pace team 1 pamd presentation july 2013
DESCRIPTION
Students from Hongik University, Inha University, Northwestern University and Tuskegee University collaborated on this Personal Assisted Mobility Device project as part of PACE (www.pacepartners.org). They presented their project at the PACE Annual Forum in July 2013.TRANSCRIPT
1
Team structure / Collaboration process
Design concept / User scenario / Positioning map /
Folding system / Modular structure / Docking system /
Customizing / Mock-up process
Project management / Target market
Business plan / Marketing strategy /
Carbon footprint / Plant safety
Collaboration / Overall / Powertrain / Stability /
Frame / Driving / Module /
Vehicle Technical Specification
Contents
2
3
01 Team structure
4
01 Team structure
5
01 Team structure
6
01 Team structure
7
01 Team structure
8
01 Team structure
9
01 Team structure
10
01 Team structure
11
02 Process(January 2013~)
12
02 Process (January 2013~)
13
02 Process (January 2013~)
14
02 Process (January 2013~)
15
02 Process (January 2013~)
16
17
02 Process (January 2013~)
18
02 Process (January 2013~)
19
02 Process (January 2013~)
20
02 Process (January 2013~)
21
22
01 Design concept
23
01 Design concept
24
25
01 Design concept
26
01 Design concept
27
01 Design concept
28
01 Design concept
29
02 User scenario
30
02 User scenario
31
02 User scenario
32
02 User scenario
33
01 Design concept
34
35
Price
Weight
03 Positioning map & Package
36
Price
Weight
03 Positioning map & Package
37
03 Positioning map & Package
38
39
04 Folding system
40
04 Folding system
41
05 Modular structure
42
05 Modular structure
43
06 Customizing
44
06 Customizing
45
06 Customizing
46
handle
06 Customizing
47
06 Customizing
48
06 Customizing
49
50
07 Docking system / Smart application
51
07 07 Docking system / Smart application
52
07 Docking system / Smart application 07 Docking system / Smart application
53
07 Docking system / Smart application 07 Docking system / Smart application
54
07 Docking system / Smart application 07 Docking system / Smart application
55
07 Docking system / Smart application 07 Docking system / Smart application
56
07 Docking system / Smart application 07 Docking system / Smart application
57
07 Docking system / Smart application 07 Docking system / Smart application
58
07 Docking system / Smart application 07 Docking system / Smart application
59
07 Docking system / Smart application 07 Docking system / Smart application
60
07 Docking system / Smart application 07 Docking system / Smart application
61
07 Docking system / Smart application 07 Docking system / Smart application
62
07 Docking system / Smart application 07 Docking system / Smart application
63
07 Docking system / Smart application 07 Docking system / Smart application
64
65
08 Mock-up process
66
08 Mock-up process
67
08 Mock-up process
68
08 Mock-up process
69
08 Mock-up process
70
71
01 Project management
72
02 Target market
73
02 Target market
74
02 Target market
75
02 Target market
76
02 Target market
77
02 Target market
78
02 Target market
79
02 Target market
80
02 Target market
81
02 Target market
82
02 Target market
83
02 Target market
84
02 Target market
85
02 Target market
86
87
Driving
Brake Suspension
Powertrain
Motor Battery
Frame
Ergonomics Material selection Structure design Folding mechanism
01 Overall
Stability
Pitching direction Roll direction
88
02 Powertrain
36 V & 300 W in front wheel Weight 3 kg Fork size 14 cm Wheel diameter 30 cm
Powertrain
BLDC Hub motor
89
Traction force & Total running resistance
Slope (deg)
Power
Velocity (km/h)
Tra
ction fo
rce / T
ota
l runnin
g re
sistance
(kgf) Motor power : 300 W
Target Maximum speed : 10 km/h at 10% (6˚) uphill
02 Powertrain - Motor
Weight of STIGO: 12 kgf Weight of user : 75 kgf Air density : 1.205 kg/m^3 Frontal area : 1.1 m^2 Drag coefficient : 0.7 Rolling resistance coefficient : 0.01
90
Weight of STIGO: 12 kgf Weight of user : 75 kgf Viscosity of the air : 1.86*10^-6 kg/m-s Driveway slope : 6 degrees Driving speed : 10 km/h
300 W is enough
02 Powertrain - Motor
Verification by simulation
91
Type : BLDC hub motor
Power : 300 W
Voltage : 36 V
Torque : 14 N-m
Maximum Speed : 280 RPM
Weight : 3 kg
Fork size : 14 cm 14 cm
30 cm
14.8 cm
02 Powertrain - Motor
Specifications Location
92
Powertrain
Powertrain – Battery pack 02 Powertrain
Battery Pack
Li-ion Battery 36 V 5000 mAh / 180 Wh 22.8 x 12 x 3.8 (cm)
93
Supposing
75%
25% Walking time
Time of using
Public transportation
Average commuting Time (OECD)
35 min.
