alternatively powered all terrain vehicle

ALTERNATIVELY POWERED ALL-TERRAIN

VEHICLE

GROUP 5

ME/CEE 1770

Dr. Akash Dixit

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INDEX

Group Approval Document……………… …………..6

Overview

Section D……………………………………………………….. 7

Section C……………………………………………………… 44

Section M…………………………………………………….. 73

Action Items

Section D…………………………………………………….. 93

Section C……………………………………………………… 94

Section M…………………………………………………….. 95

Task Assessment Table……………………………… 96

Assembly Description………………………………… 99

Conclusions………………………………………………122

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TEAM DIRECTORY

SECTION D

Miad Karimi [email protected]

Stephen Rehberg [email protected]

Zhen Kang Pang [email protected]

Ankit Verma [email protected]

SECTION C

Lee Caldwell [email protected]

Jan Happel [email protected]

Ryan Krusko [email protected]

Gonzalo Salazar [email protected]

Youmei Zhou [email protected]

SECTION M

Abram Champion [email protected]

Tyler Pinuad [email protected]

Vikram Chharbria [email protected]

Matthew Walter [email protected]

Michael Jones [email protected]

mailto:[email protected]



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Group 5 Proposal: ATV

Group 5 is working on the Alternatively Powered All-Terrain Vehicle project. In its

current stage, the ATV is a dune buggy with limited all-terrain capabilities and alternative energy

sources. The goal of this group is to improve the functionalities of this vehicle not only in

various terrestrial environments but also to add flight capabilities to allow for further mobility. In

terms of mobility the first priority is to integrate a tread system to improve off-road travel, the

second priority is adding a propeller system to allow to flight capabilities, and the third priority is

to add skis to allow to travel on snowy or icy environments. A crucial task in allowing for these

capabilities is to integrate the transmission system. Other major considerations include focusing

on minor changes and making sure that the current model for the ATV works in its simplest

form.

In regards to this working model, Section C will focus on ensuring the feasibility of the

dune buggy as a ground vehicle. Section C will make adjustments to the engine and transmission

systems to make sure they integrate with the other systems of the vehicle. The current

transmission is severely lacking and we hope to optimize the system to enable and improve the

various functions of the ATV. A related goal is to replace the existing drive shafts with a

telescoping axle assembly in order to integrate the propellers from group D with the existing

transmission. Section C will also add alternative energy sources such as a wind turbine to harness

the energy of motion and a regenerative braking system that consists of a MGU (motor generator

unit) and a PCU (power control unit) which will convert the kinetic energy lost while braking

and to electrical energy. Further additive measures include safety features such as an airbag

system, a convertible top and possible skis.

Section M of group 5 will focus on the working model aspect of the dune buggy project;

our goal will be to confirm the working condition of the previous model. Section C will focus on

the working aspect of the previous transmission and engine design; whereas our group will

assess the frame, cooling system, electrical system, and suspension system, as well as any minor

components of the body and frame, such as the seats. We will bear in mind the safety aspect of

the previous design as well; this means we will assess the functionality of the seatbelts and

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suspension and make any necessary changes accordingly to ensure that the dune buggy is both

marketable and free of liability.

Team 5 from section D is responsible for the tread and propeller system. The treads will

enable the dune buggy to travel on more terrains like snow. The treads will be attached to the

wheels of outer side of the propellers. We can use the propeller to lift the dune buggy into the air

to overcome the obstacles that the wheels could not do. Since the dune buggy is designed to fly

in low altitude, all wheels and propellers will use the same power source of the dune buggy.

The goal of this project is to improve on the existing dune buggy model to make it an

energy efficient, functional and feasible option for travel on various terrain both on the ground

and off.

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GROUP APPROVAL DOCUMENT

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Overview

Team D

Section D from group 5 is responsible for the track system and propulsion system and makes

revolutionary changes to the original design of the dune buggy. The conventional four-tire

differential system is being replaced by a linked track system. This has been designed by using

multiple rims on each side of the dune buggy. The tracks will roll around each set of rims in

order for the dune buggy to move and travel on uneven terrains. Another unique feature has also

been added to the dune buggy, the ability to fly and hover. Four small turbojet engines are to be

located inside the rims. The propellers will deploy outward and perpendicular in order to lift the

dune buggy. The freedom of the rotation axis of the propeller will allow the thrust vector to

change the direction. This change of direction will decompose the thrust vector into two

components, lift, and thrust. This will allow the dune buggy to remain in the air and fly in

multiple directions and orientations.

The following sketches have been drawn by each team member to show a detailed view of the

parts that are involved in each segment of the dune buggy. Each isometric sketch is followed by

a multi view sketch and full dimensions. The explanation and brief description of each part is

also included along with a picture of the part made in AUTODESK INVENTOR. Finally, a table

consisting of the team member names, the corresponding links to the part file, drawing files,

presentation files, rendering images and the animations is provided.

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Track shape:

When we first planned the shape of the tracks, we decided upon a triangular shape. The two

bottom rims were the actual drive rims and the top rim was a free spinning tension rim. Each of

these details can be seen in the sketches shown below.

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Since the track system is a new feature to be added to the original design, the shape of the track

is designed to be similar to normal wheels to prevent major changes to original design of the

dune buggy.

While planning the track shape with the frame team, we realized that the triangular shape would

not work. The top free spinning rim prevented easy access to the door of the dune buggy. After

further discussion we decided to remove the top rim and only use the bottom rims. The new track

shape can be seen in the image below.

The final assembly of the tracks on the rim still used the same shape. The assembly can be seen

in the following image.

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Track linkage:

The track linkage is designed to connect each individual piece of the track to the other and allow

for proper rotation. The two holes on either side of the link allow a pin to slide through into the

track and secure each piece together. The screw on the top applies a certain amount of tension on

the pins. Below is the isometric and multi-views.

Below displays the new designs for the link. There are no new changes, only new displays. The

screw used for applying tension the pins is also now displayed.

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Finally in our concluding assembly, many changes were made in order to make everything fit

together properly. The link design changed to a basic, but rugged single piece design. This

change can be seen below.

This new link design uses a bolt that will insert though the hole in the link, the hole in the track,

and the another corresponding link on the backside of the track. The bolt will be secure on the

backside of the track with a threaded nut. The bolt and nut can be viewed in the following

images.

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Individual track:

The individual track is the actual piece that will be in contact with the ground and will rotate

about both rims. It is connected with each other piece of the track by use of the linkage shown

above. Because of the depth of the rims, each individual piece of track can be connected end-to-

end depth wise by use of pins that will be the length of the depth of the rim. The isometric and

multi-view sketches are displayed below.

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New Design:

The new design is not changed except for some dimension. The new design is displayed below.

In our final assemble, the track design had to change considerably in order to fit. It still used the

same concept, but the dimensions and look changed. The track shown above is now split into

three separate pieces, the base, the inside of the track, and then the top of the track. These pieces

and then a final assembled track can be seen in the following images.

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Base of Track

Inside of Track

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Top of Track

Track Assembled

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Inside of Each Track: The inside of each track pad consist of a skeleton to give it sufficient

strength to support the load. Below is the isometric and multi-view sketch.

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New Design:

The new design did not change except for some dimensions. The new design is displayed below.

