abrupt forces transmitted into the frame and the occupants of the vehicle. Secondly, the
suspension must keep each wheel on the ground at all times so that control of the vehicle is
maintained. Thirdly, the suspension must be designed so that the change in angle of the wheel
with respect to the ground is constant through the travel of the wheel [7]. Figure 8. Suspension
Overview [8] describes different types of suspension systems.
8
Figure 8. Suspension Overview [8]
Figure 9. Suspension Performance [8]
9
As shown in Figure 8. Suspension Overview [8], the suspension with the best performance is the
independent suspension. Although an independent suspension system is more costly, it features
benefits in control and comfort that outweigh the increase in complexity and cost.
Figure 10. Single A-arm Suspension
Photo credit: Lisa Dohn
There are several different independent suspension designs. The first is a single A-Arm design as
shown in Figure 10. Single A-arm Suspension
Photo credit: Lisa DohnFigure 9. Suspension Performance [8] on the 2012 SIU moonbuggy. The
single A-Arm is the simplest, but provides poor control due to the constantly changing angle of
camber throughout wheel travel. Excessive camber will provide increased rolling resistance,
poor control over terrain, and increased tire wear. This was a contributing factor to the
moonbuggy’s inability to complete the course in less than ten minutes.
10
Figure 11. McPherson Strut [8]
Another suspension option is the McPherson strut. Although is improves upon the single a-arm
design because it limits the camber change of the wheel throughout travel, it induces vertical and
lateral forces onto the strut [8].
11
Figure 12. Double Wishbone Suspension [8]
The best choice is the double wishbone suspension. The double wishbone suspension improves
upon the McPherson strut in that it directs lateral forces through the a-arms so that only vertical
loading is induces on the shock absorbers [7].
To dampen the impact forces and provide support vehicle weight, a coil-over shock absorber is
necessary. A shock absorber which has high travel, adjustability and low weight is desired.
Mountain bike shock absorbers are the most compact units available. Many moonbuggies at
competition use them and performed well, including the Rhode Island School of Design.
12
Table 2. Coil-over Shock Comparison [9]
Coil-over Shock
Absorber
Romic D
Manitou Swinger
Adjustability
Travel
Length
Spring Rate
Price
2 Way
4 Way
2.25 in
2.50 in
7.875 in
8.5 in
350 lbs., non-adjustable
400 lbs., adjustable
$69.99
$99.95
Suspension travel is extremely important in designing a moonbuggy. Because of rough terrain,
the suspension must be able to travel over obstacles without leaving the ground. The travel
gained from mountain bike shocks is not enough. To increase travel, a pushrod system may be
employed. It will increase travel to over seven inches, and provide a means to adjust the ride
height.
Figure 13. Pushrod Suspension [10]
To enable the A-Arms to articulate about the upright, as well as provide a pivot for steering
systems, the rod end has been employed. Many teams, including the Rhode Island School of
Design, install the rod end in bending, which is poor design practice. Rod ends are made to
handle only tension and compression. When placing a rod end in bending, it must be
substantially increased in size to remain safe. This increase in size adds weight.
13
Figure 14. Rod Ends in Bending and Single Shear
Photo credit: Ryan Schmidt
An alternative is to use spherical bearings. Spherical bearings allow the use of double shear
joints, and provide a stronger and lighter suspension system.
Figure 15. Spherical Bearing [11]
14
Steering
Without steering, the moonbuggy would have no control. It would not be able to complete the
course and would be a danger to the drivers and the crowd. In the past, moonbuggies have had a
variety of steering methods.
One such method is the ‘tank style’ steering system. In a tank style system, the front seat driver
uses two handlebars, connected to the wheels through tie rods and linkages, to push and pull the
wheels into the desired turning position. Many teams use this style. The 2012 moonbuggy used
tank style steering. One design feature that differentiated it from others was that the handlebars
were connected directly to the suspension. When the moonbuggy traversed obstacles, the vertical
motion would be transmitted directly into the driver’s hands, making it more difficult to keep
their hands on the handle bars.
Figure 16. SIUC Moonbuggy Tank Style Steering, 2012
Photo Credit: Lisa Dohn
15
Figure 17. SIUC Moonbuggy Joystick, 2000
Photo Credit: Christopher Chaurero
In addition, teams have likened a moonbuggy to that of a standard bicycle and have used
handlebars to steer. In 2000, the SIUC moonbuggy used a joystick. However, if you were to view
the moonbuggy as a recumbent bicycle, then the possibilities of steering systems widen even
more. The moonbuggy could then use over seat steering, under seat steering, or even pivotal seat
steering to guide it.
An over seat steering system is most similar to a traditional bicycle [12]. Handlebars that are in
front of you control the steering of the wheels. It is less complicated and has less moving parts
than any other steering for a recumbent bicycle. It is also more user friendly, as anyone who has
ever ridden a bicycle would recognize how to control it. However, this configuration requires
space and space on a moonbuggy is limited. The moonbuggy must be able to fit into a 4 foot
cube, and an over seat steering system may be more difficult to fit that criteria.
16
An under seat steering system puts the handlebars below the seat to control the front wheel [13].
This is more comfortable and can be more space saving, but it will take more practice to get used
to and it can be more difficult to make.
Figure 18. Under Seat Steering [14]
The last form of steering for a recumbent bicycle is known as center or pivotal seat steering. In
this steering system, the driver uses his or her body weight to turn the vehicle. It is extremely
maneuverable, however, it would take some getting used to and converting it into a steering style
for a four wheeled moonbuggy may prove to be more difficult than it would be worth.
17
Figure 19. Pivotal Steering [15]
Braking
Choosing a braking system may prove to be easier as the forms of braking practical to a buggy
are limited. The two choices really come down to rim brakes and disc brakes. Rim brakes apply
a squeezing pressure to the rim of the wheel. They are simple and less expensive than disc
brakes, but perform poorly in wet conditions. Rim brakes must also have a linkage which
connects them to the outer diameter of the wheel. Because they work on the outer diameter of the
rim, it is important that the wheel be perfectly round and undamaged [16].
Disc brakes apply a clamping force to a disc which is connected to the wheel [16]. Disc brakes
are more expensive than rim brakes, but they offer improved performance. Disc brakes do not
have to be mounted to the outside of the wheel, and may be attached at any point on the
drivetrain.
18
Table 3. Brakes Comparison [9]
Brakes Comparison
Brand
Type Weight
Avid
Rim
157g
Avid BB7
Disc
342g
Gusset Chute Disc