Target hour: 1 hour usage available (at 15 km/h)
02 Powertrain – Battery Pack
Target
x
Use STIGO (25%)
0.25
Round trip
2 x x
Safety factor
3
= 53 min.
94
1.7 kg
228 mm
120mm
38mm Type : Li-ion Battery pack
Capacity : 180 Wh
# of cell : 40
Type : LiFePO4
Voltage : 3.2 V
Capacity : 1400 mAH
Mass : 40 g
Battery Cell
02 Powertrain – Battery Pack
Specification Location
95
Stability
03 Stability
Stability in Roll direction Depends on driver’s position
Consideration about changing footrest position
Stability in Pitching direction Depends on distance between 2 rear wheels
Consideration about adopting tilting system
96
: Footrest positioned on rear wheel axis
Total weight : 87 kgf Driveway slope : 6 deg. Torque of Motor: 32.5 N-m Friction coefficient : stat. 0.9 / kin. 0.8
Footrest position
↑Graph of STIGO’s pitching angle
Stability test of baseline model
03 Stability – Pitching direction
97
Total weight : 87 kgf Driveway slope : 6 deg. Torque of Motor: 32.5 N-m Friction coefficient : stat. 0.9 / kin. 0.8
↑Graph of STIGO’s pitching angle
Footrest position
03 Stability – Pitching direction
Stability test of improved Model : Footrest was moved to forward 200 mm from rear wheel axis
98
A
Centrifugal force
Rollover
Rollover criteria :
(total mass) : 90 kg (user height) : 1.8 m (diameter of back wheel) : 7 in. (distance between 2 wheels) : 15 cm (acceleration of gravity) : 9.8 m/s2
(curve radius) : Variable driving speed : Variable (tilting angle) : Variable (sum of moments) : Output
03 Stability – Roll direction
Modeling
Moment equation in roll direction
+
99
An example of motor tricycle applied tilting system
No tilting STIGO Tilting STIGO (up to 10˚)
* For the sake of convenience, the right table is calculated at only 10˚, not 0~10˚ .
03 Stability – Roll direction
Stability analysis & Test
Centrifugal force
: No tilting STIGO
: Tilting STIGO (up to 10˚)
Total weight : 90 kgf STIGO height : 1.863 m (including human height) Curve radius : 3 m Driving speed : 5 km/h Tilting STIGO’s angle : 7 ˚
Top view
Back view
both Stable(not rollover).
3m radius curve at 5km/h,
100
An example of motor tricycle applied tilting system
No tilting STIGO Tilting STIGO (up to 10˚)
* For the sake of convenience, the right table is calculated at only 10˚, not 0~10˚ .
3m radius curve at 9.5 km/h, 9.5
No tilting STIGO turns over.
Centrifugal force
: No tilting STIGO
: Tilting STIGO (up to 10˚)
Total weight : 90 kgf STIGO height : 1.863 m (including human height) Curve radius : 3 m Driving speed : 9.5 km/h Tilting STIGO’s angle : 10 ˚
Top view
Back view
03 Stability – Roll direction
Stability analysis & Test
101
No tilting STIGO Tilting STIGO (up to 10˚)
* For the sake of convenience, the right table is calculated at only 10˚, not 0~10˚ .
Tilting of just small degrees
(10deg.)
Improving stability of rollover direction considerably
SAFE ZONE
SAFE ZONE
03 Stability – Roll direction
Stability analysis & Test
102
Tilting of just small degrees
(10deg.)
Improving stability of rollover direction considerably
If an user tilts their body slightly,
It doesn’t need tilting system!