In the final assembly of our track system, the actual track design changed. Consequentially the

inside of the track changed to adapt to the new design. This change can be viewed in the

following image.

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Rim Design:

The wheel rims designed to have teeth in order to be able to rotate and push the track to move the

dune buggy. The hollow part is designed to accommodate the turbojet engine.

This part was built based on the isometric and multiview sketches without any changes. It can be

easily seen that there’s a counter-bore-hole which creates a hollow design for this rim. It’s the

space reserved for the fans and the fans can connected to the power supply through the smaller

hole. How the wheel will work can be seen in this video: WheelWorking.avi

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Return Rollers:

The other three are return rollers, two smaller in size and one is bigger.

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They are to help the rolling of track, as well as support the structure of this set up (to keep the

track straight). The smaller return rollers can also help to split out the pressure on the wheels so

that the dune buggy can be more stable. This is the 3d part of the smaller roller:

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Some changes were made when building this part:

i. The depths of the teeth and the main axis were modified in order to fit the depths

of other parts (e.g. wheel rim, tracks).

ii. A small gap was added between one side of the roller and the support plate to

prevent friction between them during the roller is rotating.

iii. The dimensions of the teeth are modified in order to fit the sizes of the teeth of the

wheel rims.

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And here’s the bigger return roller:

Basically this follows the dimensions of the wheel rim, the only difference is that a support plate

is added to it, which is similar to the smaller roller. However, during final discussion, the smaller

return roller is decided to be deleted in order to achieve linear design of track.

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The propulsion system:

A turbo prop engine has been selected for the propulsion system of the dune boggy in

order to make it to hover over desired fields. The following figures show four isometric and

multi view sketches of the turbine blades and the inlet, the compressor, the combustor and its

cooling system, and the exhaust nozzle. Some changes have been applied to each of these parts

and in the inventor, more detail of the sketches could be seen.

The turbine and inlet:

A picture of the propeller is shown in the following figures. There were not any changes

made in the CAD drawing compared to what is being seen in the following figure.

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The compressor:

After more investigations, it was found that more details needs to be added to the

compressor of the engine. The number of the connection holes between the inlet and the

compressor were increased. This was the only change made from the isometric and the part made

in inventor. The following figure shows the compressor of the engine.

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The combustor and the cooling part:

The main change was made to the combustor and the connecting cooling part of it. It

was found that the combustor cooling pipes are not a attached parts and needed to be assembled

to the combustor. Therefore, a separate part was made and later on it will be assembled to the

combustor holes around the wall. More features were also added to the combustor. The following

figure shows the sketch of the combustor.

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The exhaust nozzle:

The exhaust nozzle did not have many changes to it and it maintained its original shape in

the sketch. Only the exhaust part was removed and placed with a hole and shell to represent a

more real shape for the core exhaust nozzle. The following figure shows the sketch of the

exhaust nozzle.

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Front Axle:

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This is the front axle of the buggy. The axle is fitted with advanced CV Joints that do not require

boots and serve as a multipurpose front differential as well. Micro Hydraulics within the two

main centered CV joints can change the angles between the two halves of the axle up to 30

degrees in order to accommodate for almost any kind of terrain. A hole exists on the left side of

the axle so that the driving wheel axle attaches directly to the front axle. This hole contains a

component of top secret technology known as the mechatronics and gravitation integral

component (abbreviated as MAGIC) which allows the axle to be controlled by the steering wheel

directly.

Rear Axle and Differential

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This is the rear axle of the buggy. The main component of the rear axle is a highly advanced

military grade differential specifically designed for maximum torque as well as durability in any

terrain. Furthermore, this differential is lightweight and slim, giving it an unparalleled power to

weight ratio – perfect for the dune buggy’s tracks. The design was slightly modified during 3D

modeling in order to allow for more power and torque from the differential.

Drive Shaft:

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This is the driveshaft connecting the front axle to the rear axle. The two key components here are

two never before seen U-joints that look nothing at all like U-joints. Similar to the hole from the

front axle, these highly advanced U-joints also contain the mechatronics and gravitation integral

component, allowing power to be transferred from the transmission to the driveshaft and again to

the rear axle effortlessly. A revolved feature has been added in the center to improve stability,

and dimensioned have been adjusted to avoid unnecessary weight.

Driveshaft/Axle Connecting Joint

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Developments in joint technology have led to the creation of the compressor joint. This joint

connects the front axle to the driveshaft and the driveshaft to the rear axle. Simple in design yet

advanced in its function, the compressor joint is able to expand and compress as needed

depending on external stresses placed on the drivetrain, all while maintaining maximum tensile

strength without compromising ductility or malleability. Improvements in this design during the

3D design phase include an additional square piece in the center along with hollowing out of the

center for maximum flexibility.

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Team C

Section C should introduce the work that is done in this group to a person who has no idea about

the group. It will talk about what has been done, how has it been done, and why should anybody

care about what has been done. It will contain isometric sketches, multiviews, assembly,

assembly section views, assembly exploded views with/without parts list, static rendering,

animation. Atleast one example of each of the above entities must be present in the overview

section.

All-Wheel Drive Axle Overview:

The All-Wheel Drive Axle Assembly was introduced in order to allow the ATV to handle more

arduous terrains. This is a significant improvement over the previous axle system of the ATV.

The overall assembly, pictured below, connects to the driveshaft in the rear and out to the

propellers on the sides.

The assembly consisted of four components, the first of which being the housing and axle unit.

This part, pictured below, fits underneath the vehicle and contains the gears necessary for the

axle system to function properly.

The next two components of the AWD axle assembly were created in order to attach the axle and

housing component to the frame of the vehicle. These parts are important in that they secure the

axle assembly in place, and are designed to be able to withstand the wear and tear that the

vehicle would experience while travelling through rugged terrain. Images of these connecting

parts can be seen below.

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The fourth part of the AWD Axle Assembly is a bracket that connects the axle to the mode of

transport of the vehicle. In a normal vehicle this piece would connect to the wheels, but in our

case this piece will connect to the propellers. Design sketches of this part can be seen below.

Transmission:

One of the components that was redone for this project was the transmission. The previous

transmission was non-operable due to non-interlocking gears that were created as one part

instead of separate individual parts.

The transmission is very important because it takes power from the engine’s shaft and transfers

that to the driveshaft which powers the wheels rotation. This assembly was created from

seventeen different parts, three of which repeat several times. The main parts of the transmission

include the transmission case, the shafts, the dog clutches, and the gears. The shaft going into the

transmission comes from the engine, which drives the entire transmission. The gears on the first

shaft rotate with the shaft and deliver power to the second shaft. Dog clutches in between gears

on the second shaft determine which gear the vehicle is in, which then determine the speed and

power. All of these parts are then enclosed within the transmission case.

Transmission Assembly:

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Assemble the gears for the shaft going into the transmission. The first and sixth gears are each

half an inch from the ends of the shaft. Place the rest of the gears for this shaft in between. The

first and second gears are separated by an inch as well as the third and fourth gears, and the fifth

and sixth gears. Each gear is constrained so that it will rotate along with the shaft.

Completed Shaft Going Into Transmission:

For the second shaft going out, each gear is attached to a dog clutch for the gears and is

constrained so that they rotate together.

Completed Gear with Dog Clutch:

For the second shaft going out, each gear is placed onto the shaft and is separated by the same

distance as the first shaft with their corresponding gear.

