Introduction

Introduction

Project Status Update R09220 Competitive FSAE Autosports Systems Aaron Heyman (IE) Shijo George (ME) Stephanie Malinowski (ME) Alex Sandy (ME) Greg Wall (ME) Ken Mcloud (ME) Project Status Update Project Number R09220 Project Family Competitive FSAE Autosports Systems Track Vehicle Systems Technology Start Term 2008-2 End Term 2012-3

Faculty Guide Dr. Alan Nye (Mechanical Engineering) Faculty Consultant Dr. Martin Gordon, P.E. (Mechanical Engineering Technology) Primary Customers Formula SAE Mini Baja SAE Project Mission Statement Product Description /Project Overview Developing a road map with a vision of where competitive auto-sports should be three years from now. Includes progressive innovation of senior design projects in the FSAE auto-sport discipline. Project Deliverables Competitive FSAE Autosports Roadmap Detailed project proposals beginning 2008-2 Values and Norms Punctual Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict

comes up, the absent team member will notify at least one team-mate prior to the expected absence. An absent team-member should confirm that a team-mate has received their message (in person, voice mail, email, etc). Thorough Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person. Accurate Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow. Professional and Ethical Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers. Demonstrates the core RIT values of SPIRIT. Committed Each team member will contribute an equal share to the success of the project.

Open source All information and finding should be accessible to the RIT and public community Preliminary Roadmap Filament Winding Machine Project Name Filament Winding Machine Project Number P09226 Project Family Competitive FSAE Autosports Systems Project Leads Shijo George (ME) Alex Sandy (ME) Start Term

2008-2 planned academic quarter for MSD1 End Term 2008-3 planned academic quarter for MSD2 Faculty Guide Dr. Alan Nye (Mechanical Engineering) Faculty Consultant TBA (Dr. Ghoneim, Dr. Kempski) Primary Customers Formula SAE, Mini Baja SAE Filament Winding Machine Mission Statement: To develop a low cost, first generation filament winding machine which produces simple composite tubing that can be further developed by future senior design teams Roadmap Objective:

Fundamental step in developing carbon fiber tubing to be used in space frame of Formula Racing vehicles Objectives and Project Deliverables Filament Winding The process by which a continuous strand of impregnated fibers is wound onto a mandrel with specific fibers orientation which is controlled by computer. After the resin has cured, the mandrel is withdrawn Components produced include pipe work, pressure vessels, storage tanks, and helicopter blades Schematic of the wet filament winding process

http://www.sciencedirect.com/cache/MiamiImageURL/B6TX5-4GY86TM-1-4/0?wchp=dGLbVzb-zSkWb Layout http://www.globalsecurity.org/wmd/library/report/2004/isg-final-report/ch4_img09.jpg Staffing 1 Computer Engineer Design Develop program/controls for relative speed of mandrel to feed eye (determines fiber orientation) Build 4 Mechanical Engineers Design CAD Design Determine speed, tension, machine layout Determine fiber orientation, tube specifications (based on testing capabilities) Build

Build set-up based on design (new machine system or off of existing lathe) Test Determine strength of tubing in tension, bending, torsion Preliminary Work Breakdown Structure Team Member ME (Project Manager) ME (Chief Engineer) Week 1 Week 2 Week 3 Establish team values Establish individual team member roles

Establish project direction and provide future WBS Analyze proposed designs for feasibility Begin theoretical composite analysis and norms Initiate brainstorming Provide team with technical background information and design constraints ME ME CE

Develop understanding of project and consider possible designs Determine feasibility of proposed designs Research applicable control components Determine machine criteria (rpm, fiber tension, etc.) Determine machine design layout Begin control system design Concerns and Constraints Project o Sponsor(s)

o Advisor(s) o Build Space for filament winding machine o Finalize Budget o Raw Matl $800-$900 o Motor and misc. $600- $700 Design o Fiber/Resin/Mandrel material o Control of fiber orientation angle o Existing lathe vs. build from scratch Water Propulsion

http://www.pbase.com/dhnieman/image/43076690 Gregory Wall Stephanie Malinowski Background Every year, the RIT club known as mini baja designs a water land vehicle to compete in competitions all over the nation. The vehicle is put through rigorous events that test the student's ability to engineer a fast, durable vehicle that meets certain specifications set forth by the SAE organization. http://www.rit.edu/news/newsevents/2006/Feb02/photos.php Customer Needs Water Propulsion system light weight and durable Water proof Able to be remanufactured Ability to turn in water Propelled forward quickly in water

Mission Statement To design and develop a test stand for the water propulsion system that will measure the output force, durability and control of the system. The test stand must accommodate a full scale model of the propulsion system and be able to lift the tires in and out of the water as well as rotate freely. The stand must also and have a user friendly interface that displays quantitative information about the system. This will aid in the design of the water propulsion system that will be build later in the project. Staffing Requirements Name Discipline Role / Skills TBD TBD

Faculty Guide, Will work closely with the team on an on-going basis to facilitate success. TBD TBD Faculty Consultant, Will provide discipline technical support on an intermittent basis. TBD TBD Teaching Assistant Stephanie Malinowski ME Project Manager, Schedule meeting, book keeping, and keep team and project on track. Encourage team members.

