ADJUSTABLE UNIVERSAL GOLD MEDAL SAILING SEAT Andrew Sulik Timothy Slattery Marion Paredes Pages Derek Topper Detailed Design Review 2/8/13, 3:30 pm
2 Agenda Meeting Purpose Overview of Project Review Customer Needs & Eng. Specifications Review Decomposition of System Detailed Design Test Plan Review Project Plan Review Risk Assessment Conclusions
3 Project Goals Make system comfortable and adjustable to multiple users Allow enough room for the use of a jib transfer bench Increase and/or maintain the functionality already available Adapt for any C4-5 quadriplegic user such as Richard Ramos on a 3 person Sonar keel boat that meets all IFDS regulations
4 Customer Needs Recap Customer Need # Importance Level* 1 Description Comments/Status CN1 1 Designed specifically to fit SONAR sailboat CN2 1 Adjustable foot rests CN3 1 Seat Mobility (up/down) CN4 1 Hand crank Adjustability (up/down) CN5 1 Mechanical Advantage 6.4x CN6 1 Corrosion Resistance Powder Coat CN7 1 Seat Locking mechanism (2 Positions around arc) CN8 1 Cost $3,000 CN9 1 Allows space for jib transfer bench CN10 1 Safe system to operate for long periods 4 years minimum CN11 1 Portable, non-permanent installation no damage to boats CN12 1 Fits on 1 pallet to ship CN13 1 Emergency quick release for rudder control CN14 1 System Controls Rudder CN15 1 Crank Geometry fits multiple users Product for range of users, ie. Yacht club CN16 2 System weight CN17 2 Better Functioning 'Fast Pin' system All fast pin locations CN18 2 Crew Safety CN19 2 Enlarge Track Platform CN20 2 Improved harness CN21 2 Interchangeable seats CN22 3 Grab Handle at top of seat CN23 3 Fit to multiple boats CN24 3 Easy to assemble & install *1=Most important
Engineering Specs Recap Engineering Specification # Importance* 1 Source Specification Unit of Measure Marginal Value Ideal Value Comment/Status ES1 1 CN1, CN11 Secure to Sonar with non-permanent attachments Binary Yes ES2 1 CN2 Adjustable Foot Rests in 4< ES3 1 CN3 Seat Adjustment (up/down) in 3< ES4 1 CN4 Hand Crank Adjustment in 4< ES5 1 CN5 Percentage Amplification of User Force Input % 3rev/ 90 Tiller 4rev/ 90 Tiller ES6 1 CN6 Corrosion resistance Binary Yes Material Selection ES7 1 CN7 Seat locks into position anywhere in travel Binary Yes ES8 1 CN8 Cost of components manufactured for MSD $ 3000> Entire seating system is moved aft from previous ES9 1 CN9 iteration in 0< 3< ES10 1 CN10 Minimum FOS of critical elements found via analysis # 2 3< ES11 1 CN13 Steps required to release rudder in emergency # 3> 1 ES12 1 CN14 Degree of movement of rudder from centerline of boat degrees 40< 90< ES13 1 CN14 Backlash in lines controlling rudder in 1> 0.5> ES14 1 CN15 Distance between hand attachment points in 18±2 18±0.5 ES15 2 CN22 Grab handle(s) to assist seat movement Binary Yes ES16 2 CN17 Time required to attach or detach hands s 30< 15< ES17 2 CN18 System has limited number of sharp corners or edges # 10> 0 ES18 2 CN19 Pinch points created by track platform # 2> 0 ES19 2 CN20 Steps required to release from harness # 3> 1 ES20 3 CN21 System fits multiple seats # 2< ES21 2 CN11, CN21 Time to fit system in SONAR sailboat minutes 60> 30> ES22 2 CN11, CN21 Time to adjust system for new user minutes 60> 30> ES23 2 CN24 Time to assemble system minutes 60> 30> ES24 1 CN3 Seat Adjusetmenyt (fore/aft) in 3< *1 For importance level 1 is must have, 2 is nice to have, 3 is preference only 5