In addition to these gears, three dog clutches are placed in between the first and second gears, the

third and fourth gears, and the fifth and sixth gears. These are constrained to rotate along with

the shaft but are also able to slide along the shaft.

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Completed Shaft Going Out of Transmission:

When each shaft is completed, place them inside the transmission casing. The first shaft is placed

inside the two holes on the top, while the second shaft is placed in the bottom two holes. When

the two shafts are placed, the reverse gear is placed between the sixth gears of both shafts.

Completed Transmission with both Completed Shafts Encased:

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Gear Shift:

The gear shift assembly allows the ATV to change gears and adjust to differences in terrain and

be more suitable to changes in elevation while driving. The gear shift system is connected to the

transmission and allows for contact with the driver so that the ATV is able to move. The former

gear shift did not include any connections to the transmission and had no way to actually change

gears or have any effect at all. The new gear shift assembly contains a shift lever, shaft clutch,

gasket and fork clutch that will allow it to interface with other systems in the ATV and enable

drive capabilities.

Shift Lever:

The shift lever connects the shaft of the gear to the crankshaft that then connects to the

transmission. Below are the isometric sketches and multiviews of the shift lever.

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The following is the three dimensional Autodesk Inventor model of the shift lever. No changes

were made in the three dimensional model.

Shaft Clutch:

The shaft clutch connects to the shift lever to transfer motion to the transmission. Below are the

isometrics and multi views of the shaft clutch.

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The following is the three dimensional Autodesk Inventor model of the shaft clutch. The

dimensions for the end of the rod were changed to accommodate another groove in the shaft

clutch. Detailed threads were also added to the 3D model as rectangular extrudes.

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Gasket:

The gasket is a mechanical seal used to join mechanical parts. It is used to connect various parts

of the gear assembly. Below are the isometric and multiviews sketches of the gasket.

For the three dimensional model of the gasket the depth of the gasket was reduced to reflect the

actual dimensions of functioning gaskets. The cut extrude in the center was also expanded and

modified for greater functionality. Finally four smaller holes were added near the center for

better mounting of the gasket.

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Fork Clutch:

The fork clutch stops transfer of engine power to the drive wheels by pivoting and sliding the

release bearing along the transmission input shaft and into the clutch unit. This applies enough

pressure to disengage the clutch and stop engine power transfer to the drive wheels. Below are

the isometric and multi views drawings.

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In the three dimensional model of the fork clutch many changes were made to improve the

functionality. The original design could not have handled the stress of power transmission and

the design was impractical. The new design has a longer thinner cylinder with a fork that extends

downwards. A separate attachment feature was also added for connections with other parts.

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Gear Shift:

The gear shift is a lever to manually change the gears and affect action in the clutches to transfer

power from the engine to the transmission and drive wheels.

The three dimensional model of the gear shift includes a loft and a sweep feature. This lever is

more formfitting and comfortable in the hand than its predecessor.

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Assembly Description:

Below is a rendering of the assembly of the gear shift with all parts assembled.

The exploded view of the assembly is provided below and assembly instructions follow.

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The first part was the modified gear box from the previous semester’s submission. The gear box

was modified to fit the shift lever and shaft parts of the gear shift assembly. The box was

widened and the extrusion modified. A hole was also extruded into the side of the box so that the

shaft clutch could pass through.

A comparison of the old and new gear boxes are shown below.

Old Gear Box New Gear Box:

Inserted into this gear box is the gear shift assembly with the gear shift, shift lever, shaft clutch

and fork clutch. The gear shift is inserted into the shift lever which transfers the torque applied to

the gear shift to the clutch and in turn the transmission.

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The shift lever then turns the shaft clutch which is connected to the fork clutch and continues the

transfer to the transmission system of the ATV. The shaft clutch is inserted into the hole

extruded into the side of the shift lever and the indentation in the fork clutch is fitted into the

shaft clutch.

The final assembly of the gear shift is then covered with a gasket at the bottom to secure all

components in place.

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Wind Turbine:

Dune Buggy Wind Turbine Design:

A wind turbine will be attached to both sides of the dune buggy in order to generate electricity to

charge up internal batteries when moving. The following figures show three isometrics and multi

view sketches of the Frame, Dynamo, Blade and Blade Ring. Some changes and additions have

been made to these parts in Inventor.

Frame:

The idea of the frame is to display how the turbines would be attached to the dune buggie’s

chassis and to get a good overview of how the turbine will look like from far.

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Changes:

We changed the old frame mount into a new one which is much more aerodynamic. In this case

the wind turbine will have less drag and thus wont slow the dune buggy down as much. The new

design can be seen below.

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Dynamo:

The dynamo ring was the part designed to transform the kinetic energy into electrical energy and

generate power. We made no changes to this part.

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Blade:

A total of 12 Blades were designed to be attached to the Blade ring and turn it. The idea is that

the wind blows into the blades and makes the ring spin.

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Changes:

The main change we worked on was the profile of the blade. As the wind blows into them we

wanted to create the optimal blade profile with the highest efficiency. Below you can briefly see

how much the tips bend away.

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Blade Ring:

The blade ring we designed completely new. Below you can see how there are two tracks in the

outside of the ring, which will slide inside of the inverted tracks of the dynamo ring and generate

the electricity. The 12 Blades will be attached to this ring which make it spin.

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Wind Turbine Final Assembly

The Wind Turbine Assembly exploded view can be seen below. The purpose of the wind turbine

is to help generate power and increase the overall energy efficiency of the vehicle. Since we are

designing our ATV with a focus on alternative energy, we thought it was important to utilize

wind power. The parts list is included in this drawing file.

KERS MGU:

The KERS (Kinetic Energy Recovery System) MGU attaches to the front of the engine and takes

the kinetic energy lost while braking and converts it to electrical energy. This will be highly

beneficial to our hybrid engine, and will allow the driver to either boost performance or battery

life, depending on its use.

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KERS PCU:

The KERS PCU monitors the MGU and regulates the energy being sent to and taken from the

battery. It also allows the driver to direct the electrical energy from the battery and directed back

through the MGU in order to improve the performance of the vehicle.

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STEERING WHEEL:

Made of carbon fiber, the new steering wheel adds an updated look to the buggy while

accommodating the airbag system. The steering column is the same diameter as the old steering

column, so no other changes to the buggy will be necessary. An example of a similar assembly

can be seen below, along with the steering wheel itself.

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AIRBAG/COMBUSTION CHAMBER:

The combustion chamber is what inflates the airbag in the event of a crash. They are

permanently attached to each other in order to ensure a reliable seal and to allow for easier

removal/replacement.

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AIRBAG MOUNTING PLATE:

Steel plate that facilitates the attachment of the airbag/combustion chamber inside the steering

wheel. An example of a similar plate can be seen in the steering wheel/airbag assembly pictured

above, along with the plate itself pictured below.

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STEERING WHEEL FACE COVER:

The face cover is designed to resemble Buzz and is made of carbon fiber. This removable face

makes the installation/removal of the airbag assembly much easier. An example of a similar face

plate can be seen in the steering wheel/airbag assembly pictured above, along with the cover

itself pictured below.

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AIRBAG SENSOR:

Attaches to the front of the vehicle and detects a collision. Upon the detection of a collision, it

immediately triggers the combustion chamber, which inflates that airbag.

