me462buv design team
TRANSCRIPT
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BUV DESIGN TEAM
Mike NaughtonAaron McKibbenGabe CurrierWilliam Ortiz
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Introduction
Task: To design and build a Basic Utility Vehicle (BUV) prototypeVehicle to be used in developing countries in rural areasUse many existing components Bottom line: Low cost – High durability
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Customer Requirements
Cost as a kit $900 (less engine)Payload of 1000 lbsTop speed of 20mphRange of 100 milesWidth 4.4ft Ground clearance 8inFull safety equipment
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Performance Requirements
Climb 10% slope at 6mph (full loaded)Engine dry in 3ft of waterBrakes lock two or more wheelsTow 385lb trailer w/ 50lb tongue wtAccess to brake when pushing in reverse
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Front Suspension
Double A-armLeaf/solidCoil/solidMacPherson StrutTransverse leafNone
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Criterion Wt Double
A-A
rm
Leaf/
Solid
Coil/S
olid
MacP
hers
on S
trut
Tra
nsvers
e
None
Cost 7 -1 -1 -1 -1 -1 D
Durability 10 1 1 1 1 1 A
Simplicity 8 -1 -1 -1 -1 -1 T
Load Capability 7 0 0 0 0 0 U
Maintenance 6 -1 -1 -1 1 0 M
Manufacturing 7 -1 -1 -1 -1 -1
Attach to Chassis 6 -1 0 -1 -1 -1
Light Weight 4 -1 -1 -1 1 -1Vibration Transfer to Chassis 4 1 1 1 1 1
Comfort 5 1 1 1 1 1
Safety 6 1 1 1 1 1
Handling 8 1 1 1 1 1Logical Failure Mode 6 1 1 1 1 1
Aesthetics 1 1 1 1 1 1
Compact 5 -1 0 -1 -1 0
Total + 7 7 7 9 7 0
Total - 7 5 7 5 5 0
Overall Total 0 2 0 4 2 0
Weighted Total -3 8 -3 17 8 0
Front Suspension
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Best result for front suspension
MacPherson StrutHas good handling and low vibrationIt is durableEasy integration
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Steering
Rack and PinionGo-kart4 WheelerRecirculating-ball
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Criterion Wt Ra
ck a
nd
Pin
ion
Go
-ka
rt
4 W
he
ele
r
Re
cir
cu
latin
g
ba
ll
Cost 7 0 1 1 D
Durability 5 1 -1 1 A
Simplicity 8 0 1 1 T
Maintenance 9 1 1 1 U
Availability 7 -1 1 1 M
Replace ability 4 0 1 1
Lightweight 3 -1 1 -1
Aesthetics 1 1 -1 1
Attachment to vehicle 7 1 1 1
Low input force required to turn 10 1 -1 -1
Driver feedback 3 1 -1 1
Total + 6 7 9
Total - 2 4 3
Overall total 4 3 5
Weighted total 25 26 38
Steering
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Best result for steering
4 WheelerSimple designEasy to maintainLow costEasy to handle
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Brakes
Mechanical Cam BrakeMechanical Spread LeverMechanical Disc BrakeHydraulic ServoHydraulic SimplexHydraulic Disc Brake
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Criterion Wt Me
ch
an
ica
l
Ca
m B
rake
Me
ch
an
ica
l
Sp
rea
d L
eve
r
Me
ch
an
ica
l
Dis
c B
rake
Hyd
rau
lic S
erv
o
Hyd
rau
lic
Sim
ple
x
Hyd
rau
lic D
isc
Bra
ke
Cost 7 1 1 1 1 1 D
Durability 8 -1 -1 -1 -1 -1 A
Simplicity 8 1 1 1 1 1 T
Performance 6 -1 -1 -1 -1 -1 U
Maintenance 6 -1 -1 -1 1 1 M
Availability for mass production 10 1 1 -1 0 0
Replace ability 7 1 1 1 1 1
Lightweight 2 1 1 -1 1 1
Lubrication 4 1 1 1 0 0
Attachment to vehicle 7 1 1 1 0 0
Input Force 9 -1 -1 1 -1 -1
Logical failure mode 7 -1 0 0 0 0
Total + 7 7 7 5 5
Total - 5 4 5 3 3
Overall total 2 3 2 2 2
Weighted total 9 16 10 7 7
Brakes
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Best result for brakes
Mechanical Spread LeverSimple designTorque ranging from 3500lb.in. to 74000lb.inApplicable to many designsLow cost
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Rear Suspension
MacPherson StrutDouble A-armSwing armTwo leaf over solid axleSolid axle with trailing arm and coil over shocksNone
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Criterion Wt Ma
cP
he
rso
n
Str
ut
Do
ub
le A
arm
Sw
ing
Arm
Tw
o L
ea
f O
ve
r
So
lid
Axe
.
