PSU Human Powered Team Chain Reaction SOW Report Commented [NG1]: Spell this out

February 20, 2020

Alexander Kuitz – [email protected] Kezi Liu – [email protected] Xinyi Ying – [email protected] Zehao Liu – [email protected] Ghadeer Al Laiwati – [email protected] Adam Schaltz – [email protected]

Dr. Anne Mertin – [email protected] Commented [NG2]: Indicate that this is your sponsor.

No – Intellectual Property Rights Agreement No – Non-Disclosure Agreement

1 Executive Summary Commented [NG3]: Succinctly summarizes technical areas, budget, and schedule...good! Team Chain Reaction is tasked with making improvements upon the current Pennsylvania State University (PSU) Human Powered Vehicle (HPV). Fixing the major components, implementing an aerodynamic windshield and adding aesthetics are the main challenges the team is faced with. After initially meeting with the team’s sponsor, Dr. Anne Martin, the team discovered that the major components to be fixed are the braking system and seat adjustability. The main deliverable of the project is a working and improved HPV that will succeed in the American Society of Mechanical Engineers Engineering Festival (ASME E-Fest) North Human Powered Vehicle Challenge (HPVC). The HPVC will take place at Michigan State on April 3 - April 5.

The team has a limited budget of $1000 that will be spent primarily on materials since registration and travel fees are mostly covered. The team anticipates needing to spend about 80% of the total budget to successfully complete the project. Most of the budget will be spent on creating the aerodynamic windshield. The rest of the budget will be allocated towards the other major components, safety requirements, aesthetics, and a poster. In order to complete the required tasks on time, a Gantt chart was created and is constantly being updated. Using a Gannt chart allows the team to layout major milestones and tasks that need to be completed within the restricted time frame. The Gannt chart assists the team in differentiating tasks for the HPVC and the Penn State Mechanical Engineering (ME) 440 Capstone course. The overall deliverable deadlines for the HPVC and ME 440 Capstone are April 3 and May 5, respectively. The Gannt chart ensures the students are on track and will succeed in both the HPVC and ME 440 Capstone.

2 Table of Contents Commented [NG4]: Uses Microsoft Word automated Table of Contents…good! Executive Summary ...... 2 1.0 Introduction ...... 4 1.1 Initial Problem Statement ...... 5 1.2 Objectives ...... 5 2.0 Customer Needs Assessment ...... 5 2.1 Gathering Customer Input ...... 5 2.2 Weighting of Customer Needs ...... 6 3.0 External Search ...... 7 3.1 Patents ...... 8 3.2 Existing Products...... 8 4.0 Engineering Specifications ...... 11 4.1 Establishing Target Specifications ...... 11 4.2 Relating Specifications to Customer Needs ...... 14 5.0 Concept Generation and Selection ...... 16 5.1 Concept Generation ...... 16 5.2 Concept Selection ...... 18 6.0 System Level Design ...... 20 7.0 Preliminary Economic Analyses – Budget and Bill of Materials ...... 22 8.0 Project Management ...... 23 9.0 Risk Plan and Safety ...... 25 10.0 Communication and Coordination with Sponsor ...... 26 References ...... 28 Appendix ...... 29

3 1.0 Introduction A human-powered vehicle (HPV) is a vehicle that is only powered by muscular strength (World Commented [NG5]: Nice job starting each section with an Human Powered Vehicle Association). These fall under a variety of categories: land, introductory paragraph instead of awkwardly jumping right into the next sub-section. water, rail and air. The velomobile is an example of a land HPV that makes improvements upon Commented [NG6]: Uses MS Word built-in the . The aerodynamic and protective body of the velomobile increases speed and efficiency REFERENCES, CITATION tool…good! while keeping the rider safe from any form of weather (Decker). and are examples of water HPVs used for leisurely activities. Human-powered submarines have given engineers a true challenge due to the constraints of pedaling underwater (Bennett). A draisine is a rail HPV that is used to carry workers to maintain the railroad tracks (Elder). The Icarus Cup is a competition in the United Kingdom for various forms of human-powered aircraft (British Human Powered Flying Club).

The American Society of Mechanical Engineers (ASME) Engineering Festival allows for engineering students to put developing technical skills to the test through an assortment of competitions. In addition to the engineering competitions, the ASME Engineering Festival provides additional opportunities for students to network. The first networking opportunity is “Lightning Talks” where professional engineers in industry discuss new technologies in the field (ASME E-Fests). The second networking opportunity is career mentoring where practicing engineers describe the working environment in industry upon graduating. The final networking opportunity includes a resume and professional development workshop. With all these professional experiences, the ASME Engineering Festival also provides social activities and performances for engineering students to meet other engineering students.