Gregory Wall ME Chef Engineer, Head the design and building of the test stand, and water propulsion system. Encourage team members. TBD Student EE Involved in the design and development of the sensor and wheel drive system of the test stand. Involved in any motorization of the water propulsion system that may be needed. TBD Student ME Assist with the chef engineer, and help develop an build the test system. Will do materials research for water resistance and protection of the motor. TBD Student

CE Developing the interface for the test stand to display the information collected from the sensors, and to run the test stand. TBD Student IE Develop a way to remanufacture the system quickly and efficiently. Work Breakdown Person Week 0->1 Tasks Week 1->2 Tasks Week 2->3 Tasks ME- Project

Manager Schedule team meetings and get group information, as well as get group caught up with background information of the project, and expectations. Team building exercises. Make sure everyone from the group is on task, and is up to speed with each other. Update website, and schedule any needed meetings with Baja. Update website, make sure everyone is on track. Help the other MEs with the design and fabrication of test stand. ME- Chief Engineer

Research previous designs, and get group caught up with rule and regulations. Give group members starting goals. Continue with R+D, look into materials to use on the test stand, and start collecting resources and planning design. Start finalizing designs for the test stand, and make sure all the necessary recourses are lined up for building it. EE Research sensors and suitable motors, for both the test stand and the water propulsion system.

Continue research, start looking into where we can get the resources needed for the project. Start getting a hold of motors and sensors, and wiring and testing them to make sure they will work as needed. ME Get together with the chef engineer, and help review and research designs. Work with chef engineer in material research. Continue working with chef engineer for finalizing the design of the test stand.

CE Get together with the EE and discuss sensors they will be used and make sure they can be implemented into a user interface. Continue working with the EE, and possibly start developing a program for the user interface. Continue developing a user interface. IE Work with the two MEs with the initial research and development. Continue working with the MEs in material research.

Continue working with MEs, making sure final design is manufacturable. Required Resources Old Baja Chassis Light weight, durable, water resistant materials Motors and sensors Machine shop Computer lab for user interface Lab to build test stand Wheels and tires Lots of water http://users.wpi.edu/~minibaja/images/title_page.jpg Issues and Risks Currently do not have a sponsor, and therefore no funding. Acquiring resources Time in the machine shop

Budget Materials: $750 to $1250 + Motors and sensors: $1000 to $1500 = Maximum approximate budget of $2750 http://www.clipartheaven.com/clipart/money/dollar.gif Active Suspension P09227 http://myautohub.blogspot.com/2008/04/double-wishbone-suspension.html http://www.wpclipart.com/tools/miscellaneous/magnet_with_nails.png Ken McLoud Mission Statement To Design and build an open source active

suspension system based on a linear electric motor. The system will be built on a small scale test stand that mimics a double wishbone suspension. Serve as a proof of concept Minimize Cost The control system will be able to: Minimize the effect of disturbances Accept commands to effect dynamic load transfer Staffing Requirements Name Discipline Role / Skills Ken McLoud

ME TBD EE TBD EE TBD ME Project Manger / Controls Engineer Power Systems (Actuator / Power Amp) Controls Circuitry (Sensor / Compensator) Linear Motor / Spring Design

TBD ME Test Stand Design TBD ME Control System Design Preliminary WBS Title Week 1 Task Week 2 Task

Week 3 Task Project Manager Assemble and Organize Team Research Available Define and manage Parts and Interface Specs Technologies Power Systems Engineer Study Mission Statement and Customer needs Begin Power Amp / Coil Design

Control Circuitry Engineer Aid Controls Engineer in Sensor and Compensator design Actuator Design Engineer Begin Actuator Design (W/ Power Systems Engineer) Test Stand Design Engineer Coordinate with Formula Team and Begin Test Stand

Design Controls Engineer Develop Plant Model and Begin Budge t Item N52 Neodymium Magnets Control Circuitry Very Approximate Cost ~$700 ~$600 Power Amp

~$800 Test Stand ~$300 Total ~$2500 Data Acquisition System Aaron Heyman Project Status Update Project Number R09224 Project Family Competitive FSAE Autosports Systems Track

Vehicle Systems Technology Start Term 2008-2 End Term 2008-3 Faculty Guide Dr. Alan Nye (Mechanical Engineering) Faculty Consultant TBD Primary Customers Mini Baja SAE Purpose Utilize electronic sensors to record vehicle performance and provide vital data to pit crew in order to enhance cars performance

Design and test data acquisition system that will eventually be used on the Baja vehicle Intellectual Property and SAE Regulation Concerns Project must comply with all SAE Baja rules No real time telemetry All source code must be open source Staffing Requirements Faculty Guide: TBD IE : Project Management ME: Testing lead, Auto specialist (Baja member) ME: Develop on car housing unit for DAQ CE: Develop software interface for DAQ EE: Program and develop sensor packages EE: Design control unit to record data

Work Breakdown Structure Person Week 1 Week 2 Week 3 IE Aaron Present group to project Establish goals for SD I and II Understand teams skills and Build consensus on prototype Order necessary parts Develop future WBS Feasibility Assessment

design Build preliminary budget weaknesses Establish Values and Norms ME Come up to speed on project purpose and scope Meet with customer to identify needs Begin brainstorming solutions Work with EE to design control Work with others to develop unit prototype

Develop draft of testing protocol ME Come up to speed on project Brainstorm ideas for on-board Begin designing housing purpose and scope Meet with customer to identify needs housing prototype for housing unit CE Come up to speed on project

Research potential interface Begin sensor design and purpose and scope designs Begin brainstorming solutions programming EE Come up to speed on project Begin sensor design and purpose and scope Begin brainstorming solutions Identify necessary sensors

EE Come up to speed on project Develop prototype design for Develop documentation and purpose and scope control unit Begin brainstorming solutions schematics documentation of schematics Concept Development Customer Needs: Joe Featherall Meeting with E-Board

Wednesday RPM, Low Fuel, Wheel Speed, Crankshaft Speed Robust Design Quickly extract data from on-board device Risks Lack of funding No sponsor at this time Will speak with Baja about possible funding Ability to acquire old Baja vehicle Build space to work Questions ?

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