P17025: Portable Toddler Treadmill
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Detailed Design

Table of Contents

All relevant documents can be found here

Team Vision for Detailed Design Phase

The goal of this phase is to finalize the design, engineering analysis, simulations, test documents, and engineering requirements. ISO and ASTM standards were further researched and applicable standards are shown in the engineering requirements. The mechanical system was designed in CREO and the electronics system was outlined. Coding was experimented with as well.

Progress Report

The ISO and ASTM standards were reviewed and incorporated into the engineering requirements and the test document. The electrical system was laid out and the mechanical system was modeled in Creo. Our bill of materials is completed and we are just under the budget and weight requirements.

Engineering Requirements

Engineering Requirements

Engineering Requirements

Notes for ISO and ASTM

IS020957-1

ISO20957-6

ASTM Standards

Design and Flowcharts

Block Diagram

Block Diagram

Block Diagram

System Architecture

System Architecture

System Architecture

Prototyping, Engineering Analysis, Simulation

Mechanical System

Treadmill Frame Analysis

public/Detailed Design Documents/Mechanical_analysis/8.PNG

public/Detailed Design Documents/Mechanical_analysis/8.PNG

Hand calculations:

Aluminum Frame Beam Cross Section

Aluminum Frame Beam Cross Section

Aluminum Frame Upper Beam Loading

Aluminum Frame Upper Beam Loading

Analysis

Analysis

Factor of Safety

Factor of Safety

Factor of Safety: Xs=16.25

Vertical Beam Compression Analysis:

Vertical Frame FBD

Vertical Frame FBD

Hand Calculations:

Vertical Frame Analysis

Vertical Frame Analysis

Max deflection due to Loading of 0.04"

Frame Analysis for Lifting Case

public/Detailed Design Documents/Mechanical_analysis/2.PNG

public/Detailed Design Documents/Mechanical_analysis/2.PNG

Crossection

Crossection

FBD

FBD

Ansys

Ansys

Max Von Mises Stress:2761 KSI= 19.03642 MPA

Factor of Safety: Xs= 9.8

Pulley Analysis

Pulley Ansys

Pulley Ansys

Max Von Mises Stress=51 psi=0.35 MPA

Pulley is safe for motor torque.

Motor Analysis

Motor Analysis was completed in Preliminary Design review the following motor was selected.

There are two main requirements for the motor:

System Requirements

System Requirements

Schematic of Motor and Belt Pulleys

Schematic of Motor and Belt Pulleys

Possible DC Gearmotors:

DC GearMotors

DC GearMotors

Selected motor:

Final 2 Motors

Final 2 Motors

Analysis for MDF Board

Stress and Life analysis were calculated for the current MDF board design.

Important Assumptions:

MDF_FBD

MDF_FBD

Factor of Safety: Xs=17.613

Life: 1.84*1015 cycles

The Analysis can be found here

Drive Belt Length

Motor Belt Length

Motor Belt Length

Drawings, Schematics, Flow Charts, Simulations

Mechanical System

Iso View of Total Assembly

Iso View of Total Assembly

Iso View of Total Assembly

Iso View of Total Assembly

Frame

Internal view of treadmill

Internal view of treadmill

Motor

Motor Schematic

Motor Schematic

Pulley&Belt

Pulley Drawing

Pulley Drawing

The pulley is to be attached to the motor and will drive a 21" micro-V belt attacked to the roller.

Roller

Roller Assembly

Roller Assembly

Tread

Tread is to be purchased from a company who makes custom treadmill belts to dimension. To fit the need of the portable treadmill it will have to be made 14" wide and have a total length of 51". For vendor information see BOM.
Roller Assembly

Roller Assembly

Software System

Arduino Software

The open-source Arduino Software (IDE) makes it easy to write code and upload it to the board. It runs on Windows, Mac OS X, and Linux. The environment is written in Java and based on Processing and other open-source software.

Finite State Machine/Flowchart

General Flowchart

General Flowchart

Timing Flowchart

Timing Snapshot

Timing Snapshot

Data Structures

Data Structure

Data Structure

Register Cheat Sheet

Register Cheat Sheet

Pseudo Code

Motor Control

Also includes emergency shut-off Motor Control Code

Hall Effect Sensor/Speed

Hall Effect Sensor/Speed

Hall Effect Sensor/Speed

Time Elapsed

Timing Code

Timing Code

Arduino to LCD

LCD Coding

LCD Coding

Electrical System

Overall Schematic

Schematic

Emergency Stop

 Emergency Stop

Emergency Stop

Foot Pedal

 Foot Pedal

Foot Pedal

Power Supplies & Power On/Off

 Power Supplies

Power Supplies

Motor Control Circuitry

 Motor Control Circuitry

Motor Control Circuitry

Equations

Arduino

 Arduino

Arduino

Connectors Used

Connectors

Bill of Material (BOM)

The Total BOM is located HERE. Page one represents last review and page two represents the changes/additions since then. Page two is the current BOM.

The Mechanical BOM is locatedHERE

Test Plans

Engineering Requirement to Test Plan

Engineering Requirement to Test Plan

Test and Standards Traceability

Test Procedure

Risk Assessment

Risk Assestment

Future Plans

Plans In Preparation for MSDII

To prepare for MSDII before the end of the semester, the team is going fix any issues that may have arose during the Detailed Design Review and contact suppliers to order all the necessary materials and components.

Plans For MSDII

Individual phase plans can be found here

Home | Planning & Execution | Imagine RIT

Problem Definition | Systems Design | Preliminary Detailed Design | Detailed Design

Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Integrated System Build & Test with Customer Demo | Customer Handoff & Final Project Documentation