P19231: Training Wheels
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

In the Detailed Design Phase, our team aimed to compete as many of the deliverables as possible that would allow any other team to pick up our work and complete our final product. These documents include schematics, analyses, a Bill of Materials, vendor items selected, and various flow charts that instruct engineers on how to assemble, combine, and create the O-Shift device.

Steve:

Tyler:

Kevin R:

Kevin G:

John J:

Matt W:

General Design

Some general images depicting the 2010 Ford Fusion are shown below.
General 2010 Ford Fusion Layout

General 2010 Ford Fusion Layout

Underside of wheel of 2010 Ford Fusion

Underside of wheel of 2010 Ford Fusion

Pedal Arrangement for 2010 Ford Fusion

Pedal Arrangement for 2010 Ford Fusion

Dead Pedal Zone for 2010 Ford Fusion

Dead Pedal Zone for 2010 Ford Fusion

Center Console of 2010 Ford Fusion

Center Console of 2010 Ford Fusion

Cupholder Region of 2010 Ford Fusion

Cupholder Region of 2010 Ford Fusion

A problem was discovered that would affect the mounting and operation of our clutch pedal device in the Ford Fusion. As highlighted in red in the image below, there was a region on the floor of the car with a degree of surface curvature. As the O-Shift device was initially designed to reside on a flat surface, it would not be able to mount to this location. It was further determined that relocating the clutch pedal unit any closer to the brake pedal would result in the pedals being too close together for driver comfort. So, to combat this issue, our team proposed that the best course of action would be to mount the clutch pedal unit to the dead pedal zone. This would resolve the dilemma with the surface flatness as well as create the necessary distance between pedals. A quick user test determined that the location of the pedal atop the dead pedal zone was indeed more natural. However, this adjustment lead to some problematic consequences. It would require a redesign of the clutch pedal unit as well as a new means of mounting. The volume of space to work with changed and new measurements needed to be taken. But, perhaps more troublesome was the fact that the clutch pedal unit device would not be aligned to the height of the other pedals in the Fusion, which is a common requirement for user comfort. The dead pedal zone was already almost the height of the brake pedal, and adding any amount of stroke distance to the pedal would immediately make the height alignment infeasible. So, in a decision of practicality, our team decided that the pedal height alignment requirement was less important than any of the efforts it would take to correct the problem (which might entail changing the vehicle). And, further, we might have to shorten the distance of the stroke and optimize pedal height against stroke distance through user comfort.

Surface Flatness Problem in 2010 Ford Fusion

Surface Flatness Problem in 2010 Ford Fusion

Component Selection

Bimba Pneumatic Cylinder

Bimba Pneumatic Cylinder

Bimba Pneumatic Cylinder Drawing

Bimba Pneumatic Cylinder Drawing

DigiKey Force Sensor

DigiKey Force Sensor

DigiKey Hall Effect Sensor

DigiKey Hall Effect Sensor

DigiKey Ultrasonic Sensor

DigiKey Ultrasonic Sensor

WeatherTech Floor Mat

WeatherTech Floor Mat

Wilwood Pedal

Wilwood Pedal

Atlantic Universal Ball Joint

Atlantic Universal Ball Joint

McMaster-Carr Spring

McMaster-Carr Spring

DigiKey Display

DigiKey Display

Mouser MCU

Mouser MCU

DigiKey Limit Switch

DigiKey Limit Switch

Drawings, Schematics, Flow Charts, Simulations

Clutch Module

With a new volumetric region of space to work with, the clutch pedal needed to be redesigned. As this effectively changed the entire design, some new size constraints needed to be added, and the design had to account for stability in its new location. A dual plate system was incorporated to mount the unit to the Weathertech mat. One plate would rest underneath and the other plate would clamp overtop. Holes would be drilled into the mat and duct tape and Velcro would add additional support to restrict movement during motion. The final design very closely resembled the prototype unit we had created, as we knew the size, shape, and stability of that unit was sound. The largest change to the design was the use of two beams on either side to aid with buckling and stress. The final design can be seen below. The working documents of the SolidWorks models can be seen at the following link https://drive.google.com/drive/folders/1JjinYaG37WFtNocN297c4YC_c4F8yuQC
Pedal Assembly in the Upward Position

Pedal Assembly in the Upward Position

Pedal Assembly in the Downward Position

Pedal Assembly in the Downward Position

Several analyses were conducted on the assembly to test whether it was at risk for buckling or breaking. It was discovered that SolidWorks will excessively warp each component under stress to its maximum position, regardless of the force applied, and then highlight the corresponding, more accurate stress/strain/deformation values. This leaves us with a visual image that makes the system appear to be bending, while in reality we need to simply reference the scale along the side to test for failure.