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Steering Wheel Assembly

In order to install an airbag into the vehicle, a new steering wheel and steering column had to be

designed. The resulting assembly can be seen below. The parts list is also displayed below with

arrows pointing to the corresponding parts. The combustion chamber and airbag are housed

safely inside this assembly and can easily deploy in the event of an accident. The driver’s safety

is greatly improved with this addition.

Powertrain Assembly

The Powertrain Assembly exploded view is a mix of old and new parts and can be seen below.

This assembly connects the engine, transmission, KERS MGU, and the electric motor. In the

previous iteration of the vehicle, the engine, transmission, and electric motor were simply resting

next to each other. Now, the electric motor and engine are one unit, as most hybrids are

essentially one connected unit and they are physically connected to the transmission, allowing

power to be transferred to the drivetrain. The KERS is connected to the opposite side of the

engine and will convert any lost kinetic energy while braking into electric energy.

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Section M

Section M of Group 5’s main responsibilities were to improve the existing alternatively

powered vehicle created by the previous group 5s and modify the vehicle to accommodate the

addition of tracks and flight. With these major changes to the original design, the previous

vehicle was obsolete. The original dune buggy did not have the aerodynamic body we needed. It

also did not have adequate steering wheels that could move up and down to accommodate flight,

windows to protect the passengers from weather and bugs, and shock system that can take the

forces of landing. We needed to update a lot of the previously built buggy to make it flyable. We

decided to create a brand new design for the cage and cab as well as the shock absorbers. Such

extensive changes required many parts and assemblies were created.

Parts:

Mirror components

We decided to design the housing for a mirror to be placed in because it didn’t make

much sense to have an inch and a half thick mirror.

Shock assembly

(New) (Old)

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The hydraulic cylinder has been modified so that it will fit the suspension arms that were

designed last year. The piston has also been modified to be closer to last year piston design so

that it will also fit the suspension arms

Lights

Mirrors to focus light in the headlights, brake lights, and turn signals have been designed

to fit inside of their respective housing. The light mount has been redesigned to be thinner so the

headlight can be closer to the turn signal. A lens has been designed to protect the components

that will be placed inside of the headlight.

Steering Wheel Since the dune buggy is intended to fly, a new kind of steering wheel was needed to

provide for all the necessary axes of control. The wheel can be turned from left to right as well as

pushed forward and pulled back.

Changes: No changes were made to this design when drawn into a 3D model.

Roll Cage

The roll cage was designed to provide protection to passengers in the event that the

vehicle is overturned. It was given a sleeker design to improve the aerodynamics of the entire

vehicle.

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Changes: No changes were made between the sketch and model phases.

Radio

The radio was added with the intent to provide additional entertainment to

passengers. The design was kept small to minimize modifications to the dashboard.

Changes: No changes were made to the original design.

Pedal

I made a few overall changes to the dimension of the pedal and added a few more fillets

to allow the part to fit properly onto the pedal bar. I had to add a piece to the back in order for the

pedal bar to be assembled with the pedal.

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Pedal Bar

I filleted the edges of the bar and made some adjustments to the dimensions of the bar in

order for it to properly fit onto the pedal.

Gear Stick

I added threads and additional extrusions to a better overall look and feel to the gear stick

and allow it to seem better. The gear stick has also been given aesthetic cuts in the top to allow

show that it is a manual gearshift.

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Gear Box

The gearbox was also altered in dimension but I added one plate in order for the gear

stick to be added to the gearbox while put in the gearbox during the assembly of the parts.

Door Frame

The door frame is designed to attach to either door through the hinges. It is designed to

attach to the floor plate through welding.

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Changes: This was a late addition to the list of part we needed to make.

Left Door

The left door is an improvement on the previous doors. It has a triangular window and a

door handle. It attaches to the door side hinges through welding.

Changes: The scale of the left door was changed to make it look better of the alternatively

powered vehicle.

Right Door

The right door is an improvement on the previous doors. It has a triangular window and a

door handle. It attaches to the door side hinges through welding.

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Changes: The scale of the right door was changed to make it look better of the alternatively

powered vehicle.

Door Hinge Bolt

The door hinge bolt is designed to hold the door hinge parts together. It is designed to

allow the door to swing open.

Changes: This part was a late addition to the parts list.

Hinge Door Frame Side

This part of the door hinge was designed to attach to the door frame.

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Hinge Door Side

This part of the door hinge was designed to attach to each door.


Co-Pilot Steering Wheel

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The co-pilot steering wheel is designed to fit flush with the dash. It is dsigned that in light

the co-pilot can push a button and the steering wheel would pop out of the dash and be ready to

use.

Changes: The handles were made a little smaller.

Dash Board

The dash board was designed to house the altimeter, speedometer, gps, and other

essential equipment. It was designed to fit in the dash.

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Changes: There were no changes made to this part.

Dash

The Dash is designed to hold the two steering wheels, and the dash board. It is designed

to attach the floor plate and to both door frames through welding.

Changes: This was a late addition to the list of part we needed to make.

Assemblies

The assembly files for our group are split in a bunch of sub-assemblies.

84

Overall Assembly

85

Dash and Door Assembly

The two doors were designed to attach to the das and the floor plate. The Dash and Door

Assembly Exploded View shows how each door assembly and the dash assembly fit together.

Dash Assembly

I created three parts for the dash board: the dash board, the steering wheel for the copilot, and the

dash mount. The co-pilot steering wheel was designed to fit flush in the dash. If the driver

needed a co-pilot for flight, the copilot would hit a button and the steering wheel would come

out. The dash board sits in a little groove in the dash mount. It contains places for a speedometer,

altimeter, gps, and fuel gage. The dash mount is designed to hold the steering wheel, and dash

board. It allows for ample leg room and room to see ahead. The Dash Assembly Exploded View

shows how the co-pilot steering wheel and the dash board fit onto the dash mount.

86

Door Assemblies

Each door assembly is made of four parts: the door, the door frame, and two three part

hinges. The hinges are designed to have a piece attached to the frame, one attached to a door, and

a

bolt holding them together. The hinge allows each doors to open and close. Each door has a

triangular window in it and a door handle. The two door assemblies attach to the dash assembly

which in turn attached to the base plate. Each door assembly shows how the hinge fits together.

It then, shows how the hinges attach the door to the frames.

87

Seat and Bar Assembly

The seat and bar assembly was created by combining the seat assembly (which includes

the seat and base) and the safety restraint assembly (which includes the safety restraint, support,

and fastener). It was created simply for the sake or ease in inserting and constraining the two

sub-assemblies to the buggy’s floor plate.

Seat Assembly

The seat of the dune buggy was modified from the previous design from a perpendicular

design to a more ergonomic fashion. The back and bottom of the seats are now curved inward

and ribbed, as opposed to the previous flat design. The upgrade in comfort focus will make the

dune buggy more attractive to potential buyers looking to enjoy themselves. The base of the seat

has been modified as well, with the intention of simply welding it to the floor plate and seat. It

has been designed with enough height to allow leg room for passengers, and it has been

hollowed in the middle to save manufacturing costs.








