Statement of Work

Shell Eco-marathon Team

October 2, 2014

Urban Concept Vehicle

Glen Burkhardt
Andy Jiang
Peter Subosits
Kyle Wydock
No - Intellectual Property Rights Agreement
No - Non-Disclosure Agreement

Executive Summary
The objective of this capstone project is to make modifications to Penn States Urban Concept
Vehicle (UCV) with the ultimate goal of making the vehicle drivable and safe for the 2015 Shell
Eco-marathon competition. Customer needs were evaluated based on the official Shell Ecomarathon Rules. These needs are primarily aimed at improving driver safety and vehicle
efficiency. Accordingly, this project will focus on optimizing several mechanical components of
the UCV as well as testing the major electrical components of the vehicle. After inspecting the
vehicle, the team decided upon four primary design objectives: (1) complete the braking system,
(2) realign the wheel hubs, (3) improve the door opening and latching mechanisms, and (4) test
the custom motor controller. The braking system is currently not connected and is missing
calipers on the rear axle. The team plans to add new calipers for the rear axle, design a brake
pedal, and mount a routed hydraulic system onto the vehicle. The team will correct the
misaligned wheel hubs, which will reduce friction on the brake rotors and ultimately improve the
fuel economy of the vehicle. The door, which currently opens in lateral and scissor motions, does
not rest properly in an open position, posing a risk of harming the driver. The team plans to either
make adjustments to the current hinge or implement a new soft-closing hinge to improve door
functionality. Other issues with the door are that it does not latch shut properly and it produces an
ineffective seal against the vehicle. Both of these inadequacies can create drag during vehicle
operation. The team will improve latch alignment and develop a more effective door seal to
lessen the effects of drag on the vehicle. The custom motor controller, which was designed by the
spring 2014 capstone team, needs to be tested along with the motor to validate its functionality.
The team budget will go toward purchasing parts and materials for the improvement of the
vehicle. The custom motor controller will be the first deliverable of this capstone project as this
task is essential to ensure the vehicles readiness for the 2015 competition. The braking system
and door mechanisms will follow soon thereafter due to the extended lead time of machining and
part delivery.
Table of Contents
Executive Summary.........................................................................................................................1
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1.0 Introduction................................................................................................................................4
1.1

Initial Problem Statement..................................................................................................4

1.2

Objectives..........................................................................................................................4

2.0 Customer Needs and Assessment..............................................................................................4

2.1 Gathering Customer Input......................................................................................................4
2.2 Weighting of Customer Needs...............................................................................................5
3.0 External Search..........................................................................................................................5
3.1 Patents....................................................................................................................................6
3.1.1 Brake Patents...................................................................................................................6
3.1.2 Door Hinge and Latch Patents.........................................................................................7
3.2 External Search......................................................................................................................8
4.0 Engineering Specifications........................................................................................................8
4.1 Establishing Target Specifications.........................................................................................8
4.2 Relating Specifications to customer needs.............................................................................8
5.0 Concept Generation and Selection.............................................................................................8
5.1 Problem Clarification.............................................................................................................8
5.1.1 Brakes..............................................................................................................................8
5.1.2 Motor Controller..............................................................................................................8
5.1.3 Hinge...............................................................................................................................9
5.2 Concept Generation................................................................................................................9
5.2.1 Brakes..............................................................................................................................9
5.2.2 Hinge.............................................................................................................................10
5.2.3 Door Seal.......................................................................................................................10
5.3 Concept Selection.................................................................................................................11
6.0 System Level Design...............................................................................................................12
7.0 Special Topics..........................................................................................................................12
7.1 Preliminary Economic Analysis Budget and Vendor Purchase Information....................12
7.2 Project Management............................................................................................................13
7.3 Risk Plan and Safety............................................................................................................13
7.4 Ethics Statement...................................................................................................................14
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7.5 Environmental Statement.....................................................................................................14

7.6 Communication and Coordination with Sponsor.................................................................14
Appendix A Gantt Chart.............................................................................................................16
Appendix B AHP Chart..............................................................................................................17

1.0 Introduction
1.1 Initial Problem Statement
Shell Eco-marathon is an annual competition which challenges teams across the world to design
and build the most energy-efficient vehicle. There are two different vehicle classifications that
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compete in Shell Eco-marathon: Urban Concept and Prototype. Urban Concept emphasizes
practical designs and driver comfort, while the Prototype encourages teams to design for energy
efficiency at the expense of driver comfort. This capstone project will focus on preparing the
Penn State Urban Concept vehicle (UCV) for competition in April 2015. Penn States current
UCV is a work in progress. The majority of the mechanical and electrical components on the
vehicle have been built, although the vehicle needs several major modifications before it can be
in safe working order. This capstone project team will work on the UCV to install a custom
motor controller, improve the door latch and hinge mechanisms, install a braking system, and
realign the wheel hubs.