400g
Hayes Stroker Disc
345g
$
$
$
$
Cost
33.00
79.00
62.96
279.99
Because the rim type brakes would require a large and complicated bracket to make work, they
are not feasible. Of the disc options, the Avid BB7 is the lightest, and a good value.
Figure 20. Avid Rim Brakes [9]
Figure 21. Avid BB7 Disc Brakes [9]
19
Seating
Moonbuggies in previous years have used nearly the same seating positions. The 2010, 2011,
and 2012 moonbuggies used folding seats whose bottoms were parallel to the ground and back
was slightly reclined. As seen in Figure 22. SIUC Moonbuggy, 2012
Photo credit: Lisa Dohn, the seat bottom is making contact only with the driver’s tailbone. This
issue induces driver fatigue and discomfort in a short period of time.
Figure 22. SIUC Moonbuggy, 2012
Photo credit: Lisa Dohn
To increase driver comfort and performance, recumbent bicycles use a reclined seating position,
with the seat bottom parallel to the driver’s buttocks. The seating position in Figure 23.
Recumbent Seating Position [17] increases rider support.
20
Figure 23. Recumbent Seating Position [17]
Contributing to rider discomfort in previous year’s moonbuggies was the seat material. The last
three moonbuggies have used cloth covered low density foam over a solid base. The one inch of
low density foam does not provide support necessary for the rider. It instead collapses under the
rider’s weight. In the end, the rider’s tail bone is in direct contact with the solid seat base.
The Rhode Island School of Design uses a carbon fiber seat which is formed to the contours of
the human body [18]. It therefore provides uniform support to the rider and increases the
comfort. The downside to the use of carbon fiber is cost. An alternative is to use a mesh covered
seat. Such a seat would provide the necessary support to the riders at a lower cost. Mesh would
also allow air to flow around the rider’s body, increasing ventilation and thereby comfort.
21
Figure 24. Rhode Island School of Design Seats [18]
Figure 25. Recumbent Mesh Seat [19]
22
Safety
Safety is a major concern at the moonbuggy competition. Occupants are required by rules to be
restrained onto the moonbuggy [20]. The theory is that this will be safer for the rider’s, but in the
event of a rollover, the restraints accomplish the opposite effect. Because the head is the highest
part of the buggy, when a moonbuggy rolls, the head is the first to hit the ground. As the
moonbuggy continues to roll, it is possible for the moonbuggy to land on the occupants. This has
resulted in serious injury.
Figure 26. Moonbuggy Crash [21]
23
Figure 27. Moonbuggy Rollover [21]
Figure 28. Crushed Riders [21]
24
Because the track of the moonbuggy cannot exceed four feet, the vehicle cannot be widened to
reduce the probability of a rollover [20]. Some actions, however, may be taken in order to
increase the safety of occupants. Firstly, the center of gravity may be lowered. This would reduce
the likelihood that the moonbuggy would tip over during a turn. One way to reduce the center of
gravity would be to adopt a more reclined seating position of the riders. Secondly, the
installation of a roll bar may be considered. A roll bar would be taller than the occupant’s heads,
so that in the event of a rollover, the roll bar would provide protection. Additionally, a roll bar
would make it impossible for the buggy to land on and injure the riders.
Conclusion
In order to avoid performance issues encountered by past moonbuggies, the moonbuggy should
be designed as a whole with each subsystem optimized to work with every other subsystem.
Adherence to proper techniques regarding use of components should also prove to increase
performance and reliability. Preliminary research shows that a moonbuggy built in this way will
be a good contender at competition.
25
Overall Project Description
The moonbuggy is a human powered, four wheeled vehicle that is designed and built to carry a
two person team around a 7/10 mile course. The team must consist of a male and female driver.
The entire moonbuggy must be able to fold and fit into a 4 ft3 volume. Prior to the race, the
drivers must lift and carry the folded buggy 20 feet. The course consists of 17 obstacles and
rough terrain that simulates the moon’s surface. The obstacles are made of large rocks, sand, and
gravel. Elevation changes throughout the course to the difficulty.
As shown in Figure 32 Block DiagramError! Reference source not found., the moonbuggy
design consists of five sub-systems: frame, suspension, drive train, steering, and ergonomics.
Figure 29. 2013 Moonbuggy Frame describes the frame design: a three rail, 4130 chromoly
space frame with 10° of layback. The frame must be as light as possible but strong enough to
provide a mounting point for the suspension and riders. The frame must also hinge to allow the
moonbuggy to fit in the required volume
Figure 29. 2013 Moonbuggy Frame
26
The suspension consists of an independent double wishbone design with unequal and nonparallel A-arms, and pushrod activated coil-over shock absorbers as shown in Figure 30. 2013
Moonbuggy Suspension. There will be 4 coil-over shock absorbers connected to each lower Aarm by a pushrod and rocker arm assembly. A pushrod actuated suspension allows for the 7 in.
of travel at the wheel with only 2.5 in. of shock travel. Mounting the shock absorbers inside the
frame reduces unspring vehicle weight which improves handling. The lower A-arm will be 4in.
longer than the upper to maintain stability throughout wheel travel. There will be 8° of caster and
-3° camber will which assists in turning and folding.
Figure 30. 2013 Moonbuggy Suspension
The moonbuggy will use a steering system which will be located under the seats. There will be a
handle on each side of the rider connected to the wheels by a linkage. The steering linkage will
insure both wheels turn simultaneously while maintaining proper steering geometry. To turn, the
driver will rotate the handles in the desired direction of turn. To increase the turning radius, the
riders may change the wheel camber by leaning into the turn causing the frame to pivot.
27
The drivetrain will consist of a pair of two-speed HammerSchmidt crank transmissions
connected to two tricycle style locking differential via a 1/8in. chain. Torque through the
differential will be transmitted to the wheels by a 3/4in splined shaft and two U-Joints per wheel.
Braking will be done through two front wheel mounted Avid BB7 mechanical disk brakes. The
driver will actuate the brakes via a handle mounted on the steering handle.
The ergonomics subsystem is comprised of the seats. Rider’s seats will be reclined 50°, allowing
greater rider comfort and performance. Integrated into each seat will be a roll bar capable of
supporting the driver’s weight in the event of a rollover.
Basis of Design
Below is a list of documents upon which this design is based. In the event of a conflict, the
Request for Proposal (RFP) will become the controlling document.
Table 4. Basis of Design
Document
Location
Date Retrieved
Request for Proposal (RFP)
Appendix D September 11, 2012
Competition Rules
Appendix B
October 31, 2012
Team #32 Moonbuggy Proposal
November 6, 2012
Team #32 Moonbuggy Literature Review
Page 2
October 4, 2012
Specifications