03 Stability – Roll direction
Stability analysis & Test
103
Baseline Model Improved Model
Stability
Analysis
Change footrest position
No tilting system
03 Stability
Conclusion of stability analysis
104
Ergonomics The height of handle bar
The shape of footrest
Frame
04 Frame
105
Less side force in user’s knee
74 ~ 125 cm
04 Frame - Ergonomics
The height of handle bar The shape of footrest
The sloping bottom
Less arm fatigue
Average 100 cm height position
106
Aluminum 6061 Butted tube FRP body case
Material
04 Frame
Frame
107
Aluminum 6061 in the body frame.
04 Frame - Material
Material Selection Good Normal Bad
108
Aluminum 6061
Yield strength : 255 MPa
Safety factor : 3
Type Pipe-shape tube Butted tube
Mass 0.3 kg 0.143 kg
Max stress
Compressive force
Bending force
5.437 MPa
60.36 MPa
13.61 MPa
84.15 MPa
52.33% of the mass is reduced.
04 Frame - Material
Frame tube design
109
04 Frame - Material
Fix
Fix
150 x 3 = 450N
600 x 3 = 1800N
Material Analysis for footrest
[ load and boundary conditions] Safety factor : 3
Max Stress : 169.01 MPa < Yield stress(255 MPa)
Safe 110
Frame
04 Frame
Folding mechanism Motivated by umbrella
Folding footrest
111
Umbrella
04 Frame – Folding mechanism
Motivation
One-step folding
Easy to use
Stability
112
04 Frame – Folding mechanism
Connecting bar
113
x = 12 cm
F = 625 N
x position – tension force graph
of connecting bar
Upper position of connecting bar
Designer preferred for beauty
Lower position of connecting bar
Engineer preferred for safety
Compromised position x 12 cm
Position of connecting bar
04 Frame – Folding mechanism
114
Possible cross section shapes
Staple shape
Round shape
Window shape
Shape of connecting bar’s cross section
04 Frame – Folding mechanism
115
[Case 2] : Footrest coming out from the frame
[Case 1] : Unfolding footrest coming out in the case
04 Frame – Folding mechanism
Footrest folding mechanism
[Case 2] : Footrest coming out from the frame
116
Footrest : Enough length to ride (18 cm)
Footrest-Rod : Enough length to fold (28 cm)
Footrest-Stay : Enough space to fold (32 cm)
Footrest folding mechanism
04 Frame – Folding mechanism
117
Safety factor : 3
04 Frame – Folding mechanism
Improved design 2 Baseline design 1
23.30MPa < Yield strength (O)
161.06MPa < Yield strength (O)
2747.49MPa < Yield strength (X)
71.02MPa < Yield strength (O)
117.96MPa < Yield strength (O)
FEA results of footrest
218.47MPa < Yield strength (O) Yield strength : 255MPa, 118
Driving
05 Driving
Suspension Spring coefficient 33,000 kN/m Damping coefficient 300 N·s/m
Mechanical disk brake Suitable for BLDC motor
119
Bra
ke
Caliper Cantilever V-brake Mechanical Hydraulic
Str
ength
s
Light weight Low price High braking
power
Low price Easy of repair and
maintenance Suitable for BLDC
MOTOR
High braking power
Weakness
es
Low braking power Hard to set up Moisture effect Difficulty to handle
at steep slope
High price Difficult of repair and maintenance
05 Driving - Brake
Brake requirement Mechanical disk brake
Suitable for BLDC Motor
Easy to set up
Reasonable price
Braking power
120
“First Mile/Last Mile Transition” Rough road
For better comfortable driving
05 Driving - Suspension
121
Comfortable driving
SUSPENSION
05 Driving - Suspension
For better comfortable driving
K : 33,000 N/m C : 300 N·s/m
122
Design part
Analysis part 1. Position of Suspension? 2. Angle of Suspension? 3. Enough space for suspension?