Functional Decomposition 6
Anthropometry 7
Ergonomics & Adjustability 95 th Percentile Males 5 th Percentile Females Accommodate 90% of the population Backrest Proper back support Minimum 10 rearward tilt Handles/Hand Grips Neutral wrist position Interchangeable for C5 gloves and regular grips 30 angle K45W?M%5$#$) 4:, *#&5%4>1; MHNXF K45?A466' %' #: ' 4#9 %40(>$04(4$# K$%, *#&: ; : 24#54#>*%(4: /2*%84(40%' : $) ) ' #&' &(, *(*WC&' 5%' : $#04&' %' &9, ' #&' 045#4#5(, ', *#&: %*#+0; 0(' )?@, 4040*#$(, ' %6*: ($%(, *(> $#(, ' 2$#5%/#? + + + + + + 6)7)%)". )0 [ $) 4#50$$#\ 8 WC 30
9 Adjustability Detailed Design %& $ 30º Considerations: Distance from shoulders Shoulder-forward 3 in %"#$ %"#$ 3 in 7 in "#$ 3 "#$ in Shoulder-down Distance from knees Distance between legs Rotation effects and distance
10 Adjustability Detail Design Crank Up/Down Below shoulder Accommodate user s preference
11 Adjustability Detailed Design Seat Up/Down Height Comfort Seat Back/Forth Distance from crank Foot Rests Up/Down Leg length Detachable Foot Rests Angle Comfort/Disability
12 Material Selection Selection criteria Good corrosion resistance Good strength Readily available Easy to weld Ideal Material Aluminum 6061-T6 Yield Strength 40 ksi Tensile Ultimate 45 ksi Young s Modulus 10 ksi
13 Fastener Material Selection Fastener Material 316 Stainless Steel Limited Galvanic Corrosion Cheap and readily available Yield Strength 34 ksi Tensile Ultimate 79 ksi Galvanic Corrosion Reduced by material selection Reduced by Delrin washers at all bolts
Seat & Footrest Adjustability 14
Hand Crank Adjustability 15
16 States of Loading Worst Case (P12031) 170 lb applied horizontally to hand crank 150 lb applied downward on collection barrel 1349 lb impact force applied to end of track
17 Detailed Design-Track Platform Similar to original design ½ thick marine fir Aluminum L-beam (underneath) adds support to track platform Added 2 detachable pieces in the front Secured using dovetail tabs Drilled holes in plates on allow for the adjustment of handle locks Rubber plugs are used to eliminate sharp edges and corners on the handle locks
Shear Force (lb) Normal Stress Top (kpsi) Normal Stress Bottom (kpsi) W (in) DW Moment (lb*in) 18 Track Platform Analysis Track deflection with load Max deflection = 0.2960 in Max deflection = 0.1224 in 0 Beam Deflection 0.03 Beam Slope 1500 Beam Bending Moment -0.05 0.02 1000-0.1 0.01 500-0.15-0.2 0 0-0.25-0.01-500 -0.3-0.02-1000 -0.35 0 10 20 30 40 x(in) -0.03 0 10 20 30 40 x(in) -1500 0 10 20 30 40 x(in) 200 Beam Shear Force 4 Beam Maximum Tensile Stress 4 Beam Maximum Tensile Stress 150 3 3 100 2 2 50 0-50 1 0-1 -2 1 0-1 -2-100 -3-3 -150 0 10 20 30 40 x(in) -4 0 10 20 30 40 x(in) -4 0 10 20 30 40 x(in)
19 Track Platform Analysis Stress on bolts during impact of 1349 lb (worst case. From P12031.) Shear strength = 30000 psi ¼ -20 aluminum bolts Stainless Steel bolts to be used
20 Detailed Design-Pedestal Base Clamping fixture same as P12031 Platform extended aft 3 in to accommodate Jib Transfer Bench Support Ribs contoured to boat deck
21 Detailed Design-Pedestal Swivel plate provides rotation and deceleration Pedestal will interface with swivel via welded plate or bolt pattern Maximum loading parameters determined by manufacturer
22 Pedestal Forces M A =M B =2804.88 lb*in R B =260 lb Specified at 750lb compression (Trendler) 13 in Specified moment of 9000 lb*in (Trendler)