Folded dimensions must be less than 4x4x4 feet*

Target vehicle weight: 125 lbs.

Time around course: 4:00 minutes

Frame:
o Foldable frame with hinge and latch system
28

Assembly time of less than 15 seconds
o Must support forces from suspension and weight of riders


Combined weight of riders: 325 lbs.
Drivetrain:
o Must be capable of handling 1800 in-lbs. of torque
o Four wheel drive

Suspension:
o 10° layback
o 8° degrees caster
o -3° camber
o 7 inches travel
o Must withstand vertical force of 2.5 g’s on two wheels
o Must withstand horizontal 1.5 g’s and vertical 1.5g’s of force on two wheels

Steering:
o 30° swivel from center

Maximum turning radius must be 15 feet*
o Less than 5° bump steer through travel

Forward Facing Recumbent Seating:
o 50° seat recline
o Minimum rider height must be 15 inches above the ground*

Safety:
o Roll bars capable of holding a combine 500 pounds
o Lowered center of gravity to prevent tipping on slopes of 30°
o Automotive grade seatbelts*
o Braking system*

NASA Simulation Requirements*
o Video camera
o High gain antenna
o One cubic foot of enclose storage volume
o Fenders
* Dictated by Competition Rules
29
Technical Description
Frame
The purpose of the frame is to provide a mounting point for all other subsystems. The block
diagram, Figure 32 Block Diagram, describes how each subsystem relates to one another. The
frame must be lightweight, but strong enough to withstand forces from the suspension and
weight of the riders.
The frame will be a three rail, 4130 chromoly space frame design. The three rail frame is more
rigid than a single frame rail, and provides easier mounting. The frame rails will be 0.75in.
diameter tube with 0.049in. wall thickness. Frame reinforcement will come from 0.625in.
diameter tube with 0.035in. wall thickness. By loading the frame with the maximum theoretical
forces in Finite Element Analysis (FEA) software, the size and location of reinforcement tubes
can be determined. A hinge will allow the frame to fold.
Table 5. Frame Elements indicates the main elements which define the frame.
Table 5. Frame Elements
Elements
Front Frame
Rear Frame
Hinge Mechanism
Locking Mechanism
Quantity
1
1
1
1
List of Activities:
1.
2.
3.
4.
Obtain raw materials
Fabricate front frame
Fabricate rear frame
Fabricate hinge
30
5. Fabricate locking mechanism
6. Assemble frame
List of Deliverables:
1. Functional frame
2. FEA analysis of frame
3. Computer-Aided Design (CAD) renderings
Suspension
The purpose of the suspension is to maintain the contact between the wheels and the ground at
all times. Additionally, the suspension acts to reduce the forces felt by the riders while traversing
rough terrain.
The suspension consists of an independent double wishbone design with unequal and nonparallel a-arms. With a high travel suspension, suspension geometry becomes an important
consideration. An independent double wishbone design with unequal a-arms will provide
negative consistent camber throughout wheel travel, helping to maintain control over bumps.
Static caster and camber will be fully adjustable, allowing for steering adjustments. Non-parallel
a-arms provide a defined roll center. High travel will be gained through the use of pushrods,
rocker arms, and mountain bike coil-over shock absorbers.
Lower a-arms will be fabricated from 0.75in x 0.049in. wall 4130 chromoly tube. Upper a-arms
will be fabricated from 0.625in. x 0.58in. wall 4130 chromoly tube. A-arms will use 0.125in.
4130 chromoly tabs to mount to the upright.
31
The upright will be made of 0.05in. 4130 chromoly plate with a 2in. diameter tube to mount the
wheel bearings. Spherical bearings in the front a-arms will allow for turning and articulation. No
rod ends will be put in bending, and all mounts will be in double shear.
Suspension will be tested by analyzing components in FEA with maximum hypothetical forces
applied. Real world testing will be done over obstacles design to simulate the race course.
Performance will be analyzed and necessary changes will be made.
Table 6. Suspension Elements indicates the main elements which define the suspension.
Table 6. Suspension Elements
Elements
Manitou Swinger Shock
Rocker Arm
Pushrods
A-arms
Upright
Quantity
4
4
4
8
4
List of Activities:
1. Analyze components with FEA
2. Obtain raw materials and parts
3. Fabricate a-arms
4. Fabricate uprights
5. Fabricate rocker arms and pushrods
6. Assemble suspension
List of Deliverables:
1. Functional suspension
2. FEA analysis results
3. CAD renderings
Drivetrain
The purpose of the drivetrain is to transmit power from the rider to the wheels. Torque will be
routed from the riders to the differentials through chain. Torque at the differential will be
32
transferred through the driveshafts and stub axles to the wheels. Avid BB7 mechanical disc
brakes provide stopping force.
After reviewing previous competitor’s choices of transmissions, it was decided that more than
two speeds is unnecessary. The added complexity increases the chances for transmission failure.
Two correctly chosen speeds will provide excellent performance. The drivetrain will consist of
two HammerSchmidt crank transmissions. The HammerSchmidts have a system of planetary
gears contained within the sealed housing which yields either a 1:1 or a 1.6:1 overdrive gear
ratio. With the 1:1 gear set, when the pedal makes one revolution, the chainring makes one
revolution. In Overdrive, the chainring makes 1.6 revolutions for every revolution of the pedals.
Table 7. Transmission Comparison [2], [3], [4] compares different types of transmission options
and important information about each.
Table 7. Transmission Comparison [2], [3], [4]
Transmission Brand Speeds Cost (Per Unit) Torque Capability (ft•lb)
14
$1,000
210
Rohloff
7
$200
95.8
Nexus
2
$730
200
HammerSchmidt
The 2013 moonbuggy differential consists of two BMX freewheels bound together with a drive
gear between them as shown in Figure 6. Tricycle Differential
Photo credit: Ryan Schmidt. Torque is transferred into the freewheels by the drive gear. The
freewheels ensure that both wheels are turning at least the same speed as the drive gear, do but
allow for the wheels to spin faster. Because both wheels will turn at least the same speed
regardless of traction, the differential is said to be a locking type.
33
Driveshafts will consist of a 3/4in splined shaft. The splined shaft is the best choice due to the
fact that while transmitting torque, it may translate axially to allow for changing in distance
between the wheel and frame during suspension travel. Stub axles are to be machined from