The team is registered for the Human Powered Vehicle Challenge (HPVC) that takes place at Michigan State University from April 3 to April 5. This competition tasks the team with utilizing engineering skills to create a human-powered form of transportation (ASME E-Fests). This year’s competition requires the teams to create a recumbent . Recumbent are similar to , but recumbent tricycles contain three and the rider lays back while riding Commented [NG7]: Microsoft Word has underlined this (Recumbent Gourmet). Considering the competition has speed events, the HPV must be capable to indicate there is a potential issue here. of traveling at high velocities for maximum success. Overall, the HPVC expects teams of I stopped editing for commas at this point. There are many online comma usage sources out there including engineering students to develop an efficient and feasible form of transportation. http://writingcenter.unc.edu/handouts/commas/

The HPVC is scored upon two different stages: design report and performance. Due by February 18, the design report is graded using specific scoring criteria. There are three major components of the design report: design, analysis and testing. In addition, the vehicle will be analyzed on safety and aesthetics. The performance of the vehicle is assessed by a drag race and an endurance race (ASME E-Fests). For both race categories, a male and a female from the team must compete. Trophies are given to the top three teams for each event with the first-place team each receiving a cash prize. The top three overall teams both receive a trophy and a cash prize. Knowing this, the team has an additional incentive to work hard on the Capstone Project and succeed at the HPVC.

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1.1 Initial Problem Statement Dr. Anne Martin, a mechanical engineering professor at Penn State, explained during the initial sponsor meeting the main problem of the Capstone Project is the major components of the previous HPV must be improved. Primarily, an aerodynamic windshield must be implemented to protect the rider and increase the overall efficiency. Secondly, the braking system is faulty and must be fixed before the competition. Finally, the aesthetics are to be enhanced to improve the dull appearance. After the discussion with Dr. Martin, the team noticed the female rider, Xinyi Yang, is too short for the HPV.

1.2 Objectives The objectives to solve the described problem are organized from most important to least important. First, the team must design an aerodynamic windshield to increase the speed of the HPV while also keeping the rider safe. Next, the braking system must be fixed. The left is faulty and needs to be replaced for safety purposes and better performance, especially in the endurance race. Third, adjustments need to be implemented to accommodate the differing lengths of the riders. Given the HPV frame is not adjustable, the seat has to be modified. Fourth, a bell, horn, headlight, side reflectors and rear-view mirrors are all to be included for both safety and aesthetic purposes. Finally, the HPV must be painted to improve the overall aesthetic.

2.0 Customer Needs Assessment The current HPV was designed and built by a different team in the 2019 fall semester. However, the vehicle is incomplete and some tasks were assigned for the current team by the previous team. In order to determine customer needs, the team discussed with the Penn State University HPV sponsor, Dr. Anne Martin, and reviewed the rules for the HPVC.

2.1 Gathering Customer Input The most important customer needs for the HPV are having a rollover protection system and a functioning braking system, which are related to the safety of the rider. Having a rollover protection system would absorb sufficient energy in a severe accident to minimize risk of injury. A functioning braking system would allow riders to stop immediately if accidents happen. In addition to having a rollover protection system and functioning braking system, the vehicle needs to be durable enough that the HPV could endure at least 8 hours of riding. Other customer needs for the HPV vehicle is maximum stability at a speed of 8 to 10 km/hr and that the vehicle is able to turn within a 6.0 m radius. The other customer needs are that the cost of designing and building the vehicle is under 1000 dollars and the HPV must be adjustable for riders who have different heights. The last customer need is that the vehicle is aesthetically pleasing which could be achieved by painting the vehicle with Penn State Blue and white colors.

5 2.2 Weighting of Customer Needs The Analytic Hierarchy Process (AHP) matrix is shown in Table 1. The AHP matrix compares Commented [NG8]: That is the proper way to define an and weighs customer needs based on relative importance. Needs are evaluated on a scale of 1 to 9 acronym…Good! where 1 represents equal importance. 3 represents moderate importance, 5 represents strong Commented [NG9]: Uses MS Word REFERENCES, CROSS REFERENCE tool…good! importance, 7 represents very strong importance, 9 represents extreme importance. Values 2,4,6, Commented [NG10]: Good job referring to a table/figure and 8 are used to express intermediate values. As shown in Table 1, a functioning braking system before including the table/figure. has the highest weight against all other customer needs. A rollover protection system is the next highest weight. The need for the vehicle to be cost efficient is weighted third because the $1000 budget places a restriction on purchasing particular materials. The other three metrics from the AHP matrix have significantly lower weights compared to the rest of the needs.