Simulation with ADAMS tool
05 Driving - Suspension
Collaboration
123
VS
Case 1-1 Front wheel
Case 1-2 Connecting bar
05 Driving - Suspension
1. Where should the suspension is located in?
• Comfortable ride : 1~1.5 [Hz]
• Excitation frequency : 0.05Sin(𝟒𝝅𝒕)
• Amplitude : 5 [cm]
• Frequency : 2 [Hz]
• Spring coefficient (k)
33000 [N/m]
• Damping coefficient (c)
300 [N•s/m]
05 Driving - Suspension
Suppose that…
Leng
th(m
m)
05 Driving - Suspension
Case
1 F
ront w
heel
Case
2 C
onnectin
g b
ar angle of frame suspension displacement
Len
gth(
m)
suspension displacement
BUMP
BUMP
05 Driving - Suspension
Case 1-1 Front wheel
Case 1-2 Connecting bar
1. Where should the suspension is located in?
Case 2-2 Tilted suspension
VS
Case 2-1 Vertical suspension
2. Which angle of suspension is suitable?
05 Driving - Suspension
05 Driving - Suspension
Case
1 V
ertica
l Case
2 T
ilted
Unstable
05 Driving - Suspension
Case 2-2 Tilted suspension
Case 2-1 Vertical suspension
2. Which angle of suspension is suitable?
Overlap with wheel
Overlap with frame
05 Driving - Suspension
3. Does STIGO have enough space for suspension?
05 Driving - Suspension
Final STIGO with suspension
Space for length of suspension
Space for radius of suspension
Enough space for suspension Final model
05 Driving - Suspension
Without Suspension Final STIGO with suspension
Conclusion
05 Driving - Suspension
With
out su
spensio
n
Optim
ized su
spensio
n
• Need suspension because STIGO passes rough road. In case of STIGO with suspension, expect a comfortable ride.
Improved the ride quality !
• Simulate vibration characteristic of STIGO with suspension by ADAMS tool.
• To apply suspension, consider two position. And Change angle at determined position. Finally, To apply actual suspension, consider space problem.
• As compared with STIGO without suspension, improved performance in case of STIGO with suspension.
Conclusion
05 Driving - Suspension
Module
06 Module
Saddle 5~95% human available Contained extra battery
136
06 Module - Saddle
Concept
Saddle concept
Extra battery concept
137
Target value: 60.0°, Radius: 50.48 cm
Saddle movement path
06 Module - Saddle
Considering 5 ~ 95%
human model
138
Pressure measurement image 3D Model
06 Module - Saddle
139
07 Collaboration
Engineers
Designers
140
07 Collaboration
Main issue
Weak connection
Unstable footrest
Frame structure
141
07 Collaboration
Final concept
Strong connection
Stable footrest
Frame structure
142
Rear rubber tire
Non-slip step pads HIPS plastic
Aluminum main frame Strength, lightweight and flexibility
LED Back light High visibility for increased safety
NBR Handle cover Comfortable grip
Battery Pack Li-ion 36V 180Wh
Front aluminum rim Strength and rigidity
Front rubber tire
FRP case Lightweight, low-thermal expansion and strength
LED Front light High visibility for wide
view and increased safety
Rear aluminum rim Strength and rigidity
Footrest Strength and rigidity
Smartphone dock system
Hub motor 36V 300W in front wheel
Stop lever Eidetic plastic lever for increased safety
Controller
Steering Bevel gear assembly
for steering
Suspension
Materials Components
07 Vehicle Technical Specifications
143
09 Vehicle Technical Specifications
Speed
Adjustable from 2 to 15 km/h
Motor BLDC Hub Motor 36V, 300W in Front Wheel
Max. endurable load 110kg
Climbing ability 10% continuous at 10km/h
Range on a full charge 1hour, 15km
Battery pack
Li-ion built-in BMS(Battery Management System) LiFePO4, 180 Wh, 1.7 kg
Brake Mechanical disk brake
Suspension Front wheel
Spring 33 kN/m, Damp 300N-s/m
Steering Bevel gear assembly
144
09 Vehicle Technical Specifications
Weight 12.7 kg
Ground clearance 6.3 cm
Wheels diameter Front : 30 cm / Rear : 17.8
cm
Frame
Aluminum 6061
Grips NBR
Body case FRP
Open STIGO dimension Length: 90 cm Width: 44.6 cm Height: 103 cm *Except handlebar Width
Folded STIGO dimension Length: 33.5 cm
Width: 30.2cm Height: 117.8 cm
*Except handlebar Width
145
146
01 Business plan
147
01 Business plan
148
01 Business plan
149
01 Business plan
150
01 Business plan
151
02 Marketing strategy
152
02 Marketing strategy
153
02 Marketing strategy
154
03 Carbon footprint
155
04 Plant safety
156
157
158