1.25in. 4130 chromoly rod. There will be two Curtis 1.25in. U-joints per axle. A total of eight Ujoints are needed to allow power to be transmitted from the transmission and differential to the
wheels while the suspension is in motion.
The drivetrain will be tested before the race in race-like conditions. Gear rations will be analyzed
and necessary changes will be made.
Table 8. Drivetrain Elements indicates the main elements which define the drivetrain.
Table 8. Drivetrain Elements
Elements
Maxxis Minion Tires
DK Anodized Spokes
Woodman Components Bill-LTC Disc Hubs
Splined shaft
Splined Coupler
1.25" Curtis U-Joint
ACS FAT Freewheel 16t 3/16"
ACS FAT Freewheel 16t 3/16" Left
HammerSchmidt FR Crankset
Gusset Squire Chain Tensioner
HammerSchmidt BB 68/73mm FR
HammerSchmidt Trigger Shifter
Avid BB7 Disc Brake
Timken Wheel Bearing
Quantity
4
144
4
1
4
8
2
2
2
2
2
2
2
8
List of Activities
1. Obtain drivetrain elements
2. Turn U-joints to accommodate splined shaft, and assemble driveshafts
3. Assemble differentials
34
4. Assemble wheels and mount tires
5. Machine stub axles
6. Mount differentials and pedals
List of Deliverables:
1. Functional drivetrain
2. Fatigue and stress calculations
3. CAD renderings
Steering
The purpose of the steering system is to translate driver inputs to rotation at the front wheels,
resulting in a change in the moonbuggy’s direction. The moonbuggy is to have an under seat
steering system. In this system, handlebars will be below the front seat which will save space
and be more comfortable. In addition, the moonbuggy is to have a pivotal steering system. By
leaning in to the turn, the riders will cause the frame to pivot resulting in a camber change at the
wheels. This camber change will help the moonbuggy turn more tightly.
The steering system must enable the moonbuggy to turn within a 15ft. radius. The steering
geometry must remain constant throughout the suspension travel. A common fault of many
moonbuggies is bump steer. Bump steer takes place when the wheels turn without driver input
over a bump due to the geometry of the steering. The 2013 SIUC moonbuggy is to have less than
5° bump steer throughout the suspension range.
Real world testing will be completed in race like conditions. Steering geometry over obstacles
will be analyzed and necessary changes will be made.
Table 9. Steering Elements indicates the main elements which define the steering system.
35
Table 9. Steering Elements
Elements
Handlebars
Steering Cam
Tie Rods
Quantity
2
1
2
List of Activities
1.
2.
3.
4.
Confirm dimensions and geometry
Obtain elements
Fabricate steering cam and handle bars
Assemble linkages
List of Deliverables:
1. Functional steering system
2. Steering geometry specifications
3. CAD renderings
Ergonomics
The purpose of the ergonomics subsystem is to provide a safe, comfortable, and efficient seat for
the drivers to operate the moonbuggy. The moonbuggy will have two forward facing seats with
the front being the driver’s seat.
Previous moonbuggy seats have not been designed to support the rider during the race. This
causes rider discomfort and reduces the amount of power the rider is able to transmit to the
pedals. The 2013 SIUC moonbuggy will have recumbent style seating. These seats are defined
by a reclined position with contours to support the upper and lower body. Seat recline will be
50°.
36
Seat frames will be fabricated from 0.75in. diameter 4130 tubing. The seat back will fold at the
base so as to remain within the 4ft3 folded volume. Support will be provided by breathable mesh
cloth which will be secured to the seat frame. To aid in safety, the seat back will serve as a roll
bar. The roll bar will prevent rider injury in the event of a roll over by providing a rigid structure
over the rider’s heads. The roll bars will be able to support 500lbs; the combined weight of the
moonbuggy and riders.
Seat backs will be loaded with 300lbs each in FEA software to ensure they can withstand the
load of the moonbuggy. Real world testing will accomplished using weight to ensure safe roll
over protection.
Table 10. Ergonomics Elements indicates the main elements which define the steering system.
Table 10. Ergonomics Elements
Elements
Lower Seat Frame
Upper Seat Frame/Rollbar
Seat Mesh
Quantity
2
2
2
List of Activities:
1. Confirm seat design
2. Obtain raw materials
3. Fabricate upper and lower seat frames
4. Wrap seats in mesh cloth
List of Deliverables:
1. Functional seats and roll bars
2. FEA results
3. CAD renderings
Contract Pricing
The Saluki Engineering Company hereby offers to do the work defined in this proposal for the
cost-plus-fixed-fee price of ten thousand dollars ($10,000.00).
37
38
Resources and Parts List
Table 11. Cost Proposal
2012 SIUC Moonbuggy Cost Proposal
Item
4130 Tubing (Frame) 6ft Length
4130 Tubing 0.75 x 0.035 (suspension) 6ft Length
4130 Tubing 0.75 x 0.049 (suspension) 6ft Length
4130 Sheet 12x12 (0.080)
4130 Sheet 12x12 (0.125)
4130 Tubing (Upright) 2ft Length
4130 Tubing 0.750x0.065 (Pushrods) 6ft Length
4130 Tubing 0.625x 0.058 (A-Arm/Steering) 6ft
Stub Axle 1.25" bar 3ft length
Diff Axle 1.75" Bar 2ft Length
4130 Tubing 1.375x0.065 (Driveshaft) 6ft Length
Diff Aluminum Plate 8"x8"x0.5" thick
Rocker Arm Aluminum 8"x8"x0.25" thick
Splined shaft
Splined Coupler
Bronze Flanged Sleeve Bearing (A-Arm)
1.25" Curtis U-Joint
Timken Bearing
HammerSchmidt FR Crankset
Gusset Squire Chain Tensioner
HammerSchmidt BB 68/73mm FR
Hammerschmidt Trigger Shifter
Truvativ HammerSchmidt Grease
Truvativ GXP BB Installation Tool
Truvativ ISIS Drive BB Installation Tool
Bottom Bracket Shell
ISCG Mount
Truvativ Hussefelt Pedals
Avid BB7 Disc Brake Calipers
Echo TR 26 Rear Rims 32h Black
DK Anodized Spokes
Woodman Components Bill-LTC Disc Hubs
Maxxis Minion Tires
Manitou Swinger Shock
FK Spherical bearing Cup
FK Spherical bearing
1/2" to 3/8" High Misalignment Spacer
Sprocket
Quantity
7
4
6
4
4
1
1
2
1
1
1
2
8
1
4
24
8
8
2
2
2
2
1
1
1
2
2
2
2
4
144
4
4
4
4
4
4
6
Part Number
A 1C25-75002
A 1C26-75012
6338K463
2456K17
32005-x
100035347
100092474
100035352
100035356
100095029
62182JB
822051010582
BB2007
MS2010
100069955
100048298
100079943
100060066
CP8
FKS8
8-6HB
2299K28
Unit Price
$
28.53
$
25.73
$
26.52
$
21.16
$
24.23
$ 114.84
$
27.11
$
29.98
$
44.42
$
52.62
$
40.19
$
19.76
$
9.18
$
31.12
$
32.50
$
1.38
$
59.25
$
15.95
$ 730.00
$
35.96
$
62.00
$ 132.00
$
22.00
$
29.14
$
20.00
$
6.46
$
8.12
$
65.00
$
63.20
$
40.00
$
0.54
$
44.96
$
68.00
$
99.95
$
9.95
$
$
$
5.95
8.95
20.66
Total Price
$ 199.71
$ 102.92
$ 159.12
$
84.64
