Statement of Work
Shell Eco-mara Eco-marathon thon Team October 2, 2014
Urban Concept Vehicle Glen Burkhardt Andy Jiang Peter Subosits Kyle ydock !o " #ntellectual Pro$erty %ights Agree&ent !o " !on"'isclosure Agree&ent Agree&ent
Executive Summary (he ob)ecti*e o+ this ca$stone $ro)ect is to &ake &odi+ications to Penn States -rban .once$t /ehicle /ehicle -./ ith the ulti&ate goal o+ &aking the *ehicle dri*able and sa+e +or the 2013 20 13 Shell co"&arathon co&$etition5 .usto&er needs ere e*aluated based on the o++icial Shell co" &arathon %ules5 (hese needs are $ri&arily ai&ed at i&$ro*ing dri*er sa+ety and *ehicle e++iciency5 e++iciency5 Accordingly, Accordingly, this $ro)ect ill +ocus on o$ti&i6ing se*eral &echanical co&$onents o+ the -./ as ell as testing the &a)or electrical co&$onents o+ the *ehicle5 A+ter ins$ecting the *ehicle, the tea& decided u$on +our $ri&ary design ob)ecti*es7 1 co&$lete the braking syste&, 2 realign the heel hubs, 8 i&$ro*e the door o$ening and latching &echanis&s, and 4 test the custo& &otor controller5 (he braking syste& is currently not connected and is &issing cali$ers on the rear a9le5 (he tea& $lans $ lans to add ne cali$ers +or the rear a9le, design a brake $edal, and &ount a routed hydraulic syste& onto the *ehicle5 (he tea& ill correct the &isaligned heel hubs, hich ill reduce +riction on the brake rotors and ulti&ately i&$ro*e the +uel econo&y o+ the *ehicle5 (he door, hich currently o$ens in lateral and scissor &otions, does not rest $ro$erly in an o$en $osition, $osing a risk o+ har&ing the dri*er5 (he tea& $lans to either &ake ad)ust&ents to the current hinge or i&$le&ent a ne so+t"closing hinge to i&$ro*e door +unctionality5 Other issues ith the door are that it does not latch shut $ro$erly and it $roduces an an ine++ecti*e seal against the *ehicle5 Both o+ these inade:uacies can create drag during *ehicle o$eration5 (he tea& ill i&$ro*e latch align&ent and de*elo$ d e*elo$ a &ore e++ecti*e door seal to lessen the e++ects o+ drag on the *ehicle5 (he custo& cu sto& &otor controller, hich as designed by the s$ring 2014 ca$stone tea&, needs to be tested along ith the &otor to *alidate its +unctionality5 (he tea& budget ill go toard $urchasing $arts and &aterials +or the i&$ro*e&ent o+ the *ehicle5 (he custo& &otor controller ill be the +irst deli*erable o+ this ca$stone $ro)ect as this task is essential to ensure the *ehicles readiness +or the 2013 co&$etition5 (he braking syste& and door &echanis&s ill +ollo soon therea+ter due to the e9tended lead ti&e o+ &achining &ac hining and $art deli*ery5 Table Ta ble of Contents 9ecuti*e Su&&ary55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555551 Page 1 of 30 ME 440.1
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150 #ntroduction555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555554 151
#nitial #nitial Proble& State&ent555 State&ent5555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 555555555555554 55555554
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Ob)ecti*es Ob)ecti*es5555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 555555555555554 55555554
250 .usto&er !eeds and Assess&ent55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555554 251 Gathering .usto&er #n$ut5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555554 252 eighting o+ .usto&er !eeds555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555553 850 9ternal Search555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555553 851 Patents555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555; 85151 Brake Patents5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555; 85152 'oor