1.2 Objectives
The ultimate objective of this capstone project is to improve Penn States UCV so that it is fully
operational. The main obstacle faced by the team is its inexperience with electronics because the
team is comprised entirely of mechanical engineers. This will limit how much the team can
accomplish with the custom motor controller. However, the team will test the motor controller
built by a previous capstone team; if the motor controller is functional, the team will design a
new housing for the motor controller and install the system on the UCV. Other objectives within
the scope of this project are mechanical modifications to the vehicle. The team will improve the
structural integrity of the vehicles thin bio-composite door by constructing an aluminum frame
to attach on the inside of the door. The team will also redesign the latching and hinge
mechanisms on the door, as well as improve the seal of the door against the body of the vehicle;
these modifications will help to reduce drag on the moving vehicle, improving the vehicles fuel
economy. The team will install a hydraulic braking system on the UCV. Finally, the team will
realign the wheel hubs to improve the ride of the vehicle and reduce unwanted friction within the
brake calipers.

2.0 Customer Needs and Assessment

2.1 Gathering Customer Input
City populations continue to swell and heavy traffic causes the average American worker to lose
38 hours of time per year [7]. Additionally, a study released in 2012 by the U.S. Treasury
Department revealed an average of 1.9 billion gallons of gas are lost per year on congested roads.
These statistics show the need for efficient and reliable vehicles to help alleviate the problem.
The team gathered customer input through conferences with our corporate sponsor, Ryan Moyer,
and Shells Eco-marathon website. The UCV is primarily designed for efficiency and practicality.
Its functionality should be as close to real-world ready as possible while meeting the design
goals specified in the competition. Because of this, safety, efficiency, and ergonomics are top
priorities in the design. Other factors to be considered were weight, durability, appearance, and
cost. These design goals were important for the UCV to operate in common urban traffic
conditions as well as light, wet weather conditions.

2.2 Weighting of Customer Needs

With this initial set of design parameters, the team conducted research to determine what
customers would value most if considering the purchase of a compact, efficient urban
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transportation vehicle. Safety is of utmost importance when vehicles are being evaluated in
Shells Eco-marathon competition. While teams are encouraged to design the most efficient
vehicle possible, safety cannot take a back seat to efficiency. Other customer needs such as cost,
vehicle weight, appearance, durability and ergonomics were considered. After constructing an
analytical hierarchy process chart, we found safety to be the most important customer need
followed by vehicle efficiency. Ergonomics was our third highest rated customer need. Due to
the fact that the Urban Concept Vehicle is required to operate as close to a modern day vehicle
with various amenities, the team agreed that these top three customer needs are appropriate.
Please refer to Appendix B to view the full AHP Matrix.

3.0 External Search

In order to design a well performing, efficient vehicle to compete in the Shell Eco-marathon
Competition, the team completed external searches for the braking system, door latch and hinge,
and motor controller. Additionally, a patent search was done and is outlined in the next section.
Much of the information regarding vehicle braking systems was acquired from the technology
and designs that are utilized in passenger vehicles. However, based on our manufacturing
abilities and budget, our braking system must be simplified compared to what was learned from
our research. Braking a vehicle safely can be made quite complex through the use of sensors and
complex valves in the hydraulic systems. The external search gave our team the knowledge to
understand what features the braking system should have based on our needed performance, use,
and safety. The door hinge and latch left more room for imagination for the design. Research
was focused on what modern vehicles use for closing and mounting doors, and was expanded
into alternative hinge designs, such as scissor doors. The teamed wanted an innovative solution
for the door that allows for simple design and operation, so again, the research about modern
vehicles allowed the team to take those ideas and simplify them for this application on the Ecomarathon car. The motor controller that will be used on the Eco-marathon car was designed and
built by a past Eco-marathon team at Penn State. There are many controllers to be purchased for
DC brushless motors, and variants from one to another include different protection features for
the motor and controller. We are not sure what features are built into our current controller. The
external searches gave the team the necessary background knowledge to design and build
working components for the vehicle.

