P18031: Accessible Motorcycle Sidecar
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Detailed Design

Table of Contents

Our group’s goal is to design an accessible motorcycle sidecar, which allows people with mobility issues to participate, and deliver a working prototype and documentation package to our customer by the end of the Senior Design. Our design solution, modeled to fit the Ural-Patrol sidecar, shall be available at a low cost with the best user experience possible while meeting needs of a variety of people with mobility issues such as paraplegia, old-age, degenerative muscle diseases and more.

Review objectives

The objective of this review is to determine if we are ready to move on to MSD2. This includes:

Team Vision for Detailed Design Phase

For the detailed design review, the team's priority was to complete the drawings necessary for production. The team also had plans to complete test plans and complete the plan for MSD 2. Our team did accomplish all of our goals.

Team Goals

Deliverables Goal Status
Mid-phase progress report sent out 100% 100%
Complete design output 100% 100%
Design Documentation 100% 100%
MSD II plan 100% 100%
Engineering Requirements 100% 100%
Risk assessment, mitigation plans & triggers 100% 100%
Test plan 100% 100%
Ready to order long lead-time parts and implement the design 100% 100%

Agenda

  1. Team Vision
  2. Agenda
  3. Preliminary Detailed Design Refresh
  4. Model
  5. Bill of Materials
  6. Drawings
  7. Feasibility/Proof of Concept
  8. Risk Analysis and Mitigation
  9. Test Plans
  10. Phase Summary And Action Items
  11. Plans for MSD II

Systems Design Refresh

# Constraints Targets Limits
1 Maintain DOT/FMVSS Reg Meets N/A
2 Fitted for Ural Patrol Meets N/A
3 Maintain Ural Patrol Bolt Pattern Meets N/A
4 DOT Requirements on Windshield Meets N/A
5 Weight 110lbs 180lbs
6 Package Dimensions <70"x22"x18" <84"x24"x20"
7 Passenger has limited use/no use of legs, lack of body strength, flexibility <70"x22"x18" <84"x24"x20"
8 Budget <$3000 $3000
9 Limited Power Source None Only on Ingress
Customer Requirements

Customer Requirements

Customer Requirements
Engineering Requirements

Engineering Requirements

Engineering Requirements
Concern Action Responsible Status Reference
Information on Paint Determined Paint color, sourcing, and method of painting Jeremy D Solved Manufacturing Report
Process for weld of sheets Process for welding sheets developed Jeremy D Solved Manufacturing Report
What is the max height of rider for a comfortable leg fit? Ergonomic validation performed Erol A Solved Ergonomic Report
How does it latch/unlatch & seal? Included pull handle latches and elastomer seal in CAD Model Dobhran B Solved CAD Model & BOM
Is the seat unlock ergonomically practical? Ergonomic study performed Erol A Solved Ergonomic Report
What releases the raising body/frame? Added pull handle latches in CAD Model Dobhran B Solved CAD Model
Weld callouts missing Weld callouts added to drawings Dobhran B Solved CAD Model
Have all Critical/major ER’s have POC? If now, when? Better linkage of Engineering report and POC Hiroki T Solved Engineering requirement detail
Is door frame bend around frame or 3 pieces welded? Confirmed to three piece, separate parts Dobhran B Solved CAD Model
How do you mount the chair? Created Exploded view to explain mounting Dobhran B Solved CAD Model & Exploded View

Progess Report

Model

Artist Drawing

Artist Drawing

Side Profile

Side Profile

Isometic Profile

Isometic Profile

Exploded Body

Exploded Body

Exploded Door

Exploded Door

Exploded Lower Panels

Exploded Lower Panels

Ingress & Egress Exploded

Ingress & Egress Exploded

Link to All Documents

Video

link to video

Bill of Materials (BOM)