852 9ternal Search5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 450 ngineering S$eci+ications55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 451 stablishing (arget S$eci+ications55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 452 %elating S$eci+ications to custo&er needs55555555555555555555555555555555555555555555555555555555555555555555555555555? 350 .once$t Generation and Selection555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 351 Proble& .lari+ication5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 35151 Brakes555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 35152 @otor .ontroller55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 35158 50 S$ecial (o$ics5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555512 >51 Preli&inary cono&ic Analysis Budget and /endor Purchase #n+or&ation5555555555555555555512 >52 Pro)ect @anage&ent55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555518 >58 %isk Plan and Sa+ety55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555518 >54 thics State&ent555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555514 Page 2 of 30 ME 440.1
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150 #ntroduction555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555554 151
#nitial #nitial Proble& State&ent555 State&ent5555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 555555555555554 55555554
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Ob)ecti*es Ob)ecti*es5555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 55555555555555 5555555555555 5555555555555 55555555555555 555555555555554 55555554
250 .usto&er !eeds and Assess&ent55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555554 251 Gathering .usto&er #n$ut5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555554 252 eighting o+ .usto&er !eeds555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555553 850 9ternal Search555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555553 851 Patents555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555; 85151 Brake Patents5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555; 85152 'oor 852 9ternal Search5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 450 ngineering S$eci+ications55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 451 stablishing (arget S$eci+ications55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 452 %elating S$eci+ications to custo&er needs55555555555555555555555555555555555555555555555555555555555555555555555555555? 350 .once$t Generation and Selection555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 351 Proble& .lari+ication5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 35151 Brakes555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 35152 @otor .ontroller55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555? 35158 50 S$ecial (o$ics5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555512 >51 Preli&inary cono&ic Analysis Budget and /endor Purchase #n+or&ation5555555555555555555512 >52 Pro)ect @anage&ent55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555518 >58 %isk Plan and Sa+ety55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555518 >54 thics State&ent555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555514 Page 2 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
>53 n*iron&ental State&ent5555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555514 >5; .o&&unication and .oordination ith S$onsor5555555555555555555555555555555555555555555555555555555555555555514 A$$endi9 A Gantt .hart55555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555555551; A$$endi9 B A
1. !ntro"uction !ntro"uction 1.1 !nitial #roblem Statement Statement Shell co"&arathon is an annual co&$etition hich challenges tea&s across the orld to design and build the &ost energy"e++icient *ehicle5 (here are to di++erent *ehicle classi+ications that Page 3 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
