Full Scale Steering and Emergency Braking Team

Week 10 this week the team worked on finishing up solid work models and conducted FEA on most of them Through rapid prototyping we were ale to see that our designs had a few problems that needed to get fixed before the final product. Articulation The problem with articulation structure where it would fail when loaded with 2500lb was fixed by adding a small section that helped reduced the moment arm caused by the bearing carriage. Shown in next figure.  The following figure shows the redesigned part. This new design greatly reduces the moment arm allowing the structure to carry more weight. This design has a factor of safety of 8.86 this means there is alot we can do to improve the design and reduce its weight from current 14 pounds. Since the bogie will not be using an axle we had to think of a new way to mount wheel housing to the new articulation system for now we designed this component which works as a carriage for the thrust bearing and also has mounting holes

For this week, the team is preparing for presentation next week. Articulation of bogies: Completed design for new, light weight Z-bracket in Solidworks. Performed FEA on the Z-bracket FEA results show a need for thickness in material, Safety factor below 1. Working on changes to design. Plan on 3D printing rapid Prototype NEED to add a rib on steering rack reduce moment arm caused by the bearing holder Possibly make plates 5mm thickness instead of 3mm Spring Loaded Guide Arm: Performed Calculations for Max load of spring and spring rate Researched for the damper criteria for selection Calculated frequency for damper and Max energy absorbed The natural frequency of the system is much lower than the frequency of force given by the track, so this means that resonance will not occur. Dr. Furman concludes,from the results, that a damper is not practical and cost effective for Maker's Faire. However, I will included into design, but not actually included in rea

Week 8 update Steering Rack mounting points for steering rack were determined. the team will be using Unit strut to bolt down the steering rack. The mounting point are shown in the following image. The dX (6.74in) is subject to change when final FEA analysis is done. this would effect the current way that the unit strut is set up. Current  height of steering rack will be 6.4 inches from bottom surface to top Guide Arm team is working on solidwork models of the guide arm FEA analysis was done on the guide component. Dr. Furman recommends a incorporation of damper into the system to make motion more smooth Calculation of the force acting on the wheel was performed using Matlab The full design of the guide arm is available on individual post from two weeks ago. Braking system  Breaking system was relocated from the inside of the track to the bottom  This new design will allow the brake pads to press on the bottom of the tracks to slow the bogie

10/4/2018 Team consulted the track team for dimensions cleared up objectives we need to finish before semester ends Had a FEA learning session as a team Began FEA procedure on guide arm assembly. Went over ideas for Rapid prototyping for emergency braking system