Rebekah’s Ride Mechanical Engineering Senior Project June 07, 2015 Alex Rowson Cameron Weinberg Jacob Hentzler Kelly Perkins Table of Contents 1.0 Introduction ........................................................................................................................................ 1 2.0 Background ......................................................................................................................................... 1 2.1 Cerebral Palsy and the Benefits of Exercise .............................................................................. 1 2.2 Types of Bicycle Trailers ........................................................................................................... 2 2.3 Previous Design Work ............................................................................................................... 4 2.4 Electric Bike Motors ................................................................................................................. 4 3.0 Objectives ............................................................................................................................................ 6 3.1 Customer Requirements ......................................................................................................... 6 3.2 Quality Function Deployment .................................................................................................... 6 3.3 High Risk Specification Discussion ....................................................................................... 9 3.4 Design Considerations ............................................................................................................ 10 4.0 Idea Generation .................................................................................................................................. 11 4.1 Brainstorming with Identifying Factors .................................................................................. 11 4.2 In Class Modeling .................................................................................................................. 12 4.3 PVC Modeling ....................................................................................................................... 13 4.4 Other Techniques ................................................................................................................... 14 5.0 Decision Process ................................................................................................................................ 14 5.1 Frame ..................................................................................................................................... 15 5.2 Seat ......................................................................................................................................... 16 5.3 Adjustability ........................................................................................................................... 17 5.4 Attachment to Lead Bicycle ................................................................................................... 18 5.5 Motivation .............................................................................................................................. 19 5.6 Wheels .................................................................................................................................... 20 6.0 Final Subcomponent Designs ............................................................................................................. 21 6.1 Frame ..................................................................................................................................... 21 6.2 Seat ......................................................................................................................................... 22 6.3 Adjustability ........................................................................................................................... 24 6.4 Attachment to Lead Bicycle ................................................................................................... 25 6.4.1 Attachment Device ................................................................................................. 25 6.4.2 Attachment Arm ..................................................................................................... 26 6.5 Motivation .............................................................................................................................. 27 6.5.1 Pedaling System ..................................................................................................... 27 6.5.2 Exercise Motivation ............................................................................................... 28 6.6 Wheels .................................................................................................................................... 29 6.7 Final Overall Design .............................................................................................................. 30 7.0 Product Realization ............................................................................................................................ 32 7.1 Frame .................................................................................................................................... 32 7.2 Seat ........................................................................................................................................ 34 7.3 Adjustability .......................................................................................................................... 35 7.4 Attachment to Lead Bicycle .................................................................................................. 35 7.5 Motivation ............................................................................................................................. 37 7.5.1 Protective Shroud .................................................................................................. 37 7.5.2 Resistance System ................................................................................................. 38 7.5.3 Electronics ............................................................................................................. 39 7.6 Wheels ................................................................................................................................... 41 7.7 Final Product ......................................................................................................................... 42 8.0 Analysis .............................................................................................................................................. 43 8.1 Frame ..................................................................................................................................... 43 8.2 Bolt Shear Strength ................................................................................................................ 44 8.3 Brake Pad Force ..................................................................................................................... 45 8.4 Full Prototype Test ................................................................................................................. 45 9.0 Cost Analysis and Finance Management ............................................................................................ 46 10.0 Build and Test Plan ............................................................................................................................ 47 10.1 Manufacturing Plan .............................................................................................................. 47 10.2 Design Verification Plan ........................................................................................................... 48 10.2.1 Seat Adjustability ............................................................................................. 48 10.2.2 Attachment to Lead Bicycle ............................................................................. 48 10.2.3 Bicycle Trailer Frame ....................................................................................... 49 10.2.4 Pedaling System ............................................................................................... 49 10.2.5 Seat ..................................................................................................................... 50 10.2.6 Electrical Systems .............................................................................................. 50 10.2.7 Wheels ................................................................................................................ 50 11.0 Method of Approach ......................................................................................................................... 51 12.0 Management Plan.............................................................................................................................. 53 13.0 Conclusion ........................................................................................................................................ 54 Works Cited .............................................................................................................................................. 56 Appendix A: QFD ..................................................................................................................................... 58 Appendix B: Sketches of Initial Ideas ......................................................................................................