3.1 Patents
3.1.1 Brake Patents
Floating caliper-type disk brake for automotive vehicles
US 5860495 A

Dual master cylinder for hydraulic automobile brakes

US 2568220 A

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Description:
This patent allows for the caliper and pad assembly to
selfalign so brake dragging is reduced.
Analysis:
By using a similar style caliper, a dual actuation caliper,
from a mountain bike we plan to achieve the same
benefits to increase vehicle efficiency.

Description:
By splitting the braking force across two cylinders a leak
in one of the lines or cylinders will still leave one system
functioning, thus increasing brake safety.
Analysis:
As a safety precaution and to design our car to be within
the rules and regulations for the competition, our design
utilizes 4 separate brake lines.

3.1.2 Door Hinge and Latch Patents

Automobile door hinge with two-position toggle type
hold-open
US 3370318 A

Car-door latch and opener

US 1370515 A

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Description:
This is a hinge having a two-position combination
cam and snap type hold-open design which can hold
the door open at a mid-open position and prevent
closing of the door when fully opened.
Analysis:
By purchasing an off-the-shelf hinge, we can design
and build door that operates and feels similar to a
modern vehicle.

Description:
This patents the ability to open, close, and lock a door with
a relatively simple design.

Analysis:
The car will have a door that can be opened from the
inside and outside; however, a lock was not planned in our
objective.

3.2 Existing Products

The fact that we are building a vehicle designed to mimic road going automobiles does create
some issues with designing completely new, innovative components and systems for our car.
With braking, many modern cars are designed with an X brake line system, where there is a
separate hydraulic system for the LF and RR and another for the RF and LR brakes. This is
allowed by the rules and regulations; however, the team opted for four separate lines for added
safety to the braking system. The hinge and the latch themselves are purchased parts and the
added design work to create a possibly inferior component was a route the team decided against.
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For the motor controller, there was a requirement in the rules that it must be designed and built
by the team. If our team could purchase a motor controller for 3-phase brushless DC motor,
there are many options that would have worked, but we have one that was designed and built by
another Penn State Eco-marathon team will be used in the 2015 Urban Concept car.

4.0 Engineering Specifications

4.1 Establishing Target Specifications
Table {} in Appendix J shows a detailed list of customer needs for each individual task and
their relative importance to the project as a whole. Table {}, also in Appendix J, shows the
metrics used to evaluate the completeness of each customer need.
*** Incomplete: will finish this afternoon

4.2 Relating Specifications to customer needs

5.0 Concept Generation and Selection

5.1 Problem Clarification
5.1.1 Brakes
The braking system for the Urban Concept Vehicle must use 4 hydraulic disk brakes. The input
needed from the driver to actuate the brakes is the same as it would be in any road going
automobile. The driver applies pressure to the brake pedal, located below the dash on the left
side of the driver. The pedal operates four separate master cylinders. Each master cylinder
operates a piston that pressurizes hydraulic fluid in a line. Each line runs to a caliper on each
wheel of the car. The pressured fluid in the lines compress pistons in each of those calipers
creating a compressive force on the brake rotor. The calipers have pads made of high friction
material that make contact with steel disks. This contact creates a torque on the steel rotors
which slows the rotation of the wheels, and results in slowing the vehicle. A higher force input
on the pedal from the driver results in increased torque acting on the wheels.
5.1.2 Motor Controller
Powering a 3-phase DC brushless motor requires a controller to convert battery power into
usable signals to create torque on the motor. The powertrain on the Urban Concept car consists
of the battery for power, a potentiometer for controlling the throttle input, the motor controller,
and a hub drive DC brushless motor that drives the right rear wheel. The operator controls the
throttle with his/her right foot. That signal goes through the controller and determines the
amount of current required from the battery which is converted into the necessary signals that are
sent to the motor to create torque on the drive wheel.
5.1.3 Hinge
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The current hinge on the UCV was designed to simulate the scissor door motion of a
Lamborghini supercar. While its original intent was to allow for more efficient door opening
motion in a cramped urban environment, the hinge has a number of flaws that keep it from
performing optimally. One major flaw is the notch currently used to hold the door in place when
in the scissor position. The door refused to hold itself in a resting position after multiple attempts
and this usability issue defeats the purpose of the hinge. The current hinge is also very heavy
because it is from a kit car set and made of solid steel. While weight reduction efforts were made
to reduce its footprint, it causes the left side of the car to be heavier than the right. A redesign of
the current hinge or a total hinge replacement is needed in order to effectively solve these issues.

