College - Author 1

College of Engineering

Department - Author 1

Mechanical Engineering Department

Degree Name - Author 1

BS in Mechanical Engineering

Date

5-2019

Primary Advisor

Eileen Rossman

Abstract/Summary

The following is the Final Design Review (FDR) Report for Framed, a team tasked with designing and fabricating the frame of the 2018-2019 Cal Poly Human Powered Vehicle (HPV) Club bike. The bike is to be raced at the 2019 World Human Powered Speed Challenge in Battle Mountain, Nevada with the goal of breaking the American collegiate speed record. The purpose of the FDR Report is to introduce the project’s background and objectives, discuss the final design, and present the results of manufacturing and testing. Prior to beginning work on the design of the frame, the group conducted extensive research on human powered vehicles. This began with interviews and observations at Battle Mountain 2018, where Cal Poly HPV club members got a first-hand account of the competition, its top competitors, and their bikes. Shortly thereafter, the project team was assembled and began working to better understand how to build a bike. The team investigated existing designs of both custom and mass-produced bikes. Research was performed on material selection, aerodynamics and ergonomics, and loading cases. Applicable standards and regulations of the competition were also researched. This research clearly defined the project outline. The team identified the problem and the customer’s needs and wants. The major systems under the project scope were determined to be the frame, fork, and steering system, and the customers to be both the Cal Poly Human Powered Vehicle club and the rider, Josh Gieschen. This allowed the team to make considerations that addressed a wide range of specifications and compile a list of needs and wants. After identifying specifications and their target values, several testing procedures were developed that would verify the success of the design. Moving forward with the specifications led to the concept design process. The team began with several methods of brainstorming in order to come up with ideas for components, materials, and functions. Prototypes were then constructed that highlighted specific concepts and demonstrated their functionality. The next step was narrowing down design choices, which was accomplished with a series of matrices. The weighted decision matrix brought the team to its final concept design – a steel frame with a roll hoop, side supports with trusses, and a bottom support. The design was presented at a Preliminary Design Review (PDR) and iterated upon for the Interim Design Review (IDR). Valuable feedback was received and implemented into the design and several improvements and additions were made for the Critical Design Review (CDR). The design was supported with extensive research and analysis, as well as designs for jigs to help build the frame and fork. The team also included corresponding risks, challenges, and unknowns. The Final Design Report contains the entire design and manufacturing process, as well as successes and issues encountered. It also presents in detail all testing procedures conducted, their results, and the final values met for all specifications. Although the specification of speed will not be measured until the World Human Powered Speed Challenge, the team can confirm that all other specifications were met, and the final design was manufactured and tested with complete success. An operator’s manual is included to provide instructions for both the rider and bystanders during testing and racing

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