Fluid Power Vehicle Challenge The Incompressibles Final Design Report 2018-2019 June 12, 2019 Russell Posin Julian Rodkiewicz [email protected] [email protected] David Vitt Alex Knickerbocker [email protected] [email protected] Nicholas Gholdoian Kyle Franck [email protected] [email protected] “Comfortable Under Pressure” Instructor: John Fabijanic Sponsor: Dr. James Widmann Industry Mentor: Mark Decklar (Hydraforce) Mechanical Engineering Department California Polytechnic State University - San Luis Obispo TABLE OF CONTENTS TABLE OF CONTENTS ............................................................................................................. 1 LIST OF FIGURES ...................................................................................................................... 8 LIST OF TABLES ...................................................................................................................... 15 EXECUTIVE SUMMARY ........................................................................................................ 16 1 INTRODUCTION.................................................................................................................... 17 1.1 Problem Statement ............................................................................................................ 17 2 BACKGROUND ...................................................................................................................... 18 2.1 Customers .......................................................................................................................... 19 2.2 Existing Designs: Competition Winners 2017-18 ........................................................... 19 2.2.1 Overall Winner: ......................................................................................................................................... 19 2.2.2 Second Overall: .......................................................................................................................................... 20 2.2.3 Third Overall: ............................................................................................................................................ 21 2.3 Component Research ........................................................................................................ 22 2.3.1 Pumps and motors (driving and driven) ..................................................................................................... 22 2.3.2 Hydraulic circuits ....................................................................................................................................... 24 2.3.3 Electronics/Mechatronics ........................................................................................................................... 24 2.3.4 Accumulator ............................................................................................................................................... 24 2.3.5 Brakes ........................................................................................................................................................ 25 2.3.6 Custom bike frame ..................................................................................................................................... 26 3 OBJECTIVES .......................................................................................................................... 27 4 CONCEPT DESIGN ................................................................................................................ 29 4.1 Frame.................................................................................................................................. 29 4.1.1 Frame Type Selection ................................................................................................................................ 29 5.1.1.1 Standard Bike ....................................................................................................................................................... 30 5.1.1.2 Recumbent Bike ................................................................................................................................................... 31 5.1.1.3 Prone Bike ............................................................................................................................................................ 31 5.1.1.4 Velomobile ........................................................................................................................................................... 32 4.1.2 Preliminary Frame Design ......................................................................................................................... 33 4.1.3 Further Development ................................................................................................................................. 33 4.2 Drivetrain ........................................................................................................................... 34 4.2.1 Current Design ........................................................................................................................................... 34 5.2.1.1 Front Drivetrain .................................................................................................................................................... 34 [1] 5.2.1.2 Rear Drivetrain ..................................................................................................................................................... 36 4.2.2 New Design ................................................................................................................................................ 37 5.2.2.1 Front Drivetrain .................................................................................................................................................... 37 5.2.2.2 Rear Drivetrain ..................................................................................................................................................... 38 4.2.3 Further Development ................................................................................................................................. 39 4.3 Hydraulics .......................................................................................................................... 39 4.3.1.1 Direct Drive Mode ................................................................................................................................................ 39 4.3.1.2 Discharge Mode ................................................................................................................................................... 40 4.3.1.3 Regenerative Braking Mode ................................................................................................................................. 41 4.3.1.4 PIT Mode.............................................................................................................................................................. 41 4.3.2 Accumulator Selection ............................................................................................................................... 42 4.3.3 Pump and Motor ........................................................................................................................................ 43 4.3.3.1 Bent-Axis Pump/Motor ........................................................................................................................................ 44 4.3.3.2 Gear Pump ............................................................................................................................................................ 45 4.3.3.3 Gerotor Pump/Motor ............................................................................................................................................ 45 4.3.4 Valve Selection .......................................................................................................................................... 46 4.3.4.1 Spool-Type Solenoids .......................................................................................................................................... 46 4.3.4.2 Poppet-Type Solenoids ......................................................................................................................................... 46 4.3.5 Further Development ................................................................................................................................. 47 4.4 Mechatronics...................................................................................................................... 47 4.4.1 Past Design ................................................................................................................................................ 47 4.4.2 New Hardware Design ............................................................................................................................... 49 4.4.3 Software Design ......................................................................................................................................... 53 4.4.4 Further Development ................................................................................................................................. 54 4.5 Power Decoupling .............................................................................................................. 54 4.5.1 Friction Disc Clutch 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