23 Detailed Design-User Support Seat support frame from P12031 Main support arm fixed to top of swivel plate
24 Main Support Arm δ ya = 0.29 in M = 2804.88 (in*lbs) σ = 7250.0 psi σ y for 6061-T6 Aluminum is 45,000 psi. FOS = 6.2 δ = ML2 2EI σ = MC I FOS = σy σ
25 Detailed Design-Hand Crank Centered pulley system allows individual barrels Telescoping tube allows vertical adjustment Center pivot allows space for user entry Adjustable tensioner allows for easy set up
26 Detailed Design-Crank Support Arms Case 1 (worst case) Fa=170 lb Mb=838.68 lbin/arm σ=11981.14 psi/arm σy=45 ksi (6061-T6) FOS=3.76 σ = MC I FOS = σy σ
27 Detailed Design-Crank Support Arms Case 2 (normal conditions) Fa=20 lb Mb=98.76 lbin/arm σ=1409.57 psi/arm σy=45 ksi (6061-T6) FOS=31.9 σ = MC I FOS = σy σ
28 Detailed Design-Rotation Pin Since bearing cannot apply moment, need pin to lock crank arm into place These calculations still need to be completed
Shear Force (lb) Normal Stress Top (kpsi) Normal Stress Bottom (kpsi) W (in) DW Moment (lb*in) 29 Detailed Design-Hand Crank Lower pulley axle Aluminum 6061-T6 Yield strength:45000 psi 0 x 10-3 -1-2 -3-4 -5 Beam Deflection -6 0 1 2 3 4 5 6 x(in) 5 x 10-3 4 3 2 1 0-1 Beam Slope -2 0 1 2 3 4 5 6 x(in) 120 100 80 60 40 20 Beam Bending Moment 0 0 1 2 3 4 5 6 x(in) 100 Beam Shear Force 10 Beam Maximum Tensile Stress 0 Beam Maximum Tensile Stress 50 8-2 0-50 6 4 2-4 -6-8 -100 0 1 2 3 4 5 6 x(in) 0 0 1 2 3 4 5 6 x(in) -10 0 1 2 3 4 5 6 x(in)
30 Detailed Design-Hand Crank Upper pulley axle Same properties as before
31 Hand Crank Fatigue From quadsailor.com, we found evidence of 3 hour trips Assuming a 5 month season, 1 tack every 5 minutes, and 4 cranks per tack we get 8460 rev/season Based on a life of 8 years you get a lifetime use of 69,120 revolutions Due to this low number, fatigue analysis on these axles is unnecessary
32 Hand Crank Gearing Goal: 4 cranks for 90 degree tiller movement Want to keep 4 load pulley Based on current system, where 3 cranks give 90 degree tiller movement, we have a 1.25 pulley ratio To get 4 cranks, need pulley ratio of 0.9375 Requires 3.75 drive pulley Not Readily Available Using 1 pulley ratio need 3.75 cranks for 90 degree tiller movement
33 Hand Crank Gearing Options for gearing 1. Keep current gear ratio with 3 cranks per 90 degree tiller rotation 2. Use decreased gear ratio with 3.75 cranks per 90 degree tiller rotation Options to be given to Richard Ramos
34 Detailed Design-Hand Crank Grips System designed to mimic C5 grips Detent pin to keep hands in place Detent pin axial pull out force needs to be acquired
35 Bearing Specifications Max Dynamic Load Max Static Load 2110 Lb 966 Lb Sealed bearings to last in elements Able to withstand larger loads than applied Cheap to replace if needed Max Axial Load 966 Lb
36 Tiller Strut Same structure as P12031 Hasp fitting connection removed Replaced with clamp Clamp geometry has not been determined
37 Emergency Tiller Release Cam cleat concept has not been fully developed Requires testing of cam cleats (on Skip s boat)
38 Preliminary Test Plan MSDII Test Plan See Excel Spread Sheet
39 Project Plan MSDI final Project Plan See.pdf Files https://edge.rit.edu/edge/p13032/public/workingdocuments/project%20information/general%20information/project %20Plan%20/Project%20Plan%20MDSI%201_4.pdf
40 Risk Assessment Overall assessment of risks See Excel Spreadsheet
Questions? 41