The Auto Crash Case Study #3
The Egg Mobile
“Ted and Angelina’s Eggsellent Adventure”
Northern Highlands Regional High School
Applied Technology Department
Real World Engineering
List Design/Build Engineering Team Members
Name of Engineering Firm
Date
Instructor- Mr. Mugno
Scenario
The national Automobile Underwriter’s Insurance
Association is very concerned about the number of
accidents that are occurring and the amount of money the
insurance companies must payout to their policy holders
for bodily injuries received during automobile accidents
The automobile manufacturers are now forced to design
and build a safer vehicle and have asked engineering
firms to submit prototypes for improving auto safety.
Your engineering firm is required to design a better
energy absorbing crumple zone system and a better seat
restraint system for protecting the occupants in the
vehicle.
Statement of the Problem
The problem we had to solve was to design, build and
test an energy absorbing crumple zone and seat
restraint system in a vehicle that would allow the
occupants to survive without injury in the event of a
head on collision.
Design Criteria
Build a test vehicle that will remain intact during a head on crash.
Develop and build a crumple zone system that will absorb enough
energy to allow occupants to survive a head on crash without injury.
The crumple zone will increase the time that the vehicle is moving
until it reaches a complete stop.
The crumple zone will absorb energy and reduce the force of some
impact to the occupants.
Develop and build a seat restraint system that will keep the occupants
in their seat and uninjured during a head on crash.
The test vehicles design should simulate a real automobile as much as
possible.
The test vehicle must hold two occupants
The occupants will be two fresh large, Grade A, raw chicken eggs.
The seats and seat restraint safety system must be designed so that the
occupants can be placed in and removed easily.
Design Constraints
You must use only the materials supplied by the teacher to
construct the test vehicles frame, Top (body). You will build 3
car frames to specs and test each on the ramp.
Supplies for the seat restraint systems and crumple zone systems
must be brought in by group members.
The energy absorbing crumple zone system may not extend out
in front of the test vehicle’s body It must be contained within the
dimensions of the test vehicles body (cannot be longer than 8”).
All safety systems must be constructed by the design build team.
The test vehicles occupants must have clear visibility out of all
windows (180 degrees from left to right). You may not stuff the
interior with material
All safety systems must be constructed in the interior of the test
vehicle’s body (shell).
The occupants cannot be altered in any way.
The occupants cannot be glued into their seats.
Possible Solutions
Energy Absorbing Crumple Zone System
Hypothesis -How it will work?
Tested Results
(Discuss how the system works and how it will absorb the impact force.)
(Explain what did you observe
when it was tested?)
1)
2)
3)
Crumple Zone Solution#1
2 views Front and underside
Crumple Zone Solution#2
2 views Front and underside
Crumple Zone Solution#3
2 views Front and underside
Final Solution to Auto
Energy Absorbing Crumple Zone
Possible Solutions
Seat Restraint Safety System
Hypothesis How it will work
Tested Results
(Discuss how the system works and how it will absorb the impact force.)
(Explain what did you observe
when it was tested?)
1)
2)
3)
Seat Restraint Solution#1
2 views Front and Top
Seat Restraint Solution#2
2 views Front and Top
Seat Restraint Solution#3
2 views Front and Top
Final Solution to Seat Restraint System
Egg Mobile Test Vehicle Frame Construction
Egg Mobile Design Solution
3-D Isometric Drawing – for those who have
completed any of the CAD courses
Test Results and Conclusions
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Describe in detailed discussion what you observed when your vehicle was tested for each area.
Copy into Word and answer the questions there and then attach to Power point print out.
1. Condition of car body and frame.
2. Performance of Crumple Zone (explain in applied physics terms – impact force,
absorb, reaction force etc.)
3. Performance of Seat Constraints (explain in applied physics terms)
4. Condition of Passengers
5. The time of the vehicle
6. Speed of the vehicle.
7. Weight of vehicle
8. Mathematical calculation of the force. (F=ma)
9. Each person write a 2 paragraph evaluation about the project – likes, dislikes, was it
interesting, worthwhile, what changes would do you think should be made to the
problem, process, time constraints, materials. Please explain your responses and attach
the evaluation.
One-paragraph Conclusion: What would you do to improve your vehicle –
crumple zone & seat restraint systems? Be detailed in your explanation.
CAD drawing of your vehicle– orthographic projection (multi-view drawing) with
crumple zone and seat restraint designs due 4 class meetings after documentation
due date.
GRADING
Possible Solution Sketches of Crumple Zone and Seat
Restraints with detailed applied physics explanations of
how they will work– 15%
Frame construction, foam, crumple zone and seat retsraint
systems due dates – all Pass/Fail grades – 10%
Testing of three test vehicles and their documentation of
each – 12%
Final Prototype – 40% (20% for each the seat restraint and
crumple zone systems)
Documentation Report – 35%
Presentation – 10%
CAD Drawing – 10%
The End
Begin Case Study #4 and
FINAL EXAM
“AVIATION”