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Table 1: AHP Matrix Commented [NG11]: Uses MS Word REFERENCES, INSERT CAPTION tool…good! Having a Durable Adjustable functioning Having a for Stable at Turn for riders breaking rollover Cost enduring a speed within have braking protection under 8 hours 8 to 10 6.0 m different Aesthetic Weight system system 1000 riding m/s radius heights Pleasing Total (%) Having a functioning breaking braking system 1 2 2 3 4 5 5 6 28 22.2 Having a rollover protection system 0.5 1 2 2 3 4 5 5 22.5 17.6 Cost under 1000 0.5 0.5 1 3 3 4 5 5 22 17.4 Durable for enduring 8 hours riding 0.33 0.5 0.33 1 4 4 5 6 10.16 7.9 Stable at a Speed 8 to 10 m/s 0.25 0.33 0.3 0.25 1 5 5 6 18.13 14.3 Turn within 6.0 m radius 0.2 0.25 0.25 0.2 0.22 1 6 6 14.12 11.7 Adjustable for riders have different heights 0.2 0.2 0.2 0.2 0.2 0.14 1 7 9.14 7.2 Aesthetic Pleasing 0.17 0.2 0.2 0.17 0.17 0.14 0.14 1 2.19 1.7 126.2 Totals 4 100

3.0 External Search The team conducted an external search to help with the brainstorming process. Some existing products can be purchased rather than invented, saving time in the design process. Both patents and existing products helped the team determine quality design options for the HPV.

7 3.1 Patents Commented [NG12]: Uncorrected: “A lot of the discussion in this section is hard to follow. There are Based on the utility patent for the front windshield found online, a frame portion is elongated along numerous references to different aspects of the patent, but the circumferential edge (Honda Motor Co., LTD). There are two main components of the frame without better definition or figures, it is difficult to follow the author’s thought process.” portion. The first part is the lower edge portion which elongates around the front windshield. The second part is the recess depressed downward. In addition, there is a part of a perception mark inside the recess, permitting users to have a better understanding of the position of the vehicle.

According to a patent for polymer composition (Bayer MaterialScience AG), the invented polymer composition does not only absorb infrared radiation (IR), but also contains a transparent thermoplastic. Furthermore, the polymer composition also contains inorganic nano-scale pigments and the combination of two organic coloring agents. The polymer composition features contribute to further usage of polymer materials. Since the competition is held during the daytime, riders will benefit from getting the ultraviolet protection from the windshield if the windshield material absorbs sunlight. In this case, the team decided to use polycarbonate that has polymer composition for the windshield.

For the artistic design patent, the vehicle has two main parts: a windshield with an outer perimeter and an encapsulated body (PACCAR Inc.). Meanwhile, the vehicle also contains a structure which functions as a windshield opening. In some cases, a part of the windshield opening is a stepped free end. A part of the stepped free end is mechanically locked since the windshield is built in the windshield opening. The team must consider the height limitations of the vehicle and how these limitations affect the coverage of the rider. The team decided to have only the windshield with an outer perimeter to protect the rider during the competition. The manufacturing process follows the artistic design patent. The stepped free end is mechanically locked since the windshield will be manufactured in the windshield opening.

3.2 Existing Products Shown in Figure 1, clipless pedals are the best choice for the human-powered vehicle design (REI Co-op: Expert Advice). The working principle of clipless pedals is a small or metal cleat mounted on the sole of the rider’s shoe. Also, the clipless pedals contain a set of spring-loaded “clips” on the face of the pedal. The team decided to select clipless pedals because the riders must travel on uneven surfaces while maintaining a fast speed and having a high level of control. With clipless pedals, the possibility of feet coming off the pedals during any bumps will be rare. After some practice using the clipless pedals, riders will feel natural control of the vehicle. In the team’s case, changing the current pedals to clipless pedals can help riders have full control of the HPV.

8 Commented [NG13]: Nice job including graphics. More figures would be even better.

Figure 1: Clipless pedals for HPV design (REI Co-op: Expert Advice)

An important requirement of the competition is to incorporate an aerodynamic windshield to the original HPV. To maximize aerodynamics and fulfill the competition requirements of rider protection, the team decided to build a frontal fairing. Based on the product in Figure 2, derived from the HPV from Santa Clara University in 2013-2014 (Chester, Flores and Jones), a frontal fairing is used to sweep air around the vehicle so the fairing can cut through the air and reduce the aerodynamic drag. The elongated teardrop fairing is composed of LEXAN polycarbonate. Although building a full-coverage windshield for the rider is ideal during the competition, a small piece of the full-body fairing was selected for aerodynamic purposes due to the limitations of cost, weight, and difficulties of manufacturing. Meanwhile, the design allows riders to enter and exit the vehicle more easily.

