Team 3: TRIumph

TRIumph Team Members

Matt Disselkoen, Amy Newland, Jamison Vande Ree

Outline•Background•Project Description•Design Process•Build Process•Obstacles•Lessons Learned•Project Assessment•Acknowledgments•Questions

Background•myTEAM TRIUMPH

▫Athletic ride-alongs▫Triathlons, Marathons, 5k’s

•Stage-specific equipment▫Swimming▫Bicycling▫Running

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Background•Transition Process

▫Lost time▫Difficult

•Current Equipment▫More room for storage▫Not enough legroom

•Project Motivation▫Help others▫Solve problem

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Matt Smith & Family

Current Equipment

Running Chair, from Advance

Mobility™

Bicycle Trailer, from Cycletote®

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Project Description•Primary Goals:

▫Two-in-one: Biking and Running▫Increase height and weight capacity

•Secondary Goals:▫Improve seat comfort▫Build for easy transportation▫Strengthen connection points▫Reduce parachute effect

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Product Research

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Wike® Extra Large Special Needs Trailer

Burley® d’lite

Chariot Carriers Inc. Corsaire XL

•Existing Products▫Some convertible

▫Low capacity

▫Not built for endurance races

Research•Safety/Testing Standards

▫ASTM Bicycle Trailers Strollers

•Common Sense▫Strength▫Pinch points▫Access

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Initial Design Components•Seat•Harness•Shock Absorption•Brakes•Wheels•Windows•Roll Cage

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Initial Design•Based on mTT bicycle trailer

▫Larger capacity▫Low center-of-gravity

•Decisions needed:▫Material▫Dimensions

Initial Autodesk Inventor Model

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Design Decisions

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

•Basic Frame Structure▫Material

Aluminum Titanium Carbon Fiber

▫Manufacturing capabilities•Weight Considerations

▫Lightweight▫Current models: 25 – 30 lbs

Early SolidWorks Model

Finite Element Analysis•Objective:

▫Determine high-stress areas▫Ensure prototype strength▫Size tubing required

•Process:▫Applied loads▫Boundary conditions

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Algor FEA Results

FEA ResultsInsert many different FEA setups, results to show iterations

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

•Results:▫Maximum von Mises Stress

2.9 ksi▫Dynamic Stress

7.25 ksi▫Safety Factor: 4

Design Decisions•Frame Material

▫Aluminum 6061-T6 7/8” OD, 16 ga (0.065”)

▫Aluminum 6061-T6 3/8” Diameter Solid

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

12’

Design Decisions•Two-in-one

▫Removable bike attachment•Seat

▫Sling-style▫Folding seat back

•Frame structure▫V-shape design

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Frame Structure•Tube Bending

▫Conduit Bender▫Hydraulic▫CNC Bender

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Frame Structure•Cutting Tube

▫Fish-mouth slot Mill Hole Saw

▫Mate surfacesfor welding

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Frame Structure•Welding

▫MIG▫TIG

•Issues▫Welding Aluminum▫Thin-walled tube

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Frame Structure

Upper seat pivot point

Lower seat attachment point

7/8” Dia. Tube

3/8” Dia. Round

Superb weldquality

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Frame Features•Wheel mounts

▫Forces axle into mount

•Seat mount plates▫Two separate pieces▫Reduced weight

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Seat Design•Two piece, sling style

▫No cross tube ▫Increased comfort

•Seat Back▫Folding▫Locking

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Roll Cage•Aluminum tube shell

▫Strong connections▫Pinned/clamped in place

•Foldable▫Unpin joints▫Loosen clamps

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Fabric Components•PVC-Lined Polyester Shell

▫Water-resistant▫One piece

•Vinyl Seat▫Padded inserts

•Iterative Design▫Four miles of thread▫Perfect fit

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Retractable Polyester roof

Polyester shell

Vinyl seat

Roll Cage Covering•Vinyl to Mesh

▫Better airflow▫Allows sunlight

•Mesh airflow panels▫Decreased drag

•Windows▫Increased visibility

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Hand Controls•Brakes

▫Caliper brakes▫Locking levers▫Cable + housing

•Front swivel pin▫Waiting on part

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Bicycle Attachment•Similar to current design

▫Bent tubes▫Ball joint

•Removable tubes▫Two pins

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Running Attachment•Sliding tube-in-tube design

▫Pin in place

•Steel fork and plate▫Balanced weight▫Reduced wobble

Pins

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Obstacles•Design vs. Build

•Make vs. Buy

•Machining Skills

•Manufacturing Capabilities

vs.

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Valuable Lessons•Concurrent Engineering

▫Redesign time•Teamwork

▫Task Delegation•Scheduling

▫Step by step goals▫Realistic

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Project Assessment•Success?

▫Convertible prototype▫Increased capacity▫Foldable for transportation▫Metal connection points▫Improved seat comfort▫Decreased parachute effect ? /

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Acknowledgments•myTEAM Triumph•Phil Jasperse•Senior Design Professors•Progressive Technologies•Rapid-Line•Highlight Industries•Kenneth Haan Jr.

Background – Description – Design – Build – Obstacles – Lessons – Assessment – Thanks

Questions?