co&$ete in Shell co"&arathon7 -rban .once$t and Prototy$e5 -rban .once$t e&$hasi6es $ractical designs and dri*er co&+ort, hile the Prototy$e encourages tea&s to design +or energy e++iciency at the e9$ense o+ dri*er co&+ort5 (his ca$stone $ro)ect ill +ocus on $re$aring the Penn State -rban .once$t *ehicle -./ +or co&$etition in A$ril 20135 Penn States current -./ is a ork in $rogress5 (he &a)ority o+ the &echanical and electrical co&$onents on the *ehicle ha*e been built, although the *ehicle needs se*eral &a)or &odi+ications be+ore it can be in sa+e orking order5 (his ca$stone $ro)ect tea& ill ork on the -./ to install a custo& &otor controller, i&$ro*e the door latch and hinge &echanis&s, install a braking s yste&, and realign the heel hubs5
1.$ %b&ectives (he ulti&ate ob)ecti*e o+ this ca$stone $ro)ect is to i&$ro*e Penn States -./ so that it is +ully o$erational5 (he &ain obstacle +aced by the tea& is its ine9$erience ith electronics because the tea& is co&$rised entirely o+ &echanical engineers5 (his ill li&it ho &uch the tea& can acco&$lish ith the custo& &otor controller5
$. Customer 'ee"s an" (ssessment $.1 )atherin* Customer !nput .ity $o$ulations continue to sell and hea*y tra++ic causes the a*erage A&erican orker to lose 8? hours o+ ti&e $er year E>F5 Additionally, a study released in 2012 by the -5S5 (reasury 'e$art&ent re*ealed an a*erage o+ 15 billion gallons o+ gas are lost $er year on congested roads5 (hese statistics sho the need +or e++icient and reliable *ehicles to hel$ alle*iate the $roble&5 (he tea& gathered custo&er in$ut through con+erences ith our cor$orate s$onsor, %yan @oyer, and Shells co"&arathon ebsite5 (he -./ is $ri&arily designed +or e++iciency and $racticality5 #ts +unctionality should be as close to real"orld ready as $ossible hile &eeting the design goals s$eci+ied in the co&$etition5 Because o+ this, sa+ety, e++iciency, and ergono&ics are to$ $riorities in the design5 Other +actors to be considered ere eight, durability, a$$earance, and cost5 (hese design goals ere i&$ortant +or the -./ to o$erate in co&&on urban tra++ic conditions as ell as light, et eather conditions5
$.$ Wei*htin* of Customer 'ee"s ith this initial set o+ design $ara&eters, the tea& conducted research to deter&ine hat custo&ers ould *alue &ost i+ considering the $urchase o+ a co&$act, e++icient urban Page 4 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
trans$ortation *ehicle5 Sa+ety is o+ ut&ost i&$ortance hen *ehicles are being e*aluated in Shells co"&arathon co&$etition5 hile tea&s are encouraged to design the &ost e++icient *ehicle $ossible, sa+ety cannot take a back seat to e++iciency5 Other custo&er needs such as cost, *ehicle eight, a$$earance, durability and ergono&ics ere considered5 A+ter constructing an analytical hierarchy $rocess chart, e +ound sa+ety to be the &ost i&$ortant custo&er need +olloed by *ehicle e++iciency5 rgono&ics as our third highest rated custo&er need5 'ue to the +act that the -rban .once$t /ehicle is re:uired to o$erate as close to a &odern day *ehicle ith *arious a&enities, the tea& agreed that these to$ three custo&er needs are a$$ro$riate5 Please re+er to A$$endi9 B to *ie the +ull A
+. External Search #n order to design a ell $er+or&ing, e++icient *ehicle to co &$ete in the Shell co"&arathon .o&$etition, the tea& co&$leted e9ternal searches +or the braking syste&, door latch and hinge, and &otor controller5 Additionally, a $atent search as done and is outlined in the ne9t section5 @uch o+ the in+or&ation regarding *ehicle braking syste&s as ac:uired +ro& the technology and designs that are utili6ed in $assenger *ehicles5
+.1 #atents +.1.1 ,rake #atents Dloating cali$er"ty$e disk brake +or auto&oti*e *ehicles -S 3?;043 A
'ual &aster cylinder +or hydraulic auto&obile brakes -S 23;?220 A
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Shell Eco-marathon Urban Concept Vehicle
'escri$tion7 (his $atent allos +or the cali$er and $ad asse&bly to sel+align so brake dragging is reduced5 Analysis7 By using a si&ilar style cali$er, a dual actuation cali$er, +ro& a &ountain bike e $lan to achie*e the sa&e bene+its to increase *ehicle e++iciency5
'escri$tion7 By s$litting the braking +orce across to cylinders a leak in one o+ the lines or cylinders ill still lea*e one syste& +unctioning, thus increasing brake sa+ety5 Analysis7 As a sa+ety $recaution and to design our car to be ithin the rules and regulations +or the co&$etit ion, our design utili6es 4 se$arate brake lines5