Figure 2: Teardrop windshield design (Chester, Flores and Jones)

According to the product generated from the University of Toronto Human Powered Vehicle Design Team in Figure 3, the shape of the rider, the need for ventilation, and limits on the convexity for the purpose of mold construction and release are the key factors for determining the structure of the shell (University of Toronto Human Powered Vehicle Design Team). In addition, the aerodynamic design principle also states the shell should be manufactured as narrow as possible, and curvature changes are reduced to a minimum for less supervelocities on the surface. Meanwhile, the width is extended until reaching the maximum value. For the Toronto team, a

9 positive pressure gradient can lead to an extended laminar flow. Overall, the PSU team will follow similar principles to reach maximum efficiency.

Figure 3: Placement of the fairing on the vehicle (University of Toronto Human Powered Vehicle Design Team)

To build the frame for the windshield, the team needs to weld the steel material. There are three ways of welding available in the market: TIG welding, brazing the tubes together using silver or brass and using lugs to join the tubes (REI Co-op). TIG welding, shown in Figure 4, is welding the frame by using the same material as the tube. The TIG welding method is widely used for very high-end bikes. TIG welding is cost-effective and creates a stable weld. The TIG welding method will be the preferred strategy for welding the windshield frame.

Figure 4: TIG welding (Miller)

Disk , shown in Figure 5, have become one of the most popular braking system options Commented [NG14]: Figure 5 actually does not show any since disk brakes can provide stronger braking power compared to cable brakes (Alexandrou). The disk brakes.

10 main advantage of using the disk brakes is the stopping power and will work when a is warped. The brake pads squeeze the rotor allowing for the wheel to slow down. For cable and hydraulic disc brakes, a cable housing is attached to the brake lever. However, for the hydraulic disc brakes, there is mineral oil inside the housing which provides pressure for the pads to contract. Since the current braking system contains hydraulic brakes, “bleeding” is one of the best strategies that can get rid of air bubbles from the housing.

Figure 5: Rear hub with the ability to have a rotor attached

4.0 Engineering Specifications In order to manufacture the most competitive HPV, the team first needed to determine the engineering specifications that would help guide the design and manufacturing process. The specifications were translated from the customer needs which were a combination of the required ASME competition rules and the sponsor needs. The translated needs provide detailed requirements for various parts of the design and manufacturing process. For example, one customer need is that the vehicle must meet the pre-competition safety requirements. The safety need was translated into many target specifications including a maximum stopping distance of six meters. Therefore, the team knows that brakes must be installed such that the vehicle can stop within six meters when traveling at 25 km/hr.

The following are the top customer needs for the HPV. The HPV transports an individual smoothly during use and comes to a complete stop following high velocity travel. The HPV reduces the chance of a rider being injured and the vehicle will be safe in a crash. The HPV lasts a long time, is easy to enter and exit, and is affordable. The vehicle is easily maneuverable through tight obstacles and is aerodynamic, thus the HPV will reach a high velocity. The HPV is visually appealing with the use of Penn State colors.

4.1 Establishing Target Specifications Table 2 provides the customer needs translated into target specifications. Each specification is associated with an importance value from 1-5 (5 being the most important), threshold value,

11 minimum acceptable value, objective value, and units for the associated specification. Table 2: Target Specifications Commented [NG15]: Reread the report template, specifically section 2.i in the last two pages of the template.

12 Specificatio Specification Importanc Threshold Valu Objective Units n No. e (1=not very, e (1) Value (2) 5=very)

1 Aerodynamic/Dra 3 0.69 0.69 Newtons Commented [NG16]: Threshold and Objective values g should typically be different values.

2 Stopping distance 5 <6 <6 Meters

3 Aesthetics 1 N/A N/A N/A

4 Turning Radius 5 8 N/A Meters

5 Travel Stability 5 30 62,500 Meters Distance

6 Roll Cage 5 2670 N/A Newtons Minimum Top Force

7 Roll Cage 5 1330 N/A Newtons Minimum Side Force

8 Maximum Roll 5 <5.1 N/A Centimeter Cage Elastic s Deformation on the Top

9 Maximum Roll 5 <3.8 N/A Centimeter Cage Elastic s Deformation on the Side

10 Safety Harness 5 4 5 Number Attachment Points

11 Minimum Ride 4 28.8*10^6 28.8X10^6 Meters Commented [NG17]: Those seem like oddly specific Distance Without values. Loosening of Components

13 12 Enter, Exit Area 4 0.4180 04180 Meters^2 (per side)

13 Foam Width 3 0.1524 0.1524 Meters

14 Mass 4 <15.8757 <11.3398 Kilograms *The NA objective values are included because the previous team reached the threshold values *In the case of aesthetics there is no metric for a normative statement

4.2 Relating Specifications to Customer Needs In order to further break down the design and manufacturing process the team created a Needs- Metrics Matrix shown in Figure 6. The matrix organizes and connects the different needs with the various metric values into visual format. The matrix allows the group to not only see the specific design targets needed but also gives a big picture view of the whole project.