5.2 Concept Generation

5.2.1 Brakes
The braking system for the car is defined in the 2015 Official Rules as The brakes must operate
independently on the front and rear axles or in an X pattern (i.e. right front wheel with left rear
wheel, and left front wheel with right rear wheel). So the above two designs would satisfy the
rules. The car was setup with 4 mountain bike rotors and calipers with 4 independent master
cylinders. From that setup we had options for how we would connect the lines coming from the
master cylinders to the calipers.
While actuating all 4 master cylinders with a single pedal 2 cylinder lines would converge into a
single line then split at the rear wheels. The other 2 cylinder lines would be connected in the
same fashion but end at the front wheels. The pros of this concept are that it allows for one
hydraulic system to fail and the driver to still maintain control of the vehicles brakes to an
extent. Although only actuating the brakes on a single axel may cause the car to become
unstable.
A X pattern brake would allow for the same safety as the front-rear split concept, but may
allow for a more stable brake balance. The left front and rear right would receive the same
pressure, and the right front and left rear would also receive the same pressure. Information
about brake force calculations are located in Appendix I.
5.2.2 Hinge
Our first concept for the hinge mechanism is to improve the current hinge already on the UCV.
The main hinge functions properly but the door itself does not rest properly when in the scissor
position. A new bolt for the door would be machined with a notch in the side for the door to rest
in when lifted to the desired position. Without this notch, the door easily slips out of its resting
position, defeating the original purpose of the scissor door design.
Our second concept is the soft-close surface-mounted hinge from McMaster-Carr. We chose this
hinge as a viable concept due to its friction to prevent door slams and its wide opening angles.
This design moves away from the scissor door action that was previously used. It also cuts
significant weight from the left side of the vehicle. The current scissor hinge is solid steel and
weighs more than the door itself. This hinge is made of a hard plastic and has a high torque value
to hold the door in place. A concern for this design would be the longevity and durability of the
hinge after extended use.
The third concept is Friction Hinge Polished Type 304 Stainless Steel. The hinge can be purchase
at McMaster-Carr. The hinge also has friction and can open as wide as 180 degrees. The plus
side of the friction hinge is that the hinge is made of stainless steel, therefore it has higher tensile
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stress and rigidity than plastic has. The down side of the friction hinge is the price. Friction hinge
cost almost twice as much as the Soft-Close hinge. All SolidWorks drawings of our three hinge
designs are located in Appendix D.
5.2.3 Door Seal
The team has considered three available seals to install around the periphery of the door frame.
Drawings of these parts are located in Appendix E. The following seals are all available on
McMaster-Carr: (1) EPDM adjustable edge-grip seal, (2) EPDM weather strip foam tape, and (3)
silicon rubber bulb seal.
The first type seal is an adjustable edge grip seal, which is essentially the same as weather strip
seals commonly used on automotive vehicle doors. The seal material, EPDM, is a closed-cell
foam rubber with a steel core. These seals are available in a number of different size ranges
including 5/64 13/64. The UCV door thickness is 0.152, which will fit within this range.
This seal is advertised to stop wind, dust, and water from entering doors, so it is ideal for our
purposes and costs $3.85/ft.
The second type of seal under consideration is weather resistant EPDM rubber adhesive strips,
which are available in 3ft long, 2 in thick strips for $5.71. This tape is advertised for outdoor use
and is ozone, aging, steam, and water resistant. Like the adjustable edge grips, this tape would be
applies around the periphery of the door frame to improve the door seal. This product has the
advantages of easy installation, simplicity, and durability. However, this seal is not designed to fit
around the edge of a vehicle door like the first option.
Another variety of rubber bulb seal is the silicon rubber bulb seal. This particular item is made of
silicon and produces a very tight seal. This option is designed to be highly resistant to water, air,
and temperature. Unlike the second option, this item does not have an adhesive back, but it can
be glued on the door frame with silicon based adhesive. This silicon rubber bulb seal is available
for $2.37/ft.

5.3 Concept Selection

The final concept for each objective was selected via a concept scoring process. First, three
concepts were chosen as promising ideas and they were put into a chart for concept screening
[insert appendix here]. For the hinge design, this included the plastic soft closing hinge, the
current scissor hinge, and the stainless steel friction hinge. These concepts were then compared
to current modifications implemented on the vehicle.
5.3.1 Brakes
The concept we chose to move forward with uses 4 completely independent lines. This concept
is not utilized in modern day vehicles, but will allow for simple diagnostics for brake problems
and give the most safety during a brake failure. It is also the simplest design to build, as there is
no joining and diverging of the lines. A main benefit for this design is if one master cylinder
fails, the rest of the brake lines are not affected. This will increase the safety of the vehicle and
the brake systems are not dependent on one another.