Pedal Unit Buckling Analysis

Pedal Unit Buckling Analysis

Pedal Unit Displacement Analysis

Pedal Unit Displacement Analysis

Pedal Unit Stress Analysis

Pedal Unit Stress Analysis

Pedal Unit Strain Analysis

Pedal Unit Strain Analysis

Engineering Drawings for the Clutch Pedal Unit are presented below. We plan to machine these components accordingly using stainless steel and the RIT Machine Shop. We have to decide whether welding or simply obtaining a larger block of stainless steel will be necessaryfor some of the components.

Clutch Pedal Assembly Drawing

Clutch Pedal Assembly Drawing

Beam ABC Drawing

Beam ABC Drawing

Beam BD Drawing

Beam BD Drawing

Beam CEF Drawing

Beam CEF Drawing

Main Base Plate Drawing

Main Base Plate Drawing

Secondary Base Plate Drawing

Secondary Base Plate Drawing

Shifter Module

The fully assembled shifter module

The fully assembled shifter module

The shifter module with the top plate removed to show lockout plates

The shifter module with the top plate removed to show lockout plates

Top view of the shifter module

Top view of the shifter module

The assembled shifter module inserted into a simplified model of the car's center console

The assembled shifter module inserted into a simplified model of the car's center console

Assembly Drawing for the shifter module

Assembly Drawing for the shifter module

Drawing of the top lockout plate

Drawing of the top lockout plate

Drawing of the lower lockout plate

Drawing of the lower lockout plate

The transfer balls to be used around the lockout plates

The transfer balls to be used around the lockout plates

Drawing of the transfer ball

Drawing of the transfer ball

Main Display

Schematics

Display MCU Pinout

Display MCU Pinout

Display Main Schematic

Display Main Schematic

Display Power Supply Schematic

Display Power Supply Schematic

Display Main MCU Schematic

Display Main MCU Schematic

Main Display Schematic Live Document

Simulations

3.3V Power Supply Current Draw

3.3V Power Supply Current Draw

3.3V Power Supply Efficiency

3.3V Power Supply Efficiency

5.0V Power Supply Current Draw

5.0V Power Supply Current Draw

5V Power Supply Efficiency

5V Power Supply Efficiency

Shifter Board

Schematic

Shifter Board Schematic

Shifter Board Schematic

System Wiring Connections Diagram

Overall Wiring Connections Diagram

Overall Wiring Connections Diagram

Signals and Required Cable Run Lengths

Signals and Required Cable Run Lengths

Bill of Material (BOM)

Price Overview

Price Overview

Price Overview

Display Subsystem BOM

Display Subsystem BOM

Display Subsystem BOM

Shifter Subsystem BOM

Shifter Subsystem BOM

Shifter Subsystem BOM

Clutch Subsystem BOM

Clutch Subsystem BOM

Clutch Subsystem BOM

Custom Board BOMs

Display Custom Board BOM

Display Custom Board BOM

Shifter Custom Board BOM

Shifter Custom Board BOM

Test Plans

Test Plan Outline

Test Plan Outline

Test Plan Page 2 - 3

Test Plan Page 2 - 3

Test Plan Page 4 - 5

Test Plan Page 4 - 5

Test Plan Page 6 - 7

Test Plan Page 6 - 7

Test Plan Page 8 - 9

Test Plan Page 8 - 9

Provided below a link to the Live Document of the Test Plans:

P19231 Test Plans

Design and Flowcharts

Software Architecture and Layout

Software Architecture Diagram

Software Architecture Diagram

Software Architecture Diagram

Software Architecture Diagram

Risk Assessment

Below updated version of the risk assessment. There was no big fundamental changes except the change of severity of our system being too close to Emergency Brake. Most of the other revised risks are items that through simulation and testing, the likelihood has been decreased.

Risk Assessment 1

Risk Assessment 1

Risk Assessment 2

Risk Assessment 2

Risk Assessment 3

Risk Assessment 3

Below a link to the live document of Risk Assessment:

P19231 Risk Assessment

Plans for Next Phase

Team Tasks Moving Forward

Individual Tasks Moving Forward

Steve:

Tyler:

Kevin G:

Kevin R:

John J:

Matt W:


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