The values for the specific metrics were chosen on a case-by-case basis. For the aerodynamic drag Adam calculated the drag force in the horizontal direction using the density of air, the windshield dimensions, a general velocity of 8 m/s, and a drag coefficient associated with the windshield angles at 42.5 degrees. The stopping distance was calculated using the competition rules. Aesthetics does not have a value because aesthetics is a normative statement. The turning radius and travel stability distance were determined from the maximum allowed turning radius, and stability distance designated in the competition rules. The same is true for the maximum side and top force, as well as the maximum elastic deformation on the top and side of the roll cage. The safety harness attachment points were determined by the fact that a four-point harness would be easier to install (at attachment points into the roll cage) rather than a five-point harness. The minimum ride distance without the loosening of components was calculated using a general velocity of 8 m/s and ride life of 1,000 hours. The enter/exit area was calculated using measurements of the HPV. The project budget is $1000 however, due to existing costs and projected design cost the anticipated budget was calculated that the team, could complete the project with approximately $900. The corresponding Needs-Metrics Matrix is shown in Figure 6.

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4

8 m

N/A

30 m

<6 m

Value

<$900

0.69 N

2670 N 1330 N

<5.1 cm <3.8 cm

0.1524 m

0.4180 m^2

<15.8757kg

28.8*10^6 m

Mass

Metric

Aesthetics

Foam Width

Project Budget

Turning Radius

Enter/Exit Area

Stopping Distance

Aerodynamic/Drag

Maximum Roll Cage Maximum Roll Cage

Travel Stability Distance

Looseningof Components

Elastic Deformation on Top

Elastic Deformation on Side

Roll Cage Minimum Top Force

Roll Cage Minimum Side Force

Minimum Ride Distance Without Safety Harness Attachment Points

Need Transports Individual Smoothly During Use * Comes to a Complete Stop Following High Velocity Travel * Reduces Chance of Rider Being Injured * Durability * * Safe in a Crash/Improved Safety * * * * Easy to Enter and Exit * Easily Maneuverable Through Tight Obstacles * Aerodynamic Windshield * Visually Appealing/Improved Aesthetics * Functional Breaking braking System * Affordable * Adjustable * Light Weight *

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Figure 6: Needs-Metrics Matrix 5.0 Concept Generation and Selection The main aim for the current semester’s team is to finish the HPV made by the previous semester’s team and ensure the vehicle meets the criterion of the competition. Because the time until the competition is limited, only additions will be made upon the vehicle. Neither changes nor deletions will be made upon the HPV. The concept generation shows how the prototypes were created and which prototype was selected.

5.1 Concept Generation For the windshield design, a few group members brainstormed a couple of windshield designs as shown in Figure 7 and Figure 8. Measurements of the HPV were taken to see if there was enough space for the designs to allow riders to get in the vehicle. The wheels, sides of the roll cage and low seat height are important factors to consider when ensuring that the rider can fit. Because the frame of the windshield must be tall enough so the driver can get into the vehicle, two new designs of windshields were generated as shown in Figure 9 and Figure 10. On the Week #4 staff meeting, Dr. Gary Neal suggested that these prototypes have inefficient aerodynamic properties. According to Dr. Martin, the team must design an aerodynamic windshield that protects the rider and accommodates riders of varying height.

Figure 7: Ghadeer’s brainstormed windshield design

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Figure 8: Alexander’s brainstormed windshield design

Figure 9: Kezi’s first SolidWorks windshield design

Figure 10: Kezi’s second SolidWorks windshield design

After brainstorming and research, another windshield design was discovered as shown in Figure 11. The disadvantage and challenge of this design is the geometry property of this type of windshield must be carefully designed to make sure the windshield can reduce the effect of the air flow to the rider within a certain environment. The advantage of this design is that this windshield is aerodynamic and accommodates all riders. The team decided to use polycarbonate for the windshield because polycarbonate has a low cost, low weight, smooth surface and transparency (Vanderveer Industrial ).

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Figure 11: Teardrop windshield design (Chester, Flores and Jones)

5.2 Concept Selection The Pugh Concept Scoring charts weigh several customer needs against one another to determine the design with the most potential. Each Pugh Concept Scoring charts’ concept ranks how well certain designs fit the customer needs or other requirements. For each concept, the weights are multiplied by the rates to obtain a weighted score. The sum of the weighted scores will determine the best design.