88

Safety Restraint Assembly

The safety restraint assembly is a new addition altogether to the buggy’s design,

replacing the former seat belt design. The restraint was designed to rotate as a lever arm about

the support and to rest in the fastener when in use. This design relies on the strength of the steel

parts of this assembly and should be sufficient to restrict lateral movement. The support was

designed to be welded to the floor plate, and the restraint is intended to rotate on its right end as

shown above about the axis of the circular hole in the support.The fastener was also designed to

be welded to the floor plate, and the restraint’s left end in the picture shown above is to rest in

the cutout of the fastener.

89

Cup Holder Assembly

The cup holder assembly is another new addition to the buggy. It was added to the design

as a consumer-friendly amenity, in order to increase buyers’ appeal. The plastic cup holder insert

has been designed to slide freely in and out of the storage compartment so passengers have a

choice of whether or not they need cup holders. The steel storage compartment is to be welded to

the floor plate, and is intended to act as an alternative to cup holders; if passengers would rather

have extra room to store their phones and wallets, this feature will accommodate them.

Gearbox Assembly

The gearbox assembly is made of two pieces, the stick shift and the actual gearbox. The gearbox

is a manual gearbox with 4 gears a reverse and a flight gear to allow for liftoff. The gearbox has a plate

on top that shifts when the gear is moved from gear is moved to the selected gear it is in.

90

Pedal Assembly

The pedal assembly is made of 6 screws, 3 pedal bars, 2 pedals (one for the gas, and one for the

clutch), 1 mounting bar and one brake. The parts come together and allow the driver to control what gear

he or she is in, and control when to become airborne. The Pedal assembly is simple yet fully functional in

allowing the driver the best possible control of the dune buggy.

91

Brakelight Assembly

This assembly will hold the lights that flash while braking.

Shock Assembly

The Shock Assembly is the component of the suspension system that will absorb the

majority of the energy that results from jolts while driving. The Shock Assembly works using a

hydro-pneumatic dampening system that we developed. Fluid is stored in the hydraulic tank and

when this system is activated by a jolt the piston pushes the hydraulic fluid upwards. The fluid

then moves through the transfer pipe into the compression tank where it compresses nitrogen

gas.

92

As a section we completed a lot of work and achieved our goals. We fixed the suspension

system to be able to take the load of landing, made the vehicle more aerodynamic, and improved

many parts from the previous incarnation. This version of the vehicle will not only be able to ride

through the dunes but fly as well.

93

Action Items

Team D

Section D was responsible to design the track system, the wheels and the flying capabilities of

the dune buggy. The conventional four-wheel moving system was decided to be replaced by

track in order to enhance the ability of the dune buggy to be able to operate on very uneven

fields. This part was done as a “modification” to the original design of the dune buggy. It was

also required for the new design to have a unique feature compared to the original design.

Therefore, the hovering and the flying ability were added. The following list shows the actions

that was taken based on the approval:

1- The propulsion system was designed to perform in low altitudes (less than 3,000 ft)

2- Four identical turbojet engines were chosen to be placed inside the rims to be able to

stabilize the dune buggy during flight and the during hovering

3- The orientation of the turbojets with respect to the rim was selected to be parallel when

the dune buggy is on the ground and perpendicular when the dune buggy is in the air

4- It was decided that the power required for the turbojet is coming from the propulsion

system composed of the inlet, compressor, combustor and exit nozzle.

*** *** *** *** *** ***

Action-Items

1. Design a propulsion system to perform in low altitudes (less than 3,000 feet).

2. Design propellers that can exert vectored thrust forward & upward.

3. Design propellers that are placed in wheels.

4. Design track system that is compatible with the propulsion system.

94

Team C

Section C’s focus was on ensuring the feasibility of the dune buggy as a ground vehicle.

Adjustments have been made to the engine and transmission systems to make sure they both

integrate with the other systems of the vehicle and allow the power produced by the vehicle to

ultimately be transferred to the wheels. The previous transmission would simply not have

allowed for this and required a complete overhaul. While the necessary overhaul to the

transmission was extensive, minimal changes were made (as stipulated in the approval) to the

engine and electrical motor. Therefore, minimal changes in the manufacturing process will be

necessary. Our new transmission, along with a more complete powertrain assembly will

optimize the power output and enable the various functions of the ATV. In addition to

overhauling the powertrain system that was already in place, entirely new systems have been

added in order to make the vehicle more dynamic and flexible in its use of alternative energy

sources. The following list details efforts that were undertaken as a result of the approval.

1. Overhauled the transmission assembly so that it contained the necessary gears

2. Overhauled the powertrain assembly into an organized, working assembly

3. A kinetic energy recovery system was designed and installed onto the engine block to

help generate electrical energy for the vehicle while driving on the ground.

4. A wind turbine was added to help generate power for the vehicle while in flight.

5. A driveshaft and axle were designed to facilitate the transfer of power to the wheels.

6. An airbag assembly was installed onto a re-designed steering wheel in order to improve

driver safety.

7. A new gearshift assembly was designed to coincide with the updated transmission.

95

Team M

Section M was responsible for the working model aspect of the dune buggy and to

confirm the working condition of the model. Adjustments were made to the original frame and

floor plate designs to accommodate the various mechanical changes that were made to the dune

buggy. The floor plate was lengthened and given a wider front base to provide more room for the

engine and transmission without sacrificing space for the passengers. The frame was also

lengthened with the floor plate, and additional supports were added to the side that the shock

system and tread system could directly attach to. Since the dune buggy is expected to handle

multiple types of terrain, the shock system was redesigned so that it can be adjusted to suit the

driving conditions. The following list outlines the actions that were taken to address these issues.

1. Design a larger floor plate to accommodate new mechanical changes.

2. Design a new frame for the tread system to attach to.

3. Adjust roll cage to be aerodynamic enough for flight.

4. Create new steering wheel that allows for 3 dimensional vehicle control.

5. Create a shock system that can be adjusted handle various types of terrain.

6. Add a dashboard to house the steering wheel and speedometer.

96

Action Item Tables Team D

Seria

l No.

Action Item Team

Responsible

Completene

ss

Contribution Comments:

1 Design a low-

altitude use

propulsion system

Team D 80% Miad: 100%

Stephen: 0

ZhenKang: 0

Ankit: 0

Miad was responsible

for this task. He

designed and

assembled this item.

2 Design propellers

that can exert

vectored thrust

forward & upward


Stephen: 0

ZhenKang: 0

Ankit: 0


for this task. He

designed and


3 Design propellers

that are placed in

wheels


Stephen: 0

ZhenKang: 0

Ankit: 0


for this task. He

designed and


4 Design track

system that is

compatible with the

propulsion system.

Team D 80% Miad: 0

Stephen:

33.33%

ZhenKang:

33.33%

Ankit: 33.33%

Stephen was

responsible for the

design of the tracks.

ZhenKang was

responsible for the

design of the rims.

Ankit was

responsible for the

drive axel and

differential.

97

Team C

Serial

No.

Action Item Team

Responsible

Percentage

Complete

Contributions Comments

5 Overhaul and

design of

transmission

Team C 95% Andrew: 100%

Youmei: 0%

Ryan: 0%

Lee: 0%

Jan:0%

Andrew was

responsible for the

design and overhaul

of this item.

6 Overhaul of the

powertrain

assembly


Youmei: 0%

Ryan: 0%

Lee: 100%

Jan: 0%

Lee was primarily

responsible for this

task.