+.1.$ oor in*e an" /atch #atents Auto&obile door hinge ith to"$osition toggle ty$e hold"o$en -S 88>081? A
.ar"door latch and o$ener -S 18>0313 A
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Shell Eco-marathon Urban Concept Vehicle
'escri$tion7 (his is a hinge ha*ing a to"$osition co&bination ca& and sna$ ty$e hold"o$en design hich can hold the door o$en at a &id"o$en $osition and $re*ent closing o+ the door hen +ully o$ened5 Analysis7 By $urchasing an o++"the"shel+ hinge, e can design and build door that o$erates and +eels si& ilar to a &odern *ehicle5
'escri$tion7 (his $atents the ability to o$en, close, and lock a door ith a relati*ely si&$le design5
Analysis7 (he car ill ha*e a door that can be o$ened +ro& the inside and outsideC hoe*er, a lock as not $lanned in our ob)ecti*e5
+.$ Existin* #ro"ucts (he +act that e are building a *ehicle designed to &i&ic road going auto&obiles does create so&e issues ith designing co&$letely ne, inno*ati*e co&$onents and syste&s +or our car5 ith braking, &any &odern cars are designed ith an HI brake line syste&, here there is a se$arate hydraulic syste& +or the =D and %% and another +or the %D and =% brakes5 (his is alloed by the rules and regulationsC hoe*er, the tea& o$ted +or +our se$arate lines +or added sa+ety to the braking syste&5 (he hinge and the latch the&sel*es are $urchased $arts and the added design ork to create a $ossibly in+erior co&$onent as a route the tea& decided against5 Page 7 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
Dor the &otor controller, there as a re:uire&ent in the rules that it &ust be d esigned and built by the tea&5 #+ our tea& could $urchase a &otor controller +or 8"$hase brushless '. &otor, there are &any o$tions that ould ha*e orked, but e ha*e one that as designed and built by another Penn State co"&arathon tea& ill be used in the 2013 -rban .once$t car5
0. En*ineerin* Specifications 0.1 Establishin* Tar*et Specifications (able L in A$$endi9 J shos a detailed list o+ custo&er needs +or each indi*idual task an d their relati*e i&$ortance to the $ro)ect as a hole5 (able L, also in A$$endi9 J, shos the &etrics used to e*aluate the co&$leteness o+ each custo&er need5 *** Incomplete: will nish this afternoon…
0.$ elatin* Specifications to customer nee"s
2. Concept )eneration an" Selection 2.1 #roblem Clarification 2.1.1 ,rakes (he braking syste& +or the -rban .once$t /ehicle &ust use 4 hydraulic disk brakes5 (he in$ut needed +ro& the dri*er to actuate the brakes is the sa&e as it ould be in any road going auto&obile5 (he dri*er a$$lies $ressure to the brake $edal, located belo the dash on the le+t side o+ the dri*er5 (he $edal o$erates +our se$arate &aster cylinders5 ach &aster cylinder o$erates a $iston that $ressuri6es hydraulic +luid in a line5 ach line runs to a cali$er on each heel o+ the car5 (he $ressured +luid in the lines co&$ress $istons in each o+ those cali$ers creating a co&$ressi*e +orce on the brake rotor5 (he cali$ers ha*e $ads &ade o+ high +riction &aterial that &ake contact ith steel disks5 (his contact creates a tor:ue on the steel rotors hich slos the rotation o+ the heels, and results in sloing the *ehicle5 A higher +orce in$ut on the $edal +ro& the dri*er results in increased tor:ue acting on the heels5 2.1.$ 3otor Controller Poering a 8"$hase '. brushless &otor re:uires a controller to con*ert battery $oer into usable signals to create tor:ue on the &otor5 (he $oertrain on the -rban .once$t car consists o+ the battery +or $oer, a $otentio&eter +or controlling the throttle in$ut, the &otor controller, and a hub dri*e '. brushless &otor that dri*es the right rear heel5 (he o$erator controls the throttle ith hisMher right +oot5 (hat signal goes through the controller and deter&ines the a&ount o+ current re:uired +ro& the battery hich is con*erted into the necessary signals that are sent to the &otor to create tor:ue on the dri*e heel5 2.1.+ in*e Page 8 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