The concepts for windshield material selection and frame structure are different. For the material selection, the concepts are mainly about the physical properties, such as tensile strength, flexural modulus, density, etc. On the other hand, the concepts for the frame are safety, aesthetic appeal, adjustability, ease of manufacturing, etc. For the frame, the difficulty of manufacturing is quite important because none of the team members have experience with welding or other manufacturing skills. Limited time and expenses also contribute to the difficulty of manufacturing. The weight of the frame is a highly weighted concept because the HPV is already close to the weight limit.

For the windshield frame as shown in Table 3, the criteria are the same as the customer needs. The durability and safety were weighted the most and are the most objective and basic elements for the frame design. Cost is also very important because of the limited budget. Adjustability is another important aspect of the HPV because the vehicle must be suitable for all riders. One main function of the windshield is the aerodynamics to increase the speed of the vehicle. Aesthetic appeal and ease to build are not as important as other criteria, yielding lower weights.

Table 3: Pugh Concept for windshield frame Commented [NG18]: Reread the report template, specifically section 2.i in the last two pages of the template.

18 Concept KL1 KL2 TD GA Commented [NG19]: Uncorrected: This makes it difficult for the reader to be able to follow the table. Either include Selection Wgtd. Wgtd. Wgtd. Wgtd. the name of the concept and/or a picture of the concept Criteria Weight Rating Score Rating Score Rating Score Rating Score As an example, this is the only place “KL1” is used in this Durability 0.19 2 0.38 4 0.76 4 0.76 4 0.76 entire report.

Safety 0.31 4 1.24 4 1.24 3 0.93 4 1.24 Cost 0.16 2 0.32 2 0.32 5 0.8 1 0.16 Adjustability 0.12 2 0.24 3 0.36 5 0.6 1 0.12 Speed 0.12 2 0.24 2 0.24 4 0.48 4 0.48 Weight 0.06 2 0.12 2 0.12 5 0.3 4 0.24 Aesthetic Appeal 0.015 3 0.045 3 0.03 3 0.045 2 0.03

Ease build 0.025 1 0.025 3 0.075 4 0.1 3 0.075 Total Score 2.61 3.145 4.015 2.865 Rank 4 2 1 3 Continue No No Yes No

Relative Performance Rating Much worse than reference 1 Worse than reference 2 Same as reference 3 Better than reference 4 Much better than reference 5

For the windshield material in Table 4 there are only two options, so the better option gets 1 point and the worse options gets 0. Tensile strength is weighted the most because the durability and Commented [NG20]: Uncorrected: “Above, you said this safety of the windshield are of maximum importance. Flexural modulus is an objective standard rating system has a scale from 1 to 5?” for the difficulty to build; a higher flexural modulus means the material is harder to bend making the product more difficult to build, yielding a lower score. A lower density is better. Since the windshield will not be exposed to extremely high temperatures, melting temperature is not a huge concern. In the manufacturing process, glass transition temperature is easier to encounter which contributes to a higher weighted score.

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Table 4: Pugh Concept for windshield material

Concepts Material Polycarbonate PVC

Selection Criteria Weight Rate Weighted Score Rate Weighted Score Tensile Strength 0.4 1 0.4 0 0 Flexural modulus 0.15 1 0.15 0 0 Density 0.15 1 0.15 0 0 Melting point 0.1 1 0.1 1 0.1 Glass transition Temperature 0.2 1 0.2 0 0

Total Score 1 0.1 Rank 1 2 Continue Yes No

Relative Performance Rating Better than the other 1 Worse than the other 0

6.0 System Level Design The human powered vehicle designed by previous HPV teams involves many mechanical subsystems without electrical or software subsystems. The current team will develop the HPV using primarily aerodynamic and mechanical subsystems. The subsections could be represented by windshield, wheel and subsections.

The black box model represented in Figure 12 shows the system’s energy material and signal inputs and outputs. In the Human Powered Vehicle, mechanical energy is the input because the rider needs to apply mechanical energy to the pedal to rotate the wheels. The material used in this system is air since air flows into and around the vehicle. The only input signal is the pressure from the rider applied in the pedals. The forces generated from the pedal rotation and the airflow are torque and drag force, which are the output energy. The friction force is also output energy, and due to the friction force, the system output material is steam.

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Figure 12: HPV Black Box Model

The HPV system, as stated previously, has many subsections due to the output forces. The subsystems are the drag force system which controls the aerodynamics of the vehicle and the friction force and the torque which control the mechanics of the vehicle. The system’s inputs (mechanical energy, wind, pedals and the pressure) use the subsystems in order to convert to the system’s outputs (different types of forces, heat, and steam). The system inputs can be divided into internal inputs which are from the rider and external inputs which are from the surrounding environment. The rider applies pressure on the pedals which generates mechanical energy as an internal input. The mechanical energy in the support system then converts into torque that applies in the wheeling system and transmits the force into the road causing wheel rotation. The mechanical energy could also be converted into friction that is applied when the rider hits the hand brakes to change the speed or direction of the vehicle. Due to the friction force, the subsystem gives off heat and steam as an output.