7 Design and

installation of

the kinetic

energy recovery

system.


Youmei: 0%

Ryan: 0%

Lee: 100%

Jan: 0%

Lee designed and

installed this system.

8 Design and

installation of

the wind turbine


Youmei: 0%

Ryan: 0%

Lee: 0%

Jan: 100%

Jan was responsible

for this task.

9 Design of

driveshaft and

axle


Youmei: 0%

Ryan: 100%

Lee: 0%

Jan: 0%

Ryan was responsible

for this task. The

final assembly used a

different axle

assembly, from Team

D

10 Design of airbag

assembly and

steering wheel


Youmei: 0%

Ryan: 0%

Lee: 100%

Jan: 0%

Lee was responsible

for designing and

assembling this item.

11 Design of new

gearshift

assembly


Youmei:100%

Ryan:0%

Lee: 0%

Jan:0%

Youmei was

responsible for

designing and

assembling this item.

98

Team M

Serial

Number Action Item

Team

Responsible

Percentage

Complete Contributions Comments

12 Design a larger

floor plate Section M 100%

Abram: 0%

Matthew: 100%

Michael: 0%

Tyler: 0%

Vikram: 0%

Matthew was

responsible

for this task.

He designed

and

assembled

this item.

13

Design a new

frame to allow

for the tread

system

Section M 100%

Abram: 0%

Matthew: 100%

Michael: 0%

Tyler: 0%

Vikram:

Matthew was

responsible

for this task.

He designed

and

assembled

this item.

14

Adjust roll cage

to make it

aerodynamic

Section M 100%

Abram: 0%

Matthew: 100%

Michael: 0%

Tyler: 0%

Vikram: 0%

Matthew was

responsible

for this task.

He designed

and

assembled

this item.

15

Create a

steering wheel

for 3

Dimensional

vehicle control

Section M 100%

Abram: 0%

Matthew: 0%

Michael: 100%

Tyler: 0%

Vikram: 0%

Michael was

responsible

for this task.

He designed

and

assembled

this item.

16

Design an

adjustable

shock system

Section M 100%

Abram: 100%

Matthew: 0%

Michael: 0%

Tyler: 0%

Vikram: 0%

Abram was

responsible

for this task.

He designed

and

assembled

this item.

17 Create a

dashboard Section M 100%

Abram: 0%

Matthew: 0%

Michael: 100%

Tyler: 0%

Vikram: 0%

Michael was

responsible

for this task.

He designed

and

assembled

this item.

99

Assembly Descriptions

Section D

i. Rim, Track and Drive Train Assembly

The Drawing file below displays how the axel system is connected to the rim and track system.

Item number 2 is the rim and track system which is connected to item number 1, the axel system.

The axel system provides the rational power to the track and rim system.

Part/Assembly

Corresponding Isometric/Multiview Sketches

Corresponding Part/Assemblies

Section Responsible

Student Responsible

Corresponding Drawing File

Comments

Full_Track_System

Drive_Train Track_with_Wheel_Engine

D Ankit Verma Miad Karimi Stephen Rehberg Zhenkang Pang

Full_Track_System_Explosion

100

ii. Drive Train Assembly

The drawing file below displays how the axel system is assembled. Item number 2 is the

differential which is located in the rear of the dunebuggy. This item will be secured to the

transmission as its power system. Item number 3 is a shaft joint which simply secures item

number 1 and 2 together and also allows these two parts to have free movement while still

rotating. Item number 4 is the front drive axel and is connected to item number 1 where it

recieves its power from.

Part/Assembly



Section Responsible

Student Responsible


Comments

Drive_Train connecting joint isometric connecting joint multiview drive shaft multiview drives shaft isometric front axle

DriveShaft FrontAxle RearAxleandDifferential ShaftAxleJoint

D Ankit Verma

Drive_Train_Explosion Drivetrain part multiviews

101

isometric front axle multiview rear axle isometric rear axle mutliview

102

iii. Track and Rim Assembly

The drawing file below displays how the track system is connected to the rims. Item number 1 is

the track system. It is similar to a belt that wraps around a pully. In this case, the tracks wrap

around item number 2 which is a rim containing our turbo engine. These rims are rotated which

rotates the tracks that moves the dunebuggy. Item number 3 is an additional rim that provides

support between the two drive rims. It is free rotating with the track.

Part/Assembly



Section Responsible

Student Responsible


Comments

Track_with_Wheel_Engine

Full_Track TurbojetEngine_with_Wheel Return_Roller_Big

D Miad Karimi Stephen Rehberg Zhenkang Pang

Track_Explosion

103

iv. Track assembly

The drawing file below displays how the tracks are assembled on the rim. Item number 1 is the

rim that the tracks wrap around. Each individual track contains three pieces, the base, the inside,

and the top. The base of the track which is item number 4 is what touches the rim and is

connected to other tracks. Item number 2 is the inside of the track and is connected to the base of

the track. The inside of the track provides the support it needs to withstand the extreme weights

and rugged terrains the track will see. Item number 3 is the top of the track which covers the

inside of the track and connects to the base of the track. Each track is connected via a link (Item

number 5), linking bolt (Item number 6), and linking bolt nut (Item number 7). The linking bolt

goes through the link first, then the base of the track, and then through another link. It is then

secured on the back side with the linking bolt nut. Each complete track is secured to the next via

the linking system described previously.

Part/Assembly



Section Responsible

Student Responsible


Comments

Rim_Assembly_With_Track

IsometricIndividualTrack IsometricInsideTrack IsometricLin

Wheel_Rim Inside_Of_Track Top_Of_Track Base_Of_Tr

D Stephen Rehberg Zhenkang Pang

Base_Of_Track Multi&Isometric_Inside_Of_Track Multi&Isom

104

k IsometricTrack MultiviewIndividualTrack MultiviewInsideTrack MultiviewLink SectionD_MultiviewTrack wheel_rim_iso wheel_rim_multiview

ack Link Linking_Bolt Linking_Bolt_Nut

etric_Link Multi&Isometric_Linking_Bolt Multi&Isometric_Linking_Bolt_NutMulti&Isometric_Top_Of_Track Wheel_Rim Exploded_Part_View_List_Rim&Tack_Assembly

105

v. TurboJet Engine and Rim Assembly

The drawing file below displays how the turbojet engine is connected to the rim. Item number 2

is the rim that has been designed to Item number 1, the turbojet engine. The turbojet engine is

simply slid inside of the rim and secured via the axel system.

Part/Assembly



Section Responsible

Student Responsible


Comments

TurbojetEngine_with_Wheel

wheel_rim_iso wheel_rim_multiview

Turbojet_Engine Wheel_Rim

D Miad Karimi Zhenkang Pang

Turbojet_ Engine_with_Wheel_Explosion

PropellerWorking.avi WheelWorking.avi

106

vi. TurboJet Engine Assembly

The drawing file below displays the assembly of the turbojet engine. The turbojet engine consists

of five separate parts. The first part(item nomber 1) is the propeller which is responsible to intake

the air to the core of the engine. This part is then attached to the compressor(item number 2)

inorder to increases the pressure and the temperature of the air. The compressed air is then goes

into the combustor(item number 3) where it mixes with the fule to produce high enthalpy

products. Due to the very high temperature of inside the combustor, combustor cooling part (item

number 4) is added to the both sides of the combustor in order to avoid the combustor walls from

reaching the melting temperature. The hot mixture is then sent through the exit nozzel (item

number 5) in order to accelerate the flow and produce thrust. In this process the conseravation of

energy is applied since the thermal energy is converted to the kinetic energy and ultimatly the

thrust is generated.