So
lid
axil w
ith
tra
ilin
g a
rm a
nd
co
il o
ve
r sh
ocks
Da
tum
No
Su
sp
en
sio
n
Durability 10 1 1 1 1 1
Cost 7 -1 -1 -1 -1 -1Vibration Transfer to Chassis 6 1 1 1 1 1
Integration to chassis 5 -1 -1 0 -1 -1 Availability for mass production 8 0 0 0 0 0
Compactness 5 -1 -1 0 -1 -1
Maintenance 6 0 -1 0 -1 -1
Handling 7 1 1 1 1 1
Simplicity 8 -1 -1 -1 -1 -1
Replacement 4 1 0 0 0 0
Light Weight 3 -1 -1 -1 -1 -1Load Capability 8 1 1 1 1 1
Logical Failure Mode 7 1 1 1 1 1
Aesthetics 1 1 1 1 -1 -1
Total + 7 6 6 5 5
Total - 5 6 3 7 7
Overall total 2 0 3 -2 -2
Weighted total 15 5 21 3 3
Rear Suspension
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Best result for rear suspension
Swing armLow costSimple designLoad carrying
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Best result for rear suspension
Swing armHonda 4 wheeler
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Drive train
CVT with chainCVT with FNR gear boxHydrostatic transaxleManual transaxleManual gear box with clutch
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Criterion Wt CV
T w
/ch
ain
CV
T w
/ F
NR
g-b
ox
Hyd
rosta
tic
tra
nsa
xle
Ma
nu
al tr
an
sa
xle
Ma
nu
al g
-bo
x
w/c
lutc
h
Cost 10 1 0 1 1 D
Avaliability 8 2 2 1 1 A
Efficiency 6 0 0 -1 0 T
Light weight 4 2 1 1 1 U
Durability 10 0 0 -1 0 M
Simplicity 7 1 0 -1 0
Maintence 8 1 0 0 0
Replacement 5 2 1 0 0Integration to chassis 7 1 1 0 0
Reverse? 3 -1 0 0 0
Vibration 6 0 0 1 0
Noise 3 -1 -1 1 0
Ease of operation 7 1 1 1 0
Total + 11 6 6 3
Total - 2 1 3 0
Overall Total 9 5 3 3
Weighted Total 44 34 8 22
Drivetrain
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Best result for drive train
CVT with chainVery efficient Light weightSimple designLow cost
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Chassis
Triangulated space frameUnit body constructionLadder frame
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Criterion Wt Tri
an
gu
late
d
sp
ace
fra
me
Un
it b
od
y
co
nstr
uctio
n
La
dd
er
fra
me
Mat. Cost 8 0 -1 D
Manuf. Cost 10 0 -2 ABending Stiffness 6 0 0 T
Torsional Stiffness 9 1 1 U
Lightweight 5 1 1 M
Repair 9 1 -1
Integration of components 7 1 1
Aesthetics 2 0 1
Total + 4 4
Total - 0 4
Overall Total 4 0
Weighted Total 30 -12
Chassis
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Best result for chassis
Triangulated space frameLow material costLow manufacturing costHigh strengthFairly simple design
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Preliminary Design
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Begin Final Design Process
Decided on final chassis designMaterial selectionConducted preliminary chassis analysis by handConducted advanced chassis analysis using ANSYSConstructed modelComplied all data
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Final Chassis Design Sketch
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Pro-E Drawing of Final Design
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Shear & Moment Analysis
Chassis modeled as simple beamExternal forces modeled as distributed loads across beamReaction forces found at shock locationsShear force and bending moment diagrams plotted
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Shear Force DiagramShear Force
-150.00
-100.00
-50.00
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00
x (ft)
V (lb
s)
V
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Bending Moment DiagramBending Moment
-400.00
-350.00
-300.00
-250.00
-200.00
-150.00
-100.00
-50.00
0.00
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00
X (ft)
Mc
(lb ft
)
Mc
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Bending-Moments by Parts
Simplified by 2-D analysis.(M/EI) diagram is drawn for each load, and the angle θ is obtained by adding algebraically the areas under the various diagrams. (EIθ = A1 + A2 + A3)(M/EI) diagram is drawn for each load, the tangential deviation t is obtained by adding the first moments of these areas about a vertical axis. (EIt = c1A1 + c2A2 + c3A3)
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Areas and centroids of common shapes
When a bending-moment or (M/EI) diagram is drawn by parts, the various areas defined by the diagram consist of simple geometric shapes, such as rectangles, triangles, and parabolic spandrels.
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The bending-moment results
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ANSYS Analysis Steps
Model in Pro-EngineerImport to ANSYSAdd constraintsAdd loadsRun solutionAnalyze results
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Loads and Constraints
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Maximum Stress Area
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Comparison of the two analysis
Analytically we obtained a bending-moment of 341.27 lbs-ft at the cargo area inner weld joints, considering point loads and 2-D analysis. ANSYS we obtained a stress of 3111 psi at the seating area weld joints, considering distributed loads and 3-D analysis.
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BUV Model
Scale: 1 inch = 1 footThe model helped the group make recommendations for improvements.
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Recommendations
Add 1 foot to the cargo areaAdd additional support under seating areaChanges to front of chassis to accommodate steering linkages
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Questions?