$
96.92
$ 114.84
$
27.11
$
59.96
$
44.42
$
52.62
$
40.19
$
39.52
$
73.44
$
31.12
$ 130.00
$
33.12
$ 474.00
$ 127.60
$ 1,460.00
$
71.92
$ 124.00
$ 264.00
$
22.00
$
29.14
$
20.00
$
12.92
$
16.24
$ 130.00
$ 126.40
$ 160.00
$
77.76
$ 179.84
$ 272.00
$ 399.80
$
39.80
$
23.80
$
35.80
$ 123.96
39
ACS FAT Freewheel 16t 3/16"
ACS FAT Freewheel 16t 3/16" Left
Sunlite Double Brake Lever
FK Rod Ends (Pushrod) 3/8"
FK Rod Ends (Pushrod) 3/8"
FK Jam Nuts 3/8 R
FK Jam Nuts 3/8 L
FK Weld In Bung (Pushrod) 3/8" L
FK Weld In Bung (Pushrod) 3/8" R
Safety Washer (Pushrod) 3/8"
FK Rod End 5/16" (A-Arm)
FK Weld In Bung 5/16 (A-Arm)
Safety Washer 5/16 (A-Arm)
FK Jam Nuts 5/16 R
FK Rod End 5/16" R (Steering)
FK Rod End 5/16" L (Steering)
FK Weld In Bung 5/16 R (Steering)
FK Weld In Bung 5/16 L (Steering)
FK Jam Nuts 5/16 R
FK Jam Nuts 5/16 L
Safety Washer 5/16 (Steering)
Miscellaneous*
2
2
1
4
4
4
4
4
4
16
8
8
16
8
2
2
2
2
2
2
8
1
18614JB
125766
13748
ALJM6
ALJML6
ALJMRO6
ALJNLO6
1504L
1504
MEZ-SW38L
FKB-ALJM5
FKB-1303
MEZ-SW-51L
AJNRO5
FKB-ALJM5
FKB-ALJML5
FKB-1303
FKB-1303L
AJNRO5
AJNLO5
MEZ-SW-51L
-
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
17.99
18.68
15.00
9.95
9.95
0.75
0.75
4.95
4.95
2.15
8.95
3.95
2.15
0.50
8.95
8.95
3.95
3.95
0.50
0.50
2.15
700.00
Total:
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
35.98
37.36
15.00
39.80
39.80
3.00
3.00
19.80
19.80
34.40
71.60
31.60
34.40
4.00
17.90
17.90
7.90
7.90
1.00
1.00
17.20
700.00
$ 6,640.97
*Miscellaneous denotes general components including fasteners, paint, fiberglass, welding
materials, specialized tools, and other small parts.
Validity Statement
This proposal is valid for a period of thirty days from the date of proposal. After this time, Saluki
Engineering Co. reserves the right to review it and determine if any modification is needed.
40
Project Organization Chart
Figure 31. Project Organization Chart
The project organization chart describes the division of labor between subsystems.
41
Action Item List
Table 12. Action Item List
Project: Moonbuggy
Action Item List
Sec Ref #: F12-32-MOON
Date:
5-Nov-12
Team Members:
Ryan Schmidt
Caleb McGee
Dylan Sartin
Nick Sager
Dan Rogers
#
Activity
Person
Assigned
Due
1
Verify Frame and Suspension Specifications
Verify Parts List and Order Components
Finalize Suspension Design
Finalize Frame Design
Fabricate A-Arms
Finalize Steering Design
Finalize Drivetrain Design
Fabricate Uprights
Commence Basic Frame Fabrication
Water Jet Suspension Tabs
Commence Drivetrain Fabrication
Commence Steering Fabrication
Commence Seat and Roll Bar Fabrication
Final Frame Fabrication
Assemble Moonbuggy
Full Systems Testing
Competition
DR
DS
NS
CM
RS
NS
DR
RS
CM
DS
DR
NS
DS
CM
ALL
ALL
ALL
14-Jan
14-Jan
14-Jan
14-Jan
14-Jan
21-Jan
21-Jan
21-Jan
21-Jan
21-Jan
4-Feb
11-Feb
18-Feb
25-Feb
4-Mar
11-Mar
21-Jan
21-Jan
21-Jan
21-Jan
21-Jan
28-Jan
28-Jan
4-Feb
4-Feb
28-Jan
18-Feb
18-Feb
4-Mar
4-Mar
11-Mar
15-Apr
25-Apr
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
New Due
Status
Comments
42
Timeline
Table 13. Timeline
43
References
[1] McMaster-Carr. (n.d.). Retrieved September 28, 2012, from http://www.mcmaster.com
[2] Shimano. (n.d.). Retrieved October 2, 2012, from http://
www.shimano.com/publish/content/global_cycle/en/us/index/products/0/nexus.html
[3] Rohloff. (n.d.). Retrieved September 25, 2012, from
http://www.rohloff.de/en/products/speedhub
[4] Competetive Cyclist. (n.d.). Retrieved September 25, 2012, from
http;//www.competitivecyclist.com/review-cranksets-chainrings/truvativhammerschmidt_920.html
[5] Trikes and (Odd) Bikes. (2010, September 6). Retrieved October 16, 2012, from http://pedaltrikes.blogspot.com/2010/09/higgins-with-differential.html
[6] Stock Drive Products/ Sterling Instrument. (n.d.). Retrieved October 16, 2012, from
http://sdp-si.com/web/html/newprdshafts2.htm
[7] Smith, C. (1978). Tune to Win. Fellbrook: Aero Publishers, INC.
[8] Küҫükay, P. D.-I. (2011, August 3). Chassis Construction. Braunschweig, Niedersachsen,
Deutschland: Institut für Fahrzeugtechnik.
[9] Cambria Bike. (n.d.). Retrieved September 30, 2012, from http://www.cambriabike.com
[10] Maserati, E. (n.d.). The Chubasco. Retrieved September 30, 2012, from
http://www.maserati-alfieri.co.uk/maser15.htm
[11] Blumer, K. (2009, April). Off-Road. Retrieved September 29, 2012, from http://www.offroadweb.com/tech/0904or_camburg_ford_ranger_long_travel_kit
[12] OSS Recumbent Bicycles. (n.d.). Retrieved September 28, 2012, from http://www.bicycleand-bikes.com/oss-recumbent-bicycles.html
[14] Pain Free Cycling. (n.d.). Retrieved October 2, 2012, from
http://mikenv.hubpages.com/hub/Pain-Free-Cycling-The-5-Coolest-Bicycles
[15] CarvX. (n.d.). Retrieved October 1, 2012, from http://onooke.blogspot.com/2012/02/sepedaroda-empat-carvx.html
[16] Gunton, N. (n.d.). The Art of Bicycle Touring. Retrieved September 27, 2012, from
http://www.crazyguyonabike.com/doc/page/?page_id=8174
[17] Word Press. (n.d.). Retrieved October 1, 2012, from
http://wordsnax.files.wordpress.com/2009/10/recumbent-bike3.jpg%3Fw%3D500
[18] RISD Moon Buggy. (2011, May). Retrieved September 28, 2012, from
http://risdmoonbuggy0910.blogspot.com/
44
[19] Prebble, T. (2010, December 14). Recumbent Bicycles. Retrieved September 27, 2012, from
http://rbr.info/community/blog/14-travis/14952-not-meshing-with-your-challenge-trikeseat.html
[20] NASA Great Moonbuggy Race. (n.d.). Retrieved October 3, 2012, from
http://moonbuggy.msfc.nasa.gov/
[21] NASA/MSFc. (n.d.). Flickr. Retrieved October 3, 2012, from http://www.flickr.com
45
Appendix A
Resumes
Caleb McGee
caleb.mcgee@gmail.com
1611 Sara Lane
Carterville, IL
62918
(618)-201-8187
Education
Southern Illinois University Carbondale: SIUC
Graduate: May 2013
Bachelor of Science in Mechanical Engineering, Minor in Mathematics
GPA: 3.97/4.0
Employment
Intelligent Measurement and Evaluation Laboratory: SIUC
Aug. 2011-Present
Undergraduate Research Assistant
 Performed research in nondestructive evaluation (NDE) of composite, carbon/carbon, and
conventional materials using immersion ultrasound, air-coupled ultrasound, and infrared
thermography.
 Used NDE and Finite Element Analysis methods to complete research projects for the
Center for Advanced Friction Studies at SIUC and Emersion Inc.
Center for Embedded Systems: SIUC
May 2012-Present
Undergraduate Research Assistant
 Conducted research work for United Technologies and General Dynamics to solve design
problems using Finite Element Analysis and Computational Fluid Dynamics computer
simulation methods.
Department of Mathematics: SIUC
Spring 2011
Tutor