(he current hinge on the -./ as designed to si&ulate the scissor door &otion o+ a =a&borghini su$ercar5 hile its original intent as to allo +or &ore e++icient door o$ening &otion in a cra&$ed urban en*iron&ent, the hinge has a nu&ber o+ +las that kee$ it +ro& $er+or&ing o$ti&ally5 One &a)or +la is the notch currently used to hold the door in $lace hen in the scissor $osition5 (he door re+used to hold itsel+ in a resting $osition a+ter &ulti$le atte&$ts and this usability issue de+eats the $ur$ose o+ the hinge5 (he current hinge is also *ery hea*y because it is +ro& a kit car set and &ade o+ solid steel5 hile eight reduction e++orts ere &ade to reduce its +oot$rint, it causes the le+t side o+ the car to be hea*ier than the right5 A redesign o+ the current hinge or a total hinge re$lace&ent is needed in order to e++ecti*ely sol*e these issues5
2.$ Concept )eneration 2.$.1 ,rakes (he braking syste& +or the car is de+ined in the 2013 O++icial %ules as (he brakes &ust o$erate inde$endently on the +ront and rear a9les or in an H $attern i5e5 right +ront heel ith le+t rear heel, and le+t +ront heel ith right rear heel5I So the abo*e to designs ould satis+y the rules5 (he car as setu$ ith 4 &ountain bike rotors and cali$ers ith 4 inde$endent &aster cylinders5 Dro& that setu$ e had o$tions +or ho e ould connect the lines co&ing +ro& the &aster cylinders to the cali$ers5 hile actuating all 4 &aster cylinders ith a single $edal 2 cylinder lines ould con*erge into a single line then s$lit at the rear heels5 (he other 2 cylinder lines ould be connected in the sa&e +ashion but end at the +ront heels5 (he $ros o+ this conce$t are that it allos +or one hydraulic syste& to +ail and the dri*er to still &aintain control o+ the *ehicles brakes to an e9tent5 Although only actuating the brakes on a single a9el &ay cause the car to beco&e unstable5 A HI $attern brake ould allo +or the sa&e sa+ety as the +ront"rear s$lit conce$t, but &ay allo +or a &ore stable brake balance5 (he le+t +ront and rear right ould recei*e the sa&e $ressure, and the right +ront and le+t rear ould also recei*e the sa&e $ressure5 #n+or&ation about brake +orce calculations are located in A$$endi9 #5 2.$.$ in*e Our +irst conce$t +or the hinge &echanis& is to i&$ro*e the current hinge already on the -./5 (he &ain hinge +unctions $ro$erly but the door itsel+ does not rest $ro$erly hen in the scissor $osition5 A ne bolt +or the door ould be &achined ith a notch in the side +or the door to rest in hen li+ted to the desired $osition5 ithout this notch, the door easily sli$s out o+ its resting $osition, de+eating the original $ur$ose o+ the scissor door design5 Our second conce$t is the so+t"close sur+ace"&ounted hinge +ro& @c@aster".arr5 e chose this hinge as a *iable conce$t due to its +riction to $re*ent door sla&s and its ide o$ening angles5 (his design &o*es aay +ro& the scissor door action that as $re*iously used5 #t also cuts signi+icant eight +ro& the le+t side o+ the *ehicle5 (he current scissor hinge is solid steel and eighs &ore than the door itsel+5 (his hinge is &ade o+ a hard $lastic and has a high tor:ue *alue to hold the door in $lace5 A concern +or this design ould be the longe*ity and durability o+ the hinge a+ter e9tended use5 (he third conce$t is Driction
Shell Eco-marathon Urban Concept Vehicle