Part/Assembly



Section Responsible

Student Responsible


Comments

Turbojet_Engine

Compressor_Iso Compressor_Multi Cooling_Iso Cooling_Multi Exhaust_Iso

Combustor Combustor Cooling Compressor Exit Nozzel Propeller

D Miad Karimi

combustor cooling multivew Combustor multiview Compressor multiviews Exit nozzle

107

Exhaust_Multi Turbine_Iso Turbine_Multi

multiview propeller multiview Turbojet assembly multiviews Turbojet sectional view

108

Section C

AWD Axle Assembly

(Not included in final assembly)

One plan for the axle assembly is shown below. Part #1 is the housing component, which the

axle runs through. Part #2 is attached to both ends of the axle, and serves as the connection

component between the axle and the mode of transport (wheels, treads, etc.). Parts #3 and #4 are

connection components that fit in between the housing and Part#2. These parts are there to

connect the axle system to the body of the vehicle and provide structural support. This system as

a whole could have served as an axle assembly for our ATV, but we decided to go with an

alternative axle assembly for the final project.

Part/Assembly



Section Responsible

Student Responsible


Comments

AWD Axle Assembly.iam

RK Part 1 iso.jpg RK part 1 multi.jpg RK part 2

RK alt housing.ipt RK outer bracket.ipt RK

C Ryan Krusko

AWD Axle Assembly Directions and Parts List1.idw

Ryan

Krusko

AWD Axle

Static

Rendering.

109

iso.jpg RK part 2 multi.jpg RK part 3 iso.jpg RK part 3 multi.jpg RK part 4 iso.jpg RK part 4 multi.jpg

horizontal.ipt RK vertical.ipt

jpg

Ryan Krusko AWD Axle Animation.avi

Wind Turbine Final Assembly

The Wind Turbine Assembly can be seen below. The purpose of the wind turbine is to help

generate power and increase the overall energy efficiency of the vehicle. Since we are designing

our ATV with a focus on alternative energy, we thought it was important to utilize wind power.

The assembly of the wind turbine starts with Part #1, the blade ring. The Dynamo and Frame are

then attached on top of this. Finally, the blade itself is added into the assembly.

110

Part/Assembly



Section Responsible

Student Responsible


Comments

FinalAssembly.iam

Iso-Dynamo.jpg Iso-Frame.jpg Iso-Blade.jpg Multi-Dynamo.jpg Multi-Frame.jpg Multi-Blade.jpg

Dynamo.ipt Frame.ipt Blade.ipt Blade Ring.ipt

C Jan Happel

\WindTurbine_Exploded.idw

111

Steering Wheel Assembly

In order to install an airbag into the vehicle, a new steering wheel and steering column had to be

designed. The resulting assembly can be seen below. The steering column and steering wheel

are actually one part made of carbon fiber. First, the Airbag is bolted to the Airbag Mounting

Plate. Once that has been accomplished, the Airbag Mounting Plate can be bolted to the Steering

Wheel. Once these parts are all bolted together, the Steering Wheel Cover can be installed onto

the Steering Wheel to cover up the airbag assembly and provide an aesthetic upgrade to the

vehicle.

Part/Assembly



Section Responsible

Student Responsible


Comments

Steering Wheel Assembly.ia

Airbag.jpg Airbag Multi View.jpg

Airbag.ipt Airbag Mounting

C Lee Caldwell

SteeringWheel Assembly

SteeringW

heelAssem

bly side

112

m

Plate.ipt Airbag Steering Wheel.ipt Airbag Steering Wheel Cover.ipt

Explode and Parts List.idw

front

Image.jpg

Lee

Caldwell\R

enderingVi

deo.avi

113

Powertrain Assembly

The Powertrain Assembly is a mix of old and new parts. The first step in this assembly is to

attach the end of the Transmission Connector that has the 3 inch hole to the crankshaft of the

Engine. The Flywheel then attaches to the front of the Transmission Connector. Next, install the

Transmission to Transmission Connector on the same end as the Flywheel. The Electric Motor

then will require the second Flywheel to be installed onto its Rotor. Once that is complete, the

KERS Connector is installed to the Engine’s Crankshaft on the opposite end of the Transmission.

The resulting assembly will then fit into the space at the rear of the vehicle.

Part/Assembly



Section Responsible

Student Responsible


Comments

EngineTransmissionElectricMotor Assembly.iam

Connection for Eng and Tran.ipt Part2.ipt KERS MGU.ipt

C Lee Caldwell

Powertrain Assembly Explode.idw

114

Gearshift Assembly

Inserted into the gear box is the gear shift assembly with the gear shift, shift lever, shaft clutch

and fork clutch. The gear shift is inserted into the shift lever which transfers the torque applied to

the gear shift to the clutch and in turn the transmission. The shift lever then turns the shaft clutch

which is connected to the fork clutch and continues the transfer to the transmission system of the

ATV. The shaft clutch is inserted into the hole extruded into the side of the shift lever and the

indentation in the fork clutch is fitted into the shaft clutch. The final assembly of the gear shift is

then covered with a gasket at the bottom to secure all components in place.

Part/Assembly



Section Responsible

Student Responsible


Comments

gear shift assembly.iam

shift lever.jpg shaft clutch.jpg gasket.jpg fork clutch.jpg

Shift Lever.ipt Shaft Clutch.ipt Gasket.ipt fork clutch.ipt

C Youmei Zhou

gear shift assembly exploded view.idw

115

shift lever multiview.jpg shaft clutch multiview.jpg gasket multiview.jpg fork clutch multiview.jpg

116

Transmission

The transmission allows power from the engine to transfer into different gears, which allow for

the vehicle to change speeds. The engine’s shaft connects to the transmission’s shaft which goes

into the transmission case from the top hole. The transmission’s shaft going in has six gears that

power the shaft going out, which also has six gears. Dog clutches on the shaft going out can lock

onto one gear at a time, which determines the speed. This shaft going out from the bottom holes

will connect to drive shafts that power all the wheels.

Part/Assembly



Section Responsible

Student Responsible


Comments

Transmission_Assembly.iam

Transmission Isometric.jpg Shaft In Isometric.jpg Shaft Out Isometric.jpg Transmission Multi View.jpg

TransmissionCase.ipt ShaftInGear1.ipt ShaftOutGear1.ipt DogClutch.ipt ShaftOutDogClutchAllGears.ipt GearShaftIn&Out.ipt

C Gonzolo (Andrew) Salazar

Transmission.idw

117

Shaft In Multi View.jpg Shaft Out Multi View.jpg

118

Section M

Overall Assembly

The overall assembly is comprised of 10 parts in which the major assemblies such as the dash

and door assembly and the seat and bar assembly attach to the floor plate. The frame, roll cage,

and fenders also are attached to this assembly.

119

Dash and Door Assembly

The two doors were designed to attach to the das and the floor plate. The Dash and Door

Assembly Exploded View shows how each door assembly and the dash assembly fit together.

