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Team Vision for Detailed Design Phase
For our Detailed Design Phase, Team 19305 aimed to integrate mechanical subsystems with electrical components, complete a BOM with part numbers, quantities, and prices clearly defined, and seek additional funding opportunities. As a result, the team planned out which materials must be purchased over summer break in order to accommodate longer lead times for parts. Finally, tasks and timelines for MSD II needed to be determined.
Progress Report
Further progress has been made in developing the electrical side of the BOM, while a complete BOM for the mechanical components has been assembled. Additional design work for the long board and for the Cam Assembly was conducted.
Drawings, Schematics, Flow Charts, Simulations
From the foam model created for the last review the design was reworked to have truck mounts at an equivalent vertical height. Increasing the maximum internal volume while decreasing the overall length was also a priority.
Hand Sketches
Based off the new requirements these initial sketches were drawn up
Digital Sketching
These were then measured with calipers and refined on a tablet medium. Sections where lights could eventually reside were shaded in gray and red. For the purpose of scale, wheels with fenders were drawn as well
Conversion to CAD
Finally the tablet sketches were converted into CAD and geometry adjusted to be realistic. From here the model can be refined farther for manufacture. The deck below has a 2" deck thickness, 10" width, and 44" inch length which used to be 48". A lip on the edge of the board was included for assistance in turning.
Isometric View
Right View
Front View
Full Cam Assembly V2
Hanger v2
Baseplate V2
Cam Design
Bill of Material (BOM)
A link to the live Parts List and Bill of Materials can be found here.
Our bill of materials has three main options for construction tailored mainly around the materials used to physically fabricate the board. In summary Option A consists of materials used for building the board out of billet aluminum stock, Option B out of Delrin stock, and Option C out of a foam composite. Aluminum is a wildly expensive option without donated materials and Delrin is as well. The foam composite is much more affordable however it's a novel building method and is relatively experimental. Over the summer design will continue based on a board made of aluminum but the foam will be tested to see if it's a viable substitute down the road.
Figure 1. Snapshot of Phase IV BOM for Electronics.
Figure 2. Snapshot of Phase IV BOM for Mechanical (Option 1).
Figure 3. Snapshot of Phase IV BOM for Mechanical (Option 2).
Figure 4. Snapshot of Phase IV BOM for Mechanical (Option 3).
Risk Assessment
| Risk Category | Risk | Cause | Effect | Risk Prevention | Contingency Plan | Period Until Switching to CP | Lead Time | Likelihood | Severity | Importance | Owner(s) |
| Technical | Folding Mechanism Roadblock | Complexity in Design and Material Scarcity | Can't integrate all essential parts and can't proceed with the design. | We build a functioning prototype without a folding mechanism (mule). | We design a different folding mechanism into our mule based on hinges. | 2 weeks | 6 weeks | 9 | 9 | 81 | All |
| Technical | Failure of Force Sensors | Damage to sensing surface or blocked transmission of force to sensing surface | Complete loss of motor control/unexpected motor response | Thoroughly test force sensor installation | Use remote to control motors | 2 weeks | 6 weeks | 3 | 9 | 27 | Matthew G. |
| Safety | Motor failure | Low resistance and Electrical overload | Corrosion of the motor shafts, bearings, and rotors | Determine the full specifications for what type of motor we are looking for | Invest in a High quality motor | 2 weeks | 6 weeks | 3 | 9 | 27 | Deirdre A. Matthew G. |
| Safety | Stability failure | Trucks don't work as designed | Danger to the rider of falling and hurting themselves | Conduct tests of trucks over full range of speeds with differing loads | Find trucks that are stable | 2 weeks | 6 weeks | 3 | 9 | 27 | Tanvir M. Connor F. |
| Resource | Not Being Able to Design PCB Board | Lack of experience with PCB design. | Non-functioning PCB. | Try to find a professor to help verify. | Buy VESC. | 2 weeks | 6 weeks | 3 | 9 | 27 | Matthew G |
| Technical | Product failure or part malfunctions | Miscalculations during design process | A non-functioning product | Mechanical Design Leads must be consulting each other | Consult with Mechanical Engineering Professor. | 2 weeks | N/A | 3 | 9 | 27 | Tanvir M. Connor F. Erik L. |
| Technical | Control system causing unexpected outputs (malfunction) | Incorrect inputs were put in the system | Incorrect Outputs/System Failure | Have at least one other team member monitoring the inputs made to the system | Have a micro-controller system expert look over the system | 3 weeks | N/A | 1 | 9 | 9 | Matthew G. |
| Technical | Electronic components protection | Exposure to external environmental factors (water,rocks, etc.) | Damage to the battery and other components | Ensure proper location and protection of electrical components. | Have a guide for a particular environment that must | 3 weeks | N/A | 1 | 3 | 3 | Kristin O. |
| Safety | Pinch points in the mechanism | Folding Mechanism | Damage to hands and fingers of riders. | Proper outlined guide for Hand Placement | Wear protection gloves | 3 weeks | N/A | 1 | 3 | 3 | Tanvir M. Connor F. Erik L. |
| Safety | Overall integrity of collapsible parts | Weak focal point | Collapsible mechanism does not have a long life span and the board is damaged after few uses | Determine the best and most applicable collapsible mechanism. | Hinge system | 3 weeks | N/A | 1 | 9 | 9 | Tanvir M. Connor F. Erik L. |
| Resource | Lack of additional funding (Budget) | Not keeping track of spending | Unable to finish design or a low quality product | Proper documentation of spending | Cut costs where necessary | 3 weeks | N/A | 3 | 3 | 9 | Deirdre A. |
| Resource | Customer manufacturer quality and accuracy risk | Bad quality deliver | Low quality product | Make sure to order from reputable manufacturers. | Change suppliers | 3 weeks | 6 weeks | 1 | 9 | 9 | All |
| Resource | Lack of experienced riders to test prototypes or data collection | Lack of exposure to longboard riding | Lack of essential knowledge on the design of the longboard | Have a team meeting for instruction on how to ride the longboard | Interview experienced riders | 3 weeks | N/A | 1 | 1 | 1 | Erik L. |
| Resource | Team Members Being Absent | Exceptional Circumstances (Sickness, etc.) | Falling behind on deadlines and not being able to create longboard. | Make sure at least one person on the team has a good understanding of what the abstentee was doing, | Assign the another person the absentee's task depending on how important the task is. | 3 weeks | N/A | 3 | 3 | 9 | All |
Design Review Materials
Presentation Link: https://docs.google.com/presentation/d/1UF7ItJCJz0xoMxX7isdAEeH0Supb05U_DAbMbAtKFOk/edit
Plans for next phase
The plans for our summer and next phase are displayed in Wrike here.
- Connor Ford Summer Test Plan.docx
- Matthew Gould's Summer Plan
- Deirdre Arcand Three Week Plan Phase IV
- Kristen Hanley Three Week Plan Phase IV
- Erik Lydick Three Week Plan Phase IV
- Tanvir Majlish Tanvir Next Phase.pdf Three Week Plan Phase IV