P17214: Smart Mountain Bike Suspension
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

In this phase our team worked to do finalize the mechanical and the electrical aspects of the design, and to ensure that all prototyped mechanical parts will fit on the frame. All electrical components were laid out to minimize the number of wires required in the design.

A preliminary layout of the power control board was completed, such that power to all external components can be controlled by the microcontroller and to ease assembly through the use of headers and Molex connectors where possible.

A large amount of time was spent looking into datasheets for the various electronic components to ensure that compatibility between all devices was ensured.

Finalizing the last few line items on the bill of materials was critical in this phase as we finally secured funding from the Simone Center for Innovation. An NSF grant of $3000 was awarded, and some of the high-risk parts have been ordered as of the detailed design review.

A Test plan and an initial timeline for the completion of the physical construction of the project in MSDII was created during this phase to ensure that all available time is utilized effectively for the fall semester.


Progress Report

We plan to finish the Edge website, which includes all the electrical schematics for the system and how they will connect. We will also finish determining which equipment to use (batteries and regulator) and draw up the schematic for the board. We will hope to finish the drawings for the housing of the battery/ microcontroller, the servos, display, handlebar controls and the lidar mount. These will then be prototyped by the end of the semester. Lastly we will hopefully getting funding set up so that we will be able to purchase the equipment, such as lidar, micro controller, etc. The test plans will also be created so that when the parts get here we will be able to immediately start testing. We will start using the test plans to verify the functionality of the components once we get the parts and as time allows.

So far we have completed the electrical schematics for the full system and the power board. We have also finished the 3D modeling schematics for the power and microcontroller, along with the front and rear servos. We have begun modeling of some of the other mounts. The reason these other mounting systems have not been finished is due to our funding issue. We need some of the parts to be ordered and on hand so that dimensions can be taken.

The remaining tasks include drawing up the schematics for the housing of the display, lidar mount and the handlebar control. The next step is to 3D print all the components. This part will be completed by Lorenzo and Devin. Specifically the housing for the battery and microcontroller, the fork/ gears and screen mount will be done by Lorenzo. The housing for the servos, handlebar control and lidar mount will be done by Devin. The remaining tasks for the electrical section is to create the specific test plans for each component that we will be testing. This will require purchasing the parts and going through Richard to get the funding and signing up Lorenzo and Kristi for the class next semester. That is currently being worked on by multiple members of the team. Then we will test each component using the previously created test plans. This section is being worked on by Andrew, Nemanja, Zack and Kristi. Specifically, the bluetooth module will be worked on by Kristi, the lidar testing will be done by Andrew, the servo analysis will be done by Zack and the controls on the handlebars will be done by Nem. As time allows we will purchase more components needed for the design and then have members test these components.

We have made decisions to prototype the housing components using 3D printing on campus to verify functionality and attachability to Andrew’s bike. We have decided on the majority of all the components we will be using, except the battery and a few other smaller components (like navigational pad and display screen). We have made the decision to have two Team members, Lorenzo and Kristi, take a class through the Simone Center in order to receive additional funding for the design and prototyping of the system. Lastly, our concept for using the Lidar to detect oncoming terrain has been set for the project.

A question for our guide is to ask about the process and likelihood of being able to get a workspace for Fall of 2017, along with a locker to store parts.

Drawings, Schematics, Flow Charts, Simulations

Electrical Wiring Schematics

Below shows a comprehensive electrical wiring diagram for the entire system. It shows how each component will be connected to the power control board and the Arduino.
System Electrical Wiring Diagram

System Electrical Wiring Diagram

The Power Control Board will be a custom board that will control what components get power based on which mode the user is operating in. It also will contain some data lines so that it is easier to route all the wires throughout the bike frame. Below is a picture of the Power Control Board Schematic.

Power Control Board

Power Control Board

The Wiring Harness Diagram shows how all of the different wires will be routed on the bike from the power control board to the forward facing components located on the handlebars.

Wiring Harness

Wiring Harness

Mechanical Models

Display Case and Mount

Display Case and Mount

Display Case and Mount Exploded View

Display Case and Mount Exploded View

Above are images of the housing for the screen that will go on the top tube of the bike and function as the interface between the user and the status of the system.
Front Suspension Servo Mount

Front Suspension Servo Mount

Front Suspension Servo Mount, Exploded view

Front Suspension Servo Mount, Exploded view

Above are images of the housing designed for the front shock's servo. This will control the rotational motion for the front suspension system. It uses the wide diameter of the Suspension fork to mount on and the forks neck for extra stability.
Battery and Controller Enclosure

Battery and Controller Enclosure

Above is the case for power and the controller for the system. The purpose of the shape is to restrain the parts and provide sufficient airflow to the components. All the while keeping majority of the water, dirt, and mud out. We expect the down tube to create a barrier to not let majority of debris on to the enclosure.
Control Box

Control Box

Exploded View of Control Box

Exploded View of Control Box

Above is the control switch for when the system is in manual mode.
View 1 Of Rear Servo Mount

View 1 Of Rear Servo Mount

Vew 2 Of Rear Servo Mount

Vew 2 Of Rear Servo Mount

The Rear Servo Mount has proved to be a challenge to design. This is the third iteration on the design of the Rear servo mount. The Previous designs were a more direct approach where the servo was mounted inline with the switching mechanism. This proved to be an issue because when the shock compresses there is minimal room between the frame and the shock. This is why we had to go with a side mounted servo.

Drawings

Handlebar Controller
H001001

H001001

H002001

H002001

H003001

H003001

H004001

H004001

Bill of Material (BOM)

The updated Bill of Materials is shown below.

Bill of Materials

Bill of Materials

A link to the live document can be found here

Test Plans

Using an updated Version of our Engineering requirements shown below, we began to plan out how each of the requirements would be tested.
Test Plans

Test Plans

With the metrics from the document above in mind, we began to construct the test plans below, with a timeframe for their completion and an assigned member for each.

Test Plans

Test Plans

A link to the live Engineering requirements document can be found here

A link to the live Test Plan document can be found here

Risk Assessment

The updated version of the Risk Assessment is shown in the Figure below.
Updates to Risk Assessment

Updates to Risk Assessment

A link to the live document can be found here

Plans for next phase

MSD2 Preliminary Schedule

MSD2 Preliminary Schedule

Individual 3 Week Goals

Each member of the team has mapped out their goals and tasks for the next three week phase of the MSD 2 project. Individual plans are listed below

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