The air plays a role in the system and affects the performance of the HPV. As the HPV moves, a drag force acts on the vehicle because air particles from the opposite direction collide with the support frame. The windshield shape reduces the drag force, making the HPV perform more efficiently. The output of this subsystem is heat. The subsystem decomposition is shown in Figure 13.

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Figure 13: Example subsystem decomposition

7.0 Preliminary Economic Analyses – Budget and Bill of Materials Table 5 and Table 6 correspond to the team’s budget and bill of materials (BOM), respectively. The team has allocated the $1000 budget to primarily materials. UPAC has covered both the lodging and registration fees while travel is mostly covered. The team expects no equipment expenses. In addition to materials, a poster is to be constructed by the team, summing up to $810 in total spending. The BOM features items used to address the major components of the HPV. Safety and aesthetic components are also included in the BOM.

Table 5: Predicted Budget Category Estimated Cost Travel $0 Lodging $0 Registration $0 Equipment Usage Time $0 Equipment $0 Materials $750 Poster $60 Total Spending $810

22 Table 6: Initial Bill of Materials Part Price ($) Quantity Vendor Part # Description The Home PVC Cap Slip 5 7 611942038541 1" Diameter Depot Foam 40 1 Amazon B01H2QS5RE Seat Cushion Fabric 10 1 Walmart N/A Cushion Cover

Velcro 5 1 Walmart N/A Attach Cover to Wood

The Bicycle Cable Brake 5 1 CABM 65 " Shop Polycarbonate 260 4 Lowe’s TBD 36 " x 48" Wood 200 4 TBD TBD Windshield Mold Harness 40 1 TBD TBD Five-point Reflector 5 1 TBD TBD Safety Mirror 20 1 TBD TBD Safety Pedals 40 2 TBD TBD Spray paint 20 4 TBD TBD Aesthetic TOTAL ($) 650

8.0 Project Management Shown in Figure 14, there are seven main parts of the Gantt chart: Planning, Concept Design, Competition details, Detail design, Prototype Manufacturing and Assembly, Prototype Testing and Refinement, and Non-technical Summary. The main goal for the Capstone project is to design the windshield for the current vehicle, test the functions, and perform safety analysis so that the vehicle can be used for competition in April. The Gantt chart aims to divide the whole project into several parts, so the final goal is achievable. Under each part, specific tasks are listed, as shown. Meanwhile, all the steps are necessary for completing the final design of the vehicle. For example, to design the main part of the project, the windshield, the concept design will be determining the best material for the windshield. The Prototype Manufacturing and Assembly aspect will be purchasing and building the polycarbonate on the vehicle. The Prototype Testing and Refinement portion will be examining the safety issues after the completed setup. Other sections, such as Competition details, Detail Design, and Non-technical summary, cover other important milestones toward success at the competition and in the senior design course.

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Figure 14: Gannt Chart

The critical path is the series of tasks overall determining the length of the project. The team’s critical path is the design and construction of the windshield, the main component of the new HPV. The windshield design and construction will take up the majority of the project time frame. Steps to reduce the critical path include receiving necessary training at the Penn State Learning Factory, iterating through multiple windshield prototypes, finding a location where the windshield can be created, and purchasing the appropriate materials. In addition, to meet each task’s deadline, the group usually has meetings three times during weekdays. Besides that, a meeting on Sunday is conducted to summarize the work weekly and to have new plans in the coming week. In the end, to save time but also show critical thinking skills for the capstone design, the whole team looks for suggestions from professionals in the Learning Factory as well as revising the current ideas after each meeting with Dr. Neal and Dr. Martin.

Kezi Li is the Group Manager. Kezi has experience with SolidWorks and AutoCAD software, making Kezi the primary component designer. The optimal goal is to design a functional HPV for riders during the competition. Therefore, safety is the most important customer need. Due to the abundant Solidworks experience Kezi has, Kezi is capable of computing various analysis such as

24 CFD, structural analysis and aerodynamic analysis in the Solidworks to test whether safety issues exist in our vehicle. The group can also utilize the analysis from Solidworks to test the durability Commented [NG21]: Consider rephrasing to remove of the vehicle. Alexander Kutz is the Assistant Group Manager. Alexander has experience with vague pronoun Microsoft Excel and Microsoft Word, giving Alexander the role as editor. Alexander also helps other team members with other major roles. Xinyi Yang has experience with Microsoft Project, making Xinyi the Scheduler. Since Xinyi also has time management skills, Xinyi will make sure the whole team will meet each deadline not only for the Capstone project but also for the competition in Michigan State University. Ghadeer Al Lawati knows how to take thorough notes, making Ghadeer the Note Taker. Zehao Li is organized, allowing Zehao to be the Journal Keeper. Adam had an internship at MetLife Investment Management and understands budgeting principles; therefore, Adam is the Budget Keeper. In this case, Adam is responsible for notifying the group how much money is left and can be spendable after each purchase. In the end, the total money spent must be less than one thousand dollars.

