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Off-Road, Downhill Skateboard

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Off-Road, Downhill Skateboard Off-Road, Downhill Skateboard Senior Design Project for The Sibley School of Mechanical and Aerospace Engineering Course: MAE 491 Prepared for: Professor Andy Ruina Engineering School Cornell University email: [email protected] Prepared by: Michael Meacham Graduating Mechanical Engineer Cornell University email: [email protected] A mountain board designed from the ground up. Draft 1: May 16, 2004 Draft 2: May 20, 2004 Off-Road, Downhill Skateboard CONTENTS Abstract......................................................................................................... 3 Introduction................................................................................................... 4 Design........................................................................................................... 5 I. Overall Design Goals...................................................................... 5 II. Overall Design Elements................................................................6 III. Detailed Design - Pre Parts-Purchasing........................................9 a. Deck.................................................................................... 9 b. Frame.................................................................................. 10 c. A-arms................................................................................. 11 d. Suspension..........................................................................12 e. Steering Pivot Arm...............................................................13 f . Swing Arm........................................................................... 15 g. Wheel and Wheel Hub.........................................................16 IV. Post Part-Purchasing / Fabrication / Design Changes..................16 a. Ball and Socket Joints......................................................... 17 b. Suspension..........................................................................17 c. Deck.....................................................................................18 d. Steering Pivot Arm...............................................................18 e. Deck Stiffness......................................................................20 f. Board Steering and Stability................................................ 21 g. Brakes................................................................................. 23 h. Wheels.................................................................................23 Discussion / Conclusion................................................................................ 24 Acknowledgments......................................................................................... 25 Appendices................................................................................................... 26 I. Appendix A - Purchase List............................................................. 26 II. Appendix B - MATLAB Code For Shock Geometry........................27 III. Appendix C - Dimensions..............................................................28 a. Frame (front)........................................................................28 b. Frame (side)........................................................................ 29 c. Frame (top).......................................................................... 30 d. Swing Arm (front, top)..........................................................31 e. A-arm (top).......................................................................... 32 f. Steering Pivot Arm (top, front)............................................. 33 g. Steering Points.................................................................... 34 2 Off-Road, Downhill Skateboard ABSTRACT The goal to design a new off-road, downhill skateboard is first accomplished by studying current mountain boards for sale. These mountain boards are limited in their design and functionality in regards to off-roading. Design goals are created to make a more functional skateboard for use on off- road trails. Using SolidWorks, a design is created, which incorporates fully independent suspension, steer-by-lean action, 10" inflatable tires, a wide wheel track, and disc brakes. It features a steel frame and A-arms, with a deck that pivots above. The pivoting action of the deck controls the steering of all four wheels. During manufacturing and testing, certain design elements are changed and added. Four-wheel steering can be converted to two-wheel steering quickly for more stable high-speed runs. Skateboard stiffeners are added to the deck, which gives this skateboard a natural skateboard feel. Disc brakes are not attached due to funding and time constraints, but testing shows that the board is perfectly functional and fun to ride. 3 Off-Road, Downhill Skateboard INTRODUCTION Skateboarding, snowboarding and surfing are all successful industries. Every recreational sport involving a board, where the rider can carve turns by leaning the board in the direction of motion, has always drawn lots of attention to itself. People have a natural liking for maneuvering through an environment simply by standing and leaning on a platform. The next environment for this phenomenon to enter into is off-road, mountain trails. The reason people have only just begun to design these types of boards, known as “mountain boards,” is that it is far more complicated to design a device that will not trip over large bumps and can take the abuse of a mountain trail, while still giving the rider a comfortable ride with steer-by-lean action. Current mountain boards are just modified skateboards. They use the same principles for the steering mechanism, offer little suspension, and not much more ground clearance. They are really designed for smooth, dirt roads, not mountain trails. In order to truthfully tap into this environment, a mountain board must be completely redesigned from the ground up. A rocky, bumpy path has little similarity to a smooth, dirt or paved path. An off-road, downhill skateboard should be compared to downhill mountain biking more than skateboarding. It is necessary to have a heavy, stable frame with fully independent suspension. This will allow the rider to control the board, even at high speeds with many bumps and objects on the path. This project will take mountain boarding where it was meant to be. It will help to gain the attention that it deserves. With ten-inch tires, over six inches of ground clearance, and almost five inches of travel in each wheel, this mountain board is nothing like current mountain boards. It will be able to go down steep trails, but still offer safety to the rider with hand-controlled disc brakes on all four wheels. It will be able to go over much larger rocks and bumps, but the user will still feel a smooth, controllable ride. 4 Off-Road, Downhill Skateboard DESIGN I. Overall Design Goals To create a list of design goals, current mountain boards were first studied and problems assessed. An “all-terrain” mountain board that one can buy in stores uses trucks to steer the board. A skateboard truck is a simple mechanism that attaches the axle of the wheels to the board at a specific angle. When the board leans, the axles are forced to rotate around this angled pivot point. The mechanism works well for riding on streets or smooth, dirt roads. The problem is the lack of fully independent suspension. As can be seen by the picture, the suspension is designed to take the shock of small bumps, not large objects. The suspension it contains is the flex of the board, the trucks, which utilize small springs as the return force, and "egg shocks" below the rider's feet, which absorb around 3 cm of travel. The steering and suspension are not independent of one another at all. When one wheel travels up, the other must travel down. This feature cannot work properly while turning, as it will change the turning radius considerably. To account for this, the travel in the wheels is kept at a minimum, and the ride is unsmooth. Trucks also limit the distance between the left and right wheels. Since the entire axle turns, a long Figure 1 axle will result in large longitudinal Mongoose UniCamb All Terrain Board motion in the wheels. This will result Courtesy of mountainboardshop.com in bump steer, the undesired steering when a wheel travels up or down. If the wheels were to rotate about their own independent axis, then the wheel track could be much larger. For off-road situations, a large wheel track is preferable for stability. Current mountain boards, much like skateboards, are too easily tipped over while riding because of how narrow they are. The radius of the wheels can range from about 5 to 8.5 inches in current mountain boards. The designs for other boards are very similar to this one, in that they utilize trucks and have no independent suspension in the wheels. Because of these concerns with current mountain boards, the design goals of this downhill board are the following: 5 Off-Road, Downhill Skateboard - steer-by-lean ability – Like any other boarding sport, the rider must be able to lean and have the steering respond quickly and smoothly. - fully independent suspension – The suspension must be independent of steering so that while in a turn, the rider can still travel over objects. - large wheel track for stability - larger tires for getting over bumps – A wheel will steer on an independent axis. One wheel’s steering will not necessarily affect another’s, except through the mechanical connection to the deck. - four-wheel steering
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