Tutored engineering students in mathematics relating to calculus and differential
equations.
Computer Skills




Finite Element Analysis (ANSYS Workbench, Fluent)
Computer Aided Drafting (AutoCAD, Autodesk Inventor, SolidWorks, Creo)
Computer programming: (C++, Java, Matlab)
Microsoft Office Suite
Leadership and Involvement


Vice President, SIUC NDE, 2012-Present
Records Officer, SIUC Moonbuggy Design Team, 2012-Present
46





Treasurer, SIUC Moonbuggy Design Team, 2011-12
President, SIUC Moonbuggy Design Team, 2010-11
Member, American Society for Nondestructive Testing, 2010-Present
Member, Engineering Student Council, 2009-Present
Member, American Society of Mechanical Engineers, 2009-Present
Honors and Awards








American Society for Nondestructive Testing Engineering Undergraduate Award, 2012
SIUC College of Engineering Dean’s List, Fall 2009 - Fall 2012
Aisin Manufacturing, LLC Scholarship 2011, 2012
Donald and Verl Free Scholarship, 2010
Tau Beta Pi Honors Society, 2010
Dr. and Mrs. Thomas B. Jefferson Scholarship, 2009
Alpha Lambda Delta Honors Society, 2009
Valedictorian Scholarship, 2009
Volunteer Work



Sound Booth Technician
Tau Beta Pi community service projects
Engineering Day hosted by Engineering Student Counsel
47
Daniel Michael Rogers
618 East Campus Dr., Apt. A  Carbondale, IL  (815) 263-1206  drogers1188@yahoo.com
Targeting a career in Mechanical Engineering

Upcoming Southern Illinois University graduate in May 2013 offering a strong academic
background with internship experience.

Looking forward to an opportunity to utilize my engineering education and expand my hands-on
experience by working in areas of mechanical engineering.
EDUCATION
Southern Illinois University – Carbondale, IL
Bachelor of Science, Mechanical Engineering
Related Coursework:
-Calculus and analytic geometry I, II, III
-Thermodynamics I & II
-Engineering Economics
Degree expected 5/13
-Hydraulics and Pneumatics
-Autodesk Inventor/ FEA simulation
-AutoCAD
-President of Disney College Program Campus Rep team
- Vice President of Southern Illinois University Moonbuggy design team
Kankakee Community College, Kankakee, IL
Associate Degree in Engineering Sciences
2007 to 2009
PROFESSIONAL EXPERIENCE
Internship – The Walt Disney Company
Orlando, FL
January to May 2010

I was part of a team of attractions hosts working with tens of thousands of people daily. Our
mission was to please our guests by going above and beyond everybody’s expectations.

Coordinated with the engineering services team to inspect the parade floats to insure integrity,
reliability, and safety.

I continue as Disney’s College Program Lead Campus Representative at SIU.
Summer Internship – Simon Wong Engineering
San Diego, CA
May to August 2007

I worked with professional civil engineers on various projects, including bridges, concrete water
tanks, and train stations for the Sprinter Rail Project – a new 30-mile electric trolley system.