stress and rigidity than $lastic has5 (he don side o+ the +riction hinge is the $rice5 Driction hinge cost al&ost tice as &uch as the So+t".lose hinge5 All Solidorks draings o+ our three hinge designs are located in A$$endi9 '5 2.$.+ oor Seal (he tea& has considered three a*ailable seals to install around the $eri$hery o+ the door +ra&e5 'raings o+ these $arts are located in A$$endi9 5 (he +olloing seals are all a*ailable on @c@aster".arr7 1 P'@ ad)ustable edge"gri$ seal, 2 P'@ eather stri$ +oa& ta$e, and 8 silicon rubber bulb seal5 (he +irst ty$e seal is an ad)ustable edge gri$ seal, hich is essentially the sa&e as eather stri$ seals co&&only used on auto&oti*e *ehicle doors5 (he seal &aterial, P'@, is a closed"cell +oa& rubber ith a steel core5 (hese seals are a*ailable in a nu&ber o+ di++erent si6e ranges including 3M;4I 18M;4I5 (he -./ door thickness is 05132I, hich ill +it ithin this range5 (his seal is ad*ertised to sto$ ind, dust, and ater +ro& entering doors, so it is ideal +or our $ur$oses and costs N85?3M+t5 (he second ty$e o+ seal under consideration is eather resistant P'@ rubber adhesi*e stri$s, hich are a*ailable in 8+t long, 2 in thick stri$s +or N35>15 (his ta$e is ad*ertised +or outdoor use and is o6one, aging, stea&, and ater resistant5 =ike the ad)ustable edge gri$s, this ta$e ould be a$$lies around the $eri$hery o+ the door +ra&e to i&$ro*e the door seal5 (his $roduct has the ad*antages o+ easy installation, si&$licity, and durability5
Another *ariety o+ rubber bulb seal is the silicon rubber bulb seal5 (his $articular ite& is &ade o+ silicon and $roduces a *ery tight seal5 (his o$tion is designed to be highly resistant to ater, air, and te&$erature5 -nlike the second o$tion, this ite& does not ha*e an adhesi*e back, but it can be glued on the door +ra&e ith silicon based adhesi*e5 (his silicon rubber bulb seal is a*ailable +or N258>M+t5
2.+ Concept Selection (he +inal conce$t +or each ob)ecti*e as selected *ia a conce$t scoring $rocess5 Dirst, three conce$ts ere chosen as $ro&ising ideas and they ere $ut into a chart +or conce$t screening Einsert a$$endi9 hereF5 Dor the hinge design, this included the $lastic so+t closing hinge, the current scissor hinge, and the stainless steel +riction hinge5 (hese conce$ts ere then co&$ared to current &odi+ications i&$le&ented on the *ehicle5 2.+.1 ,rakes (he conce$t e chose to &o*e +orard ith uses 4 co&$letely inde$endent lines5 (his conce$t is not utili6ed in &odern day *ehicles, but ill allo +or si&$le diagnostics +or brake $roble&s and gi*e the &ost sa+ety during a brake +ailure5 #t is also the si&$lest design to build, as there is no )oining and di*erging o+ the lines5 A &ain bene+it +or this design is i+ one &aster cylinder +ails, the rest o+ the brake lines are not a++ected5 (his ill increase the sa+ety o+ the *ehicle and the brake syste&s are not de$endent on one another5
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Shell Eco-marathon Urban Concept Vehicle
4. System /evel esi*n 4..1 oor (he door o+ the -./ needs to increase the sti++ness o+ the structure to increase *ehicle sa+ety5 ithout this, the door cannot be $ro$erly aligned or +unction as desired5 e ha*e chosen to use a nu&ber o+ alu&inu& cross"&e&bers on the interior o+ the door to hel$ +urther de+ine the structure5 hile this does add eight to the *ehicle, sa+ety is our to$ concern and this ill greatly increase the sa+ety +or the occu$ant5 (he alu&inu& bea&s ill then be connected together ith steel bands to interconnect the rein+orce&ents5
Figure 1: Urban Concept Door with Aluminum Reinforcements
4..$ ,rakes (he brake syste& on the car as $artially designed and constructed $rior to the tea& starting ork on the car5 (he +ront cali$ers and all rotors ere in $lace, but the rear cali$ers ere &issing and the lines to each ere absent as ell5 (he &aster cylinders are &ounted to the car, but the $edal to actuate the& needs built5 (he rear brackets to &ount the cali$ers ill be &achined +ro& steel $late5 (he cali$ers ill be bolted to the brackets using the brakes &ounting bolt holes5 (his ill gi*e the rigidity needed to hold the cali$ers in $lace during hard braking5 (he brake $edal is to be ater )et cut +ro& a $late o+ alu&inu&5 (he cali$ers are connected to the &aster cylinders by +le9ible $lastic hydraulic lines5 Page 11 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
Figure 2: Brake Mounting Bracket