Bill of Materials

Bill of Materials

Bill of Materials

Drawings

Fullasm

Fullasm

Rack

Rack

Frame Base

Frame Base

Link to All Documents

Feasibility/Proof of Concept

Engineering Requirements

Engineering Requirements % Test Plan Relation

Engineering Requirements % Test Plan Relation

Mockup I Design

Mockup V1

Mockup V1

Mockup V1 Dimensions

Mockup V1 Dimensions

Test Report Test Survey

General Video

Link To Video

Results

Graph of Values From Mockup V1 Test

Graph of Values From Mockup V1 Test

Comments

Comments

Test Report (2)

Test Survey

Mockup II Design

Mockup V2

Mockup V2

Mockup V2 Dimensions

Mockup V2 Dimensions

Comments from Handicapped Testers

Comments from Handicapped Testers

Handicapped Tester

Image of Handicapped Tester

Image of Handicapped Tester

Link to Video

Video

Link to Video

Ergonomics

Percentile Passenger Area (in) Whole Leg Length(in) Space
M95 (6'3", 250lbs) 57" 49.6" 7.4"
M50 (5'10, 180lbs) 57" 45.6" 11.4"
F05 (5'1", 102lbs) 57" 39.1" 17.9"
95% Male Side Profile

95% Male Side Profile

50% Male Side Profile

50% Male Side Profile

5% Female Side Profile

5% Female Side Profile

Percentile Sidecar Width(in) Shoulder Width(in) Space
M95 (6'3", 250lbs) 23.95" 19.9" 2.03"(each side)
F05 (5'1", 102lbs) 23.95" 14.8" 4.58"(each side)
95% Male Top Profile

95% Male Top Profile

5% Female Top Profile

5% Female Top Profile

Percentile Distance Between Handle and Hand
M95 (6'3", 250lbs) 9"
M50 (5'10, 180lbs) 12"
F05 (5'1", 102lbs) 17"
Pull Down Handle Analysis

Pull Down Handle Analysis

M95 Trunk & Door Reach Analysis

M95 Trunk & Door Reach Analysis

F05 Trunk & Door Reach Analysis

F05 Trunk & Door Reach Analysis

Percentile Hip Width Seat Width Difference
M95 (6'3", 250lbs) 14.8" 15" .2"
M50 (5'10, 180lbs) 13.4" 15" 1.6"
F05 (5'1", 102lbs) 12.1" 15" 2.9"
Corbeau Baja SS Seat

Corbeau Baja SS Seat

SME Report

Structural Integrity Analysis (FEA)

Frame

Frame Stress Analysis

Frame Stress Analysis

Frame Displacement Analysis

Frame Displacement Analysis

Body

Body Analysis

Body Analysis

Cantiliver Rails

Cantilever Analysis

Cantilever Analysis

Passenger Safety Report

Frame Force Directions

Frame Force Directions

Frame Force Results

Frame Force Results

Safety Report

Manufacturing Feasibility

Manufacturing Feasibility Report

Manufacturing Feasibility Report

Fabrication Capabilities Fabrication Flow Chart [[Painting Process Sheet

Process Sheet Template

Welding Process Sheet

Weight Analysis

Weight Analysis

Weight Analysis

Takeaway

The weight is below the maximum allowed.

Mass Properties

Center of Gravity (Original Sidecar)

Center of Gravity (Original Sidecar)

DOT Requirements

DOT Requirements

DOT Requirements

Risk Analysis

Updated risk

Updated risk

Risk Graph

Risk Graph

Test Plans

Test Plan Chart

Test Plan Chart

Test Plan

Test Plan

Test Plans

Phase Summary

DDR plan

Plan for Detailed Design Review

Plan for Detailed Design Review

Lessons learned

Summary of Lessons Learned
Lessons Learned Dont wait around waiting for someone to assign you something to do. Take initiative and get ahead on work. Make time in the schedule for unplanned tasks. Things always come up, so be prepared to deal with them. Talk to sme's about problems or concerns in feasabliity. They have experience in the subject matter.
Action Taken All group members, this phase, took initiative and asked for things to do when not busy. Gantt charts added leaway for unplanned tasks, incase things were missed during the phase. Group members talked to smes about any specific topics that needed additional input.