In the office, I was involved in working with: AutoCAD drafting, product estimation, determining
concrete quantities, and correcting record drawings. Also, I worked with the field as part of the
construction management team.
EMPLOYMENT HISTORY
Server and Bartender, Buffalo Wild Wings
September 2007 to present
Bradley, IL and Carbondale, IL
Produce Clerk/Utility Clerk, Kroger Food Stores
August 2005 to September 2007
Bourbonnais, IL
AVAILABLE FOR RELOCATION & TRAVEL
References Available Upon Request.
48
Dylan A. Sartin
1146 7th Street
West Des Moines, IA 50265
(515) 664-1396
dylansartin@yahoo.com
Objective:
To obtain full-time employment as an entry level Mechanical Engineer.
Education:
Southern Illinois University Carbondale 62901
College of Engineering June 2010-May 2013
Major: Mechanical Engineering
Minor: Mathematics
Skills:
 Microsoft Office
 Autodesk Inventor Professional
 JMP
Work Experience:
SIU Craft Shop: July 2010-Present
 Assisted with sales and customer services
 Maintained the wood shop as well as assisted individuals with woodworking
projects
United Parcel Service: February 2007-May 2010
 Loaded and unloaded packages into outgoing or incoming vehicles.
 Sorted packages to their respective destination hubs.
 Trained new employees to execute the work correctly.
Lowes Home Improvement: May 2009-December 2009
 Assisted with sales and customer services
 Forklift and Sidewinder operator
 Lumber sales and assistance
Extra-Curricular Activities:
SIUC Moon Buggy Team
Design and manufacturing of a Moonbuggy to compete in the NASA sponsored 2013
Moonbuggy Race.
*References available upon request*
49
Nicholas Sager
12402 N. Sparrow Ln.
Mt. Vernon, IL 62864
(618) 316-3028
sager09@siu.edu
Education
Southern Illinois University Carbondale, May 2013
Bachelors of Science in Mechanical Engineering
Minor: Mathematics
GPA: 3.665/4.0
Dean’s list: Fall 2009, Spring 2010, Fall 2010, Fall 2011, Spring 2012
Relevant Skills
 Experience with Auto Cad, Microsoft Office, Matlab
Work Experience
 Internship at GE Aviation as process engineer for commercial and military,
turbine stator manufacturing for CF-34, CF-6, GE-90, CFM, and F414 engines
 Internship at TU Braunschweig, Germany
MAMINA Research Training with Titanium Alloys under Dr. Siemers
 SIUC Engineering Peer Mentor
 Assistant Manager at Mt. Vernon Recreational Center
 Lifeguard at Mt. Vernon Recreational Center
2012
2011
2010-2011
2011
2006-2011
Research
 Titanium Alloys for Vehicle Exhaust Systems
 Created a new titanium alloy that was lighter and less corroded by heat than the current alloy
used in exhaust systems with Dr. Siemers
Activities
 SIUC Moonbuggy Club Treasurer
2012-Present
 Tau Beta Pi Engineering Honor Society Member
2011-Present
 Up ‘til Dawn Executive Board Recruitment Chairman
2010, 2012-Present
 American Society of Mechanical Engineers Member
2009-Present
 Phi Kappa Tau Fraternity Inc. Secretary
2010
 SIUC Student Ambassador to the University of International
Business and Economics (UIBE) of Beijing, China
2010
 SIUC Research Rookie
2009-2010
 SIUC Leadership Council
2009-2010
 Alpha Lambda Delta Freshman Honor Society Member
2009
Awards and Honors
 Presidential Scholarship SIUC
 Southern Illinois University College of Engineering Honors Student Award
 Member of Southern Illinois University’s Honors Program
 Graduate of The Business Chinese Summer Camp of the University of International Business and
Economics of Beijing, China
Volunteerism and Philanthropy
 GE Volunteers Madisonville, KY-volunteered doing maintenance at local YMCA
2012
 Volunteer for City Lights in St. Louis, MO
Assisted in the creation of an urban farm for refugees in St. Louis
2012
 Up ‘Till Dawn Executive Board $94,000 raised for St. Jude Children’s Hospital
2010-2011
50
Ryan Schmidt
Permanent Address: 105 Arbor Dr., Carterville, IL 62918
618-534-2224 ● Email: ryanschmidt@siu.edu
Education
Southern Illinois University
Majoring in Mechanical Engineering
Minoring in Mathematics
Current GPA: 3.935/4.0
Carbondale
May 2013
Honors
Dean’s List: Fall 2009, Spring 2010, Fall 2010, Spring 2011, Fall 2011, Spring 2012
Valedictorian Scholarship, 2010
Robert C. Byrd Scholarship, 2009-2011
College of Engineering Scholarship, 2011
Experience
Office Clerk
Brandon Schmidt & Goffinet, Attorneys at Law
Carbondale, Il
2010 to Present
 Responsible for organizing and filing correspondence.
 Responsible for transporting trial exhibits.
Engineering Internship Abroad
Germany
2011
Technische Universität Braunschweig
 MAMINA Research Training with Titanium Alloys under the direction of Carsten Siemers.
Tasked to create a titanium alloy which was suitable for use in automotive exhaust systems, thereby reducing
vehicle weight. Titanium alloy samples were subjected to high heat for varying amounts of time. Samples were
prepared and their grain structures and oxidation layers were examined under a microscope.
 Automotive Engineering course including instruction in chassis design, suspension design, driving dynamics,
drivetrain, hybrid technologies, aerodynamics, transmissions, etc.
Extracurricular Activities
Tau Beta Pi Member
Moonbuggy Team President, Design Leader
Senior Capstone Project Manager
American Society of Mechanical Engineers Member
Instrument Rated Private Pilot
2008
Airplane Owners and Pilots Association Member
Building and Driving High Performance Cars
 Built a 1966 GT40 replica, 1965 Shelby GT350 (ground up restoration) and 1966 Shelby Cobra 427SC replica. Drove
the Shelby Cobra 427SC at Putnam Park, 2009 and Gateway International Speedway 2007, 2008.
Technical Skills
Welding TIG, stick, and oxy-acetylene
Microsoft Word; Microsoft Publisher; Microsoft Excel; Microsoft PowerPoint
Pro/Engineer Wildfire 4.0; Creo Elements
51
Appendix B
Competition Rules
NASA’s Great Moonbuggy Race has set rules and regulations to provide a safe as well as fair
competition for all teams. These rules and regulations may be divided into the sections of
Construction Guidelines, Passenger Requirements, Penalties and Disqualification, and the Code
of Conduct for all participants.
Construction Guidelines:
Any infractions may be subject to penalties or disqualification as listed in the “Penalties and
Disqualification” Section.
1. Moonbuggy Teams- each moonbuggy must be the combined work of a student team,
either from a high school or an accredited center for higher learning. However an
exception may be made if a group of high schools may work in collaboration toward a
moonbuggy entry. High school teams are considered those teams predominantly
comprised of students under age 19. University teams are considered those predominantly
comprised of students age 19 and older. Each team must be accompanied by an adult age
21 or over to serve as mentor and/ or advisor.
2. Propulsion System- must be human powered. Energy storage devices, such as springs,
flywheels or others are not allowed.
3. Collapsed Dimensions- assembly judging of the moonbuggy is conducted before any
other testing. The vehicle when collapsed must fit into a 4’× 4’ × 4’ cubic volume, or
penalization shall occur. A frame of the desired volume will be placed over the collapsed
vehicle to ensure it meets specifications. Straps, tape, or other such securing elements
may be used, but must be part of the vehicles final design.
52
4. Weight Consideration- the vehicle must have the ability to be lifted and carried 20 feet
by the two passengers, without aid of any sort (e.g., no wheels) in the unassembled 4’× 4’
× 4’ volume collapsed state. No ground contact is permitted while being carried.
5. Assembled Dimensions- the maximum width of the assembled vehicle, with riders
onboard, is four (4) feet, including wheels and other assembly elements. There are no
constraints for height and length of the assembled vehicle.
6. Vehicles must be constructed by the entering team. Moonbuggies that have been
previously entered into the race should contain modifications that attempt to improve on
design and performance. Students are expected to design, construct, and test their own
buggies. The buggy drivers chosen from each team should be involved in these activities.
7. There are no constraints to the means of contact between the buggy and the simulated
lunar surface during the race. Creativity is encouraged as long as it meets all other
guidelines.
8. The lowest surface of the moonbuggy, including the riders, must be at least 15 inches
(38.1 cm) above the ground when the buggy is at rest on a level surface and with riders
onboard. In the case of the pedals and steering controls, that measurement is to be made
when that part is in the lowest position possible position after assembly.
9. The vehicle must have a turning radius of 15ft or less.
10. For safety reasons, it is recommended that the center of gravity of the “vehicle plus