5. Special Topics 5.1 #reliminary Economic (nalysis 6 ,u"*et an" Ven"or #urchase !nformation (he esti&ated cost to co&$lete the $ro)ects ob)ecti*es is +ar +ro& the budget o+ N10005 @a)or costs +or the $ro)ect are the $arts and &aterials, &ainly, the brake cali$ers and *arious $arts needed to co&$lete the syste&, and the door hinge and latch5 'etails $ertaining to the each cost and cost esti&ate can be +ound in the a$$endi95 S$eci+ic A$$endi9 =etter
5.$ #ro&ect 3ana*ement (he tea& ill use @icroso+t Pro)ect to generate the Gantt chart +or this se&ester5 (his chart ill include all &a)or deadlines +or re$orts, $resentations, and design i&$le&entations5 Additionally, it ill also be used to kee$ track o+ design $hases and $roduct de*elo$&ent throughout the se&ester5 e ha*e included the &a)or deadlines set by our deli*erables agree&ent to hel$ kee$ us on track5 As seen in our resu&es A$$endi9 G, our e9$erience +ro& $re*ious design classes like &echanical design and design ðodology ill allo us to e++ecti*ely +abricate and i&$le&ent the design changes highlighted in this re$ort5 (he tea& ill also be constructing a @icroso+t SharePoint site +or +uture tea&s to utili6e5 (his $oer+ul tool allos +or cloud data storage, easy access, and e++ecti*e collaboration beteen $re*ious, current, and +uture co" &arathon tea&s5
5.+ isk #lan an" Safety Although the co"&arathon -rban .once$t /ehicle is not a $roduct that ill be used by or around the $ublic, sa+ety is still o+ u$&ost i&$ortance5 Arguably the &ost i&$ortant as$ect o+ a Page 12 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
*ehicle is its ability to sto$ in a sa+e and controlled &anner5 (here+ore creating a brake syste& that has 4 inde$endent hydraulic lines ill surely hel$ ith alle*iating a lot o+ risk +ro& not being able to slo the *ehicle5 (he hydraulic syste&s the&sel*es ill be built co&$letely +ro& $arts $urchased +ro& *endors to ensure any leaks o+ $roble&s in the brakes are ke$t to a &ini&u&5 Building the door hinge and latch &echanis& also in*ol*e so&e risks related to sa+ety5 (he door should stay o$en or closed hen the o$erator does so, and not ha*e $inch $oints or in*ol*e any strenuous e++ort to o$erate the latch or to o$en the door5 iring +or the $oertrain and other electrical syste&s should be $ackaged in a clean and sa+e &anner so that the *ehicles o$erator has little chance o+ recei*ing an electrical shock5 Table 1: Risk Plan
isk
/evel
(ctions to 3inimi7e
8all ,ack Strate*y
Schedule delays Syste& does not +unction +a*orably Syste& -nsa+e to users or $ublic
"-se o+ @S Pro)ect to track $rogress and current tasks ".onduct tests ".onstruct &ulti$le $rototy$es
"Add e9tra ti&e +or each task or deli*erable "Si&$li+y or start o*er on a conce$t
'elays due to shi$$ing or lead ti&es
@oderate
"All designs ill ha*e sa+ety as a $riority "Dollo all rules +or the Shell co"&arathon 2013 .o&$etition ".heck stock status be+ore deciding on $art "Send all needed in+or&ation to $urchasing early
"-se testing to deter&ine the cause o+ any dangerous situations "%edesign a+ter the reason is understood "@anu+acture instead i+ $ossible "Search +or other *endor or &odel
@oderate
5.0 Ethics Statement (he Shell co"&arathon -rban .once$t /ehicle (ea& &aintains certain $olicies to guide its &e&bers ith res$ect to standards o+ conduct e9$ected in areas here i&$ro$er acti*ities could da&age the (ea&s re$utation and otherise result in serious ad*erse conse:uences to the (ea& and &e&bers in*ol*ed5 (he $ur$ose o+ this Policy is to a++ir&, in a co&$rehensi*e state&ent, re:uired standards o+ conduct and $ractices ith res$ect to design and o$erations5 (he (ea& e9$ects all tea& &e&bers to conduct the&sel*es in a $ro+essional &anner at all ti&es hen in the $resence o+ other &e&bers, s$onsors, and su$$liers5 ach &e&ber ill use legiti&ate business $ractices and best )udg&ent hen in handling tea& a++airs5 /iolation o+ these $ractices are grounds +or disci$linary action at the discretion o+ other tea& &e&bers as outlined in the tea& contract5