Individual contribution

Summary of Individual contribution

Each team member did an equally large amount of work during this phase. This allows for a successful ending to senior design 1 and allowed us to be prepared and ready for the start of senior design 2.

Member Contributions Contribution Percentage
Erol Arican Order parts, Ergonomics report 20%
Dobhran Black System Design, Drawings, BOM, Weight Analysis 20%
Jeremy Davin Made Mockup V2, manufacturing report, sourcing parts 20%
Matthew Doroz Edge Updates, Documentation, test plan 20%
Hiroki Tanaka Gather Test subjects, MSD II plan, update Engineering requirements, Previous open Item 20%

Feedback

Summary of Feedback

Team Member Positive Improvement Areas Plan
Erol Arican Ergonomics, Willingness to Work, Good work with Edge Speak up more in meetings, need to plan tasks better Used Trello to plan
Dobhran Black Quality work Communicate when overburdened Communicate and delegate task overflow
Jeremy Davin Good knowledge of fabrication and ownership of hands-on tasks Could take on more work outside of fabrication role Next phases will be all fabrication
Matthew Doroz Good with the FEA Should continue learning more with the FEA Talk to professors and research FEA
Hiroki Tanaka High Motivation Continue to work on managing anxiety/panic. Also work on being more on-top of the schedule/gantt since that is Gary's main way of tracking our progress. Ask for help if needed. Better use of gantt chart and talking to guide

Overall MSD I Feedback

Team Member Positive Improvement Areas Plan
Erol Arican Worked well with team members, Great ergonomic analysis, Time management and planning, presentation skills Use Trello, practice presentation skills
Dobhran Black Hard Worker, good design work Volunteering more and Communicating Speak up when overburdened
Jeremy Davin Fabrication Knowledge Timeliness needed work Worked to improve timeless - no longer an issue as of Phase 3
Matthew Doroz Good at catching missing deliverables Should stay more focused during meetings Depend on team to inform when going off tangent
Hiroki Tanaka Positive Enthusiasm Better scheduling and Calming down Better use of gantt chart and talking to guide

Recommendation

What Was Done Well
MSD 1 helped improve our presentation skills significantly.
Having design reviews on specific dates helped plan our project and schedule.
Having an experienced guide helped teach us valuble skills nessesery in future employment.
Improvement areas
Have Gary do his presentation on presenting MUCH earlier in the course.
Have a document specifying direct deleverables for each phase.
Organize content on mycourses better.
More conference rooms for reviews.
Get much more tools for students to use and allow self checkout of tools.
Use WIKI website instead of edge

Next phase & Action Items

MSD II High Level

Gantt chart

plan for MSD II

plan for MSD II

PDF file

Deliverables

Phase 4 deliverables Goals
MSD I post-mortem 100%
MSD II project plan (rev 2) 100%
Status long-lead time purchases 100%
Test plan (rev 2) 100%
Test bench setup 100%
Problem tracking sheet 100%
Subsystem Functional verification 100%
Subsystem Functional documentation 100%
Full System test verfication 100%
Full System test documentation 100%
Technical Paper complete 100%
Poster 100%
Prototype handoff 100%

MSD II Phase I

Gantt chart

plan for MSD II phase I

plan for MSD II phase I

PDF file

Deliverables

Phase 4 deliverables Goals
MSD I post-mortem 100%
MSD II project plan (rev 2) 100%
Status long-lead time purchases 100%
Test plan (rev 2) 100%
Test bench setup 100%
Problem tracking sheet 100%

Individuals

Week Erol Arican Dobhran Black Jeremy Davin Matthew Doroz Hiroki Tanaka
Week 1 Create Long Leadtime Purchase update Prepare all Life size drawings Cut all Waterjet sheet Cut all Body Tube Update Test plan Update MSD2 Project plan Create Problem Tracking document
Week 2 Upload all files to EDGE Update Waterjet File Bend all sheet parts Bend all Tubes Complete MSD Post Mortem Update MSD2 Project plan Create Problem Tracking document

Parts to Order

Parts to Order

Parts to Order


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