passengers" be low enough to safely handle slopes of 30o front-to-back and side-to-side.
Any handling or vehicle dynamics that may be 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 by specified judges. Any
moonbuggy that is judged to have become unsafe while racing or passengers who are
53
found to be injured or bleeding can be disqualified from that race attempt and removed
from the course as well.
11. Each vehicle must have seat restraints for each of the two passengers. The restraints must
be worn during runs of the course to help prevent mishaps and increase safety. A
moonbuggy can be stopped by a race official if either rider is not secured by a seat
restraint and held stopped until the required restraint(s) are firmly in place, except when
rider(s) are freeing their buggy from being stuck on an obstacle. The restraints must be
capable of preventing the riders from being thrown from their seats should the buggy be
forced to a sudden stop. The preferred method of restraint is a motor vehicle seat belt. If
the pre-race safety judge determines the restraints are inadequate to perform that
function, then the team will not be allowed to run the course in that unsafe condition.
12. All sharp edges, surfaces, and protrusions must be eliminated (i.e., padded) or guarded as
necessary to the satisfaction of the judges.
13. The vehicle must be equipped with a simulated high gain antenna, other simulated
equipment, fenders, and a flag. The high gain antenna must be approximately circular in
shape and no less than 24 inches in diameter. The other simulated equipment are a TV
camera, two batteries and an electronic control panel (radio, display, buggy
controls), together totaling no less than 1ft3 volume in one or more boxes. These
equipment items can be functional, not just simulated, but must still meet the minimum
total volume requirement. A fender must be placed over each wheel. The flag must be a
national or institution flag and be visible from the front, from the side, or from the rear.
The presence and size requirements for all components will be checked prior to each race
attempt on the course. The presence of all components will be checked after successful
completion of all race attempts on the course.
14. Backing up is not required but can be useful and is recommended.
54
15. Vehicles that do not satisfy the intent or goals of the moonbuggy competition can be
disqualified.
16. Only vehicles registered for the competition will be allowed in the pits area during testing
or other elements of the competition.
17. Brakes must be present to help ensure the ability to safely stop or slow down the vehicle.
18. Appropriate protective equipment, gear, and clothing are required when engaged in a
construction activity such as welding or any other activity where the participants are
subject to danger.
19. Race officials will continue to assign moonbuggy team numbers on two printed 8.5 inch
x 11 inch sheets of paper, along with clear plastic sheet-protectors in each team's race
packet that can be affixed to their moonbuggy. Teams have the option to design a method
to affix the assigned number to their moonbuggy. The method must allow the number to
be displayed on the front and left side (port-side as for a boat) of the moonbuggy. The
number display must use a font size that is at least 5.5 inches (14 cm) in height and 4
inches (10.2 cm) in width. Numbers must be black on a white background, easily
readable, and conform to all safety requirements. However attached, the moonbuggy
number is part of the vehicle and subject to all rules pertaining to the vehicle. **Note that
the "race order number" and the "assigned number" for a moonbuggy are the same, but
will not be assigned until March.
Passenger Requirements:
Any infractions may be subject to penalties or disqualification listed in the “Penalties and
Disqualification” Section.
1. Moonbuggy Passengers- two (2) student team members (one female and one male) must
propel the moonbuggy over the course.
55
2. Eye protection (e.g., safety glasses, goggles, or face shield), head protection (a bicycle
helmet), and appropriate clothing must be worn during operation of the moonbuggy.
Shoes are required. Although at the discretion of adult riders, adult supervisors, and
parents of minors, it is recommended that clothing providing some protection against cuts
and abrasion be worn (e.g., long sleeved and long torso shirts, long pants, and socks), but
is not required because they may cause additional problems such as being caught between
gears and other moving parts.
3. No appendages such as stilts may be used on the feet of the moonbuggy passengers.
4. Pushing the moonbuggy with a pole or other prop is not allowed. A rider’s use of their
hands on the wheels to rock or otherwise facilitate moving the moonbuggy is permitted.
5. 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.
6. Only clipless style pedals require compatible and interlocking cleat-style shoes. Standard
size pedals that include cleat-style clips do not have to be matched with cleat-style shoes
for running the race. The feet of both riders must be on the pedals at the end of the timed
assembly, but do not need to be engaged with any included restraints. In addition, riders
and buggies are expected to be fully ready to race on the course, including helmets, full
fingered gloves, goggles, and attached seatbelts to complete the timed assembly exercise.
Each team will be required to develop a “Signal System” between the two riders to
ensure hands are clear of the chain. They will be asked to describe their communication
plan to the Marshall Safety Action Team (MSAT) member and/or the Starter prior to the
race.
7.
Driving moonbuggies in the parking lot in a reckless or unsafe manner is not acceptable.
Penalties and Disqualification:
56
Penalties may be incurred for the following infractionsPre-Race (0:30 seconds each):
1. Dust Abatement (Fenders)
2. High Gain Antennae (must be greater than or equal to 24 inches)
3. National or Institution Flag
4. TV Camera
5. Battery # 1
6. Battery # 2
7. Electronic Control Panel
8. The total volume of Items #5-7 must be no less than 1’ × 1’ × 1’ (1 cubic foot).
The Pre-Race specifications are listed in the Construction Guideline #13.
Assembly (2:00 minutes each):
1. Carry requirement (Construction Guideline #1)
2. Collapsed Configuration 4'x4'x4' volume requirement (Construction Guideline #3)
3. Assembled width (4') requirement (Construction Guideline #5)
4. 15" clearance requirement (Construction Guideline #8)
Post-Race Condition (0:30 seconds each):
1. Dust abatement (fenders), high gain antenna, national or institution flag, batteries #1 and
#2, TV Camera, Electronic Control Panel must be in place as in the pre-race condition.
Disqualification:
1. Passenger requirement (Passenger Requirement #1)
2. Missing an obstacle
3. Safety Disqualification (Judges' discretion)
During the Race:
1. Obstacle (1-15) penalties, penalty range 0 sec. to 2 minutes
57
2. Passenger/ground, course contact penalties, 0 sec. to 2 minutes of standard penalty
3. 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.
Pre/Post Race:
1. The vehicle must be equipped with a simulated high gain antenna, other simulated
equipment, fenders, and a flag. The high gain antenna must be approximately circular in
shape and no less than 24 inches in diameter. The other simulated equipment are a TV
camera, two batteries and an electronic control panel (radio, display, buggy
controls), together totaling no less than 1ft3in volume in one or more boxes. These
equipment items can be functional, not just simulated, but must still meet the minimum
total volume requirement. A fender (moon dust abatement device) must be placed over
each wheel. The flag must be a national or institution flag and be visible from the front,
from the side, or from the rear. The presence and size requirements for all components
will be checked prior to each race attempt on the course. The presence of all components
will be checked after successful completion of all race attempts on the course - 0:30 sec
each.
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 in writing to
Scorekeeping Lead in the scoring area within 30 minutes of the posting of the score in question.
The final decision of the Race Director shall prevail.
58
Code of Conduct
Committee members who administer the planning and operation of the Great Moonbuggy Race
strive to conduct themselves in a professional manner. We ask the same from each of the
participants. All faculty members, team members, team supporters, judges and officials are to
conduct themselves responsibly and respectfully throughout the Great Moonbuggy Race.
Anyone not doing so will be requested to leave the U S Space & Rocket Center grounds.
59
Appendix C
Block Diagram
Figure 32 Block Diagram
60
Appendix D
Request for Proposal
61
62
63
64
65
66
67