5.2 Environmental Statement Page 13 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
(he Shell co"&arathon -rban .once$t /ehicle (ea& is co&&itted to reducing its i&$act on the en*iron&ent5 e stri*e to i&$ro*e our en*iron&ental $er+or&ance here*er $ossible during design and i&$le&entation o+ *ehicle enhance&ents5 e ill co&$ly ith all a$$licable en*iron&ental $olicies, $re*ent all $ollution here*er $ossible, and c ontinue to &easure and i&$ro*e our en*iron&ental i&$act by setting goals to reduce these i&$acts5
5.4 Communication an" Coor"ination 9ith Sponsor (he tea& co&&unicates ith our s$onsor in nu&ber o+ ays5 A eekly $rogress re$ort is deli*ered to %yan @oyer *ia e&ail on (uesdays in the +or& o+ a P'D5 e also hold a eekly telecon+erence on (hursdays at 11 A@ S( to discuss $ro)ect &ilestones and tea& concerns5
Sources E1F Brady, Ja&es (5 .ar"door =atch and O$ener5 Patent -S 18>0313 A5 ? @ar5 1215 Print5 E2F Brake .alculations5 Engineering Inspiration5 ngineering #ns$iration, 20145 eb5 2 Se$t5 20145 htt$7MM5engineeringins$iration5co5ukMbrakecalcs5ht&lQ5 E8F Ben)a&in, .hristo$her <5, Jr5 'ual @aster .ylinder +or 081? A5 2> Deb5 1;?5 Print5 E3F Oertel, .le&ens, F erbach, Ada&5 (he A&erican .o&&uter S$ends 8?
Shell Eco-marathon Urban Concept Vehicle
(ppen"ix ( 6 )antt Chart
Page 15 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
(ppen"ix , 6 (# Chart AHP Chart Co st
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#nsert #n+or&ation on ho A
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Shell Eco-marathon Urban Concept Vehicle
(ppen"ix C 6 ,rake Concepts
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(ppen"ix 6 in*e Concepts
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Shell Eco-marathon Urban Concept Vehicle
(ppen"ix :Continue";
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Shell Eco-marathon Urban Concept Vehicle
(ppen"ix E 6 oor Sealant Concepts Page 20 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
Item # 11!9A! from caster$Carr Item # #899D!" 1!""%A!&from from caster$
(ppen"ix 8 6 !nitial #roblem Clarification Chart
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Shell Eco-marathon Urban Concept Vehicle
(ppen"ix ) 6 esumes Page 22 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
(ppen"ix ) :continue"; 6 esumes Page 23 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
(ppen"ix ) :continue"; 6 esumes Page 24 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
(ppen"ix ) :continue"; 6 esumes Page 25 of 30 ME 440.1
Shell Eco-marathon Urban Concept Vehicle
(ppen"ix - Concept Scorin*
)ale &: -oor (ealant ,oncept (coring
(ppen"ix ! 6 ,rake (nalysis (he braking syste& also needs to create enough +orce to hold the car steady hile on a 20 degree incline5 Assu&ing the car eighs the &a9i&u& alloable eight +or the co&$etition, 223 kg, ith a dri*er eighing in at ?0kg, the cars &ass is 803kg5 (he brakes &ust be designed, at &ini&u& to hold the car on a 20 degree incline5 At a 20 degree angle, the gra*itational +orce +ro& the car acting don the incline ould be 102; !5 (here+ore, the brakes &ust trans+er the )ale : +inge (coring ,hart
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Shell Eco-marathon Urban Concept Vehicle
necessary tor:ue to the heels to kee$ the& +ro& rotating5 (he heel radius is 0528&, and the brake radius is 050?&5 (he calculation o+ +orce needed at the rotors is7 (Braking Force!(Rotor Radius " (#ar Force $o%n the Incline!(&heel Radius (Braking Force!('.' ) " (1'*+ ,!('.*- ) Braking Force " /+' ,0 Braking Force%heel" -2' , (he 40 ! +orce is the +riction +orce needed to be actuated on each cali$er5 Dro& the s$eci+ications o+ the cali$ers and &aster cylinders e chose, the +orce re:uired o+ the& is ell ithin their abilities5
(ppen"ix < 6 Customer 'ee"s 3etric 3atrices
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Shell Eco-marathon Urban Concept Vehicle
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Shell Eco-marathon Urban Concept Vehicle