9.0 Risk Plan and Safety The team’s risk plan as shown in Table 7, focuses primarily on technical, schedule, manufacturing and financial risks. Technical risks are mostly associated with the windshield. The associated risks with the windshield are high because the windshield protects the driver and increases the performance of the vehicle. Risks associated with the windshield could be due to welding, considering welding is a new technique for all team members. Poor welding could lead to failure in the vehicle. Scheduling and financial risks are possible as with budget and time limits. Safety risks are high because safety is a prerequisite for the competition, and an unsafe vehicle will be disqualified from the HPVC.

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Table 7: Risk Plan Risk Level Actions to Minimize Fall Back Strategy Schedule delays High • Track project progress • Ask help from team consistently members • Divide the work into small • Re-build individual individual groups in order to groups accelerate the work Delays in order Moderate • Make sure parts are in stock • Build the parts yourself placement or • Make sure purchasing • Drive to NJ and pick the delivery department has all needed parts up information • Cancel order and buy • Purchase what is available the parts from other fast from the learning factory delivering vendor Student gets injured Low • Be careful when working and • Treat minor injuries as using tools in the learning soon as possible factory • Major injuries require change of rider Failure in the Moderate • Use PVC and mimic the • Redesign the windshield windshield design windshield design before building the actual design Vehicle does not High • Make sure to read all rules of • Reconstruct roll cage to pass safety test the safety test the braking points Vehicle parts break Moderate • Make sure that all parts are • Temporary fixing of during the stable and work before the broken parts during competition competition competition Poor welding Low • Practice welding before • Ask for help from TA’s quality welding the windshield in the learning factory Poor budget analysis Moderate • Track project budget • Use what is free and consistently available in the learning • Examine multiple vendors factory

10.0 Communication and Coordination with Sponsor The Chain Reaction team is communicating with the project sponsor, Dr. Anne Martin, in a consistent manner. The team is meeting with the sponsor every Wednesday at 12:45pm-1:00pm at

26 Reber Building. In these weekly meetings, each team member updates Dr. Martin on the progress and asks questions about the project. Questions and concerns that need immediate answers are sent to the sponsor via email.

27 References Commented [NG23]: Good job using the Microsoft built- in REFERENCES, BIBLIOGRAPHY tool. Along with the Alexandrou, Peter. Understanding Bicycle Braking Systems. 31 August 2019. 12 February 2020. MANAGE SOURCES and INSERT CITATION tools, you successfully cited and listed all your sources. Good job! ASME Community. Human Powered Vehicle Challenges. n.d. 10 February 2020. ASME E-Fests. About ASME Engineering Festivals. n.d. 11 February 2020. —. Human Powered Vehicle Challenge. n.d. 11 February 2020. Bayer MaterialScience AG. Polymer composition having heat-absorbing properties and high stability to weathering. 15 December 2011. 15 February 2020. Bennett, Jay. The Preposterous World of Human-Powered Submarine Racing. 9 August 2017. 11 February 2020. British Human Powered Flying Club. The Icarus Cup. n.d. 11 February 2020. Chester, Peter, et al. "Santa Clara University human powered vehicle 2013-2014." Thesis. 2014. Decker, Kris De. The velomobile: high-tech bike or low-tech ? n.d. 11 February 2020. Elder, Eric. No Trains Required to Ride the Rails. 10 June 2014. 11 February 2020. Honda Motor Co., LTD. Front windshield. 18 August 2016. 11 February 2020. Miller. How a TIG Welder Works and When to TIG Wedl. 2018. 20 February 2020. PACCAR Inc. Encapsulated Windshield Molding. 13 March 2013. 11 February 2020. Recumbent Gourmet. What is a Recumbent Trike? n.d. 11 February 2020. REI Co-op. Understanding Bike Frame Materials. n.d. 12 February 2020. REI Co-op: Expert Advice. How to Choose Bike Pedals. n.d. 12 February 2020. University of Toronto Human Powered Vehicle Design Team. "Technical Report - 2010 ASME HPV." Technical . n.d. Vanderveer Industrial Plastics. Polycarbonate Vs. PVC Machining. n.d. 12 February 2020. World Human Powered Vehicle Association. What is a HPV? n.d. 10 February 2020.

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