Dash Assembly

I created three parts for the dash board: the dash board, the steering wheel for the copilot, and the

dash mount. The co-pilot steering wheel was designed to fit flush in the dash. If the driver

needed a co-pilot for flight, the copilot would hit a button and the steering wheel would come

out. The dash board sits in a little groove in the dash mount. It contains places for a speedometer,

altimeter, gps, and fuel gage. The dash mount is designed to hold the steering wheel, and dash

board. It allows for ample leg room and room to see ahead. The Dash Assembly Exploded View

shows how the co-pilot steering wheel and the dash board fit onto the dash mount.

120

Door Assemblies

Each door assembly is made of four parts: the door, the door frame, and two three part

hinges. The hinges are designed to have a piece attached to the frame, one attached to a door, and

a

bolt holding them together. The hinge allows each doors to open and close. Each door has a

triangular window in it and a door handle. The two door assemblies attach to the dash assembly

which in turn attached to the base plate. Each door assembly shows how the hinge fits together.

It then, shows how the hinges attach the door to the frames.

121

Seat and Bar Assembly

The seat and bar assembly was created by combining the seat assembly (which includes

the seat and base) and the safety restraint assembly (which includes the safety restraint, support,

and fastener). It was created simply for the sake or ease in inserting and constraining the two

sub-assemblies to the buggy’s floor plate.

Seat Assembly















122

Safety Restraint Assembly

The safety restraint assembly is a new addition altogether to the buggy’s design,

replacing the former seat belt design. The restraint was designed to rotate as a lever arm about

the support and to rest in the fastener when in use. This design relies on the strength of the steel

parts of this assembly and should be sufficient to restrict lateral movement. The support was

designed to be welded to the floor plate, and the restraint is intended to rotate on its right end as

shown above about the axis of the circular hole in the support.The fastener was also designed to

be welded to the floor plate, and the restraint’s left end in the picture shown above is to rest in

the cutout of the fastener.

123

Cup Holder Assembly

The cup holder assembly is another new addition to the buggy. It was added to the design

as a consumer-friendly amenity, in order to increase buyers’ appeal. The plastic cup holder insert

has been designed to slide freely in and out of the storage compartment so passengers have a

choice of whether or not they need cup holders. The steel storage compartment is to be welded to

the floor plate, and is intended to act as an alternative to cup holders; if passengers would rather

have extra room to store their phones and wallets, this feature will accommodate them.

Gearbox Assembly

The gearbox assembly is made of two pieces, the stick shift and the actual gearbox. The gearbox

is a manual gearbox with 4 gears a reverse and a flight gear to allow for liftoff. The gearbox has a plate

on top that shifts when the gear is moved from gear is moved to the selected gear it is in.

124

Pedal Assembly

The pedal assembly is made of 6 screws, 3 pedal bars, 2 pedals (one for the gas, and one for the

clutch), 1 mounting bar and one brake. The parts come together and allow the driver to control what gear

he or she is in, and control when to become airborne. The Pedal assembly is simple yet fully functional in

allowing the driver the best possible control of the dune buggy.

125

Brakelight Assembly

This assembly will hold the lights that flash while braking.

Shock Assembly

The Shock Assembly is the component of the suspension system that will absorb the

majority of the energy that results from jolts while driving. The Shock Assembly works using a

hydro-pneumatic dampening system that we developed. Fluid is stored in the hydraulic tank and

when this system is activated by a jolt the piston pushes the hydraulic fluid upwards. The fluid

then moves through the transfer pipe into the compression tank where it compresses nitrogen

gas.

126

As a section we completed a lot of work and achieved our goals. We fixed the suspension

system to be able to take the load of landing, made the vehicle more aerodynamic, and improved

many parts from the previous incarnation. This version of the vehicle will not only be able to ride

through the dunes but fly as well.

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Final Assembly – ..\03 Assemblies\Floor plate with tracks

and engine assembly.iam

Assembly Rendered Image – ..\02 Visualization\Section

C\Lee Caldwell\Image.bmp

Assembly Video Animation - ..\02 Visualization\Section

C\Lee Caldwell\FinalAssemblyRendering.avi

../03%20Assemblies/Floor%20plate%20with%20tracks%20and%20engine%20assembly.iam

../03%20Assemblies/Floor%20plate%20with%20tracks%20and%20engine%20assembly.iam

../02%20Visualization/Section%20C/Lee%20Caldwell/Image.bmp

../02%20Visualization/Section%20C/Lee%20Caldwell/Image.bmp

../02%20Visualization/Section%20C/Lee%20Caldwell/FinalAssemblyRendering.avi

../02%20Visualization/Section%20C/Lee%20Caldwell/FinalAssemblyRendering.avi

128

Conclusions

Section D

Teamwork:

Two weeks after the 3D CAD project was assigned, one of our team members ended up with not

coming to class and we realized that she had dropped the course. This was rather a big issue at

the beginning of the project, since all the parts were assigned and divided between the team

members. By brainstorming and making slight changes to the design, we were able to keep on

going with the project. The good teamwork and the willingness of the team members to do extra

work made us recover from the situation. The dynamics of the group and the level of care about

the project is very important for the 3D CAD project. Unexpected situations might arise during

the team projects or meetings, however, a good teamwork can play a crucial rule on how the

consequences will be.

Section C

Lessons Learned

Professionalism:

Through the course of this project, professional behavior and expectations was an important

lesson learned. The expectations of professional behavior and deadlines do not budge for

friendships or the desire to be “nice”. In this project we learned that leniency and compassion

are not necessarily good qualities when they come at the cost of missing submission deadlines

and team member parts.

We also learned in this project that should any extenuating circumstances occur that would

affect the submission of our project that we should let the manager, in this case the professor,

know. If a team member did not get his parts in on time despite our best efforts then the

professional thing to do would be to alert the project manager and submit what we have.

In the professional work world there will be people who work extremely hard and others who

just cost by. Through this project we learned how to work with different types of people and

carry different shares of the workload to accomplish a successful submission.

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Future Recommendations

For future work on the ATV teamwork, organization, and time management is key. With proper

communication and efficient time management the ATV can be improved and modified very

successfully.

Some recommendations on future work for the ATV are:

1. Further integrate the regenerative power system into the engine and transmission assembly

2. Integrate the wind turbine system with the battery and form attachments to make it functional

3. Connect the gear shift assembly with the transmission

4. Modify transmission to include connections to all drive shafts and necessary components of the

ATV

5. Consider reintegrating the solar panel system

Section M

Organization:

During this project we learned just how important it is to be organized. The final submission of our

project involved over 2,200 files. It takes a tremendous amount of organization to coordinate this amount

of information across a group of 15 people. Dropbox was a great resource for us because it allowed us to

centralize information across three different sections. We would definitely recommend using this method

along with a standardized file system to prevent confusion among members of different sections and it

also makes hyperlinking much easier.

Team Message

We learned a lot about teamwork and communication through this project. Not only did we gain the

skills of 3D modeling and design, we also learned the group effort needed to assemble them. The work

we put in and the final result make us feel truly accomplished and expand the horizon of our

capabilities. Thanks for not constraining us to the world of physics and letting us design the coolest

flying wind turbine powered truly all-terrain vehicle ever.

alternatively powered all terrain vehicle

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