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6.0 System Level Design

6.0.1 Door
The door of the UCV needs to increase the stiffness of the structure to increase vehicle safety.
Without this, the door cannot be properly aligned or function as desired. We have chosen to use a
number of aluminum cross-members on the interior of the door to help further define the
structure. While this does add weight to the vehicle, safety is our top concern and this will
greatly increase the safety for the occupant. The aluminum beams will then be connected
together with steel bands to interconnect the reinforcements.

Figure 1: Urban Concept Door with Aluminum Reinforcements

6.0.2 Brakes
The brake system on the car was partially designed and constructed prior to the team starting
work on the car. The front calipers and all rotors were in place, but the rear calipers were
missing and the lines to each were absent as well. The master cylinders are mounted to the car,
but the pedal to actuate them needs built. The rear brackets to mount the calipers will be
machined from steel plate. The calipers will be bolted to the brackets using the brakes mounting
bolt holes. This will give the rigidity needed to hold the calipers in place during hard braking.
The brake pedal is to be water jet cut from a plate of aluminum. The calipers are connected to
the master cylinders by flexible plastic hydraulic lines.
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Figure 2: Brake Mounting Bracket

7.0 Special Topics

7.1 Preliminary Economic Analysis Budget and Vendor Purchase
Information
The estimated cost to complete the projects objectives is far from the budget of $1000. Major
costs for the project are the parts and materials, mainly, the brake calipers and various parts
needed to complete the system, and the door hinge and latch. Details pertaining to the each cost
and cost estimate can be found in the appendix. Specific Appendix Letter

7.2 Project Management

The team will use Microsoft Project to generate the Gantt chart for this semester. This chart will
include all major deadlines for reports, presentations, and design implementations. Additionally,
it will also be used to keep track of design phases and product development throughout the
semester. We have included the major deadlines set by our deliverables agreement to help keep
us on track. As seen in our resumes (Appendix G), our experience from previous design classes
like mechanical design and design methodology will allow us to effectively fabricate and
implement the design changes highlighted in this report. The team will also be constructing a
Microsoft SharePoint site for future teams to utilize. This powerful tool allows for cloud data
storage, easy access, and effective collaboration between previous, current, and future Ecomarathon teams.

7.3 Risk Plan and Safety

Although the Eco-marathon Urban Concept Vehicle is not a product that will be used by or
around the public, safety is still of upmost importance. Arguably the most important aspect of a
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vehicle is its ability to stop in a safe and controlled manner. Therefore creating a brake system
that has 4 independent hydraulic lines will surely help with alleviating a lot of risk from not
being able to slow the vehicle. The hydraulic systems themselves will be built completely from
parts purchased from vendors to ensure any leaks of problems in the brakes are kept to a
minimum. Building the door hinge and latch mechanism also involve some risks related to
safety. The door should stay open or closed when the operator does so, and not have pinch
points or involve any strenuous effort to operate the latch or to open the door. Wiring for the
powertrain and other electrical systems should be packaged in a clean and safe manner so that
the vehicles operator has little chance of receiving an electrical shock.
Table 1: Risk Plan

Risk

Level

Actions to Minimize

Fall Back Strategy

Schedule
delays
System does
not function
favorably
System
Unsafe to
users or
public

High

-Use of MS Project to track

progress and current tasks
-Conduct tests
-Construct multiple prototypes

-Add extra time for each task

or deliverable
-Simplify or start over on a
concept

Delays due
to shipping
or lead times

Moderate

-All designs will have safety as

a priority
-Follow all rules for the Shell
Eco-marathon 2015
Competition
-Check stock status before
deciding on part
-Send all needed information to
purchasing early

-Use testing to determine the

cause of any dangerous
situations
-Redesign after the reason is
understood
-Manufacture instead if
possible
-Search for other vendor or
model

Moderate

High

7.4 Ethics Statement

The Shell Eco-marathon Urban Concept Vehicle Team maintains certain policies to guide its
members with respect to standards of conduct expected in areas where improper activities could
damage the Teams reputation and otherwise result in serious adverse consequences to the Team
and members involved. The purpose of this Policy is to affirm, in a comprehensive statement,
required standards of conduct and practices with respect to design and operations.
The Team expects all team members to conduct themselves in a professional manner at all times
when in the presence of other members, sponsors, and suppliers. Each member will use
legitimate business practices and best judgment when in handling team affairs. Violation of these
practices are grounds for disciplinary action at the discretion of other team members as outlined
in the team contract.

7.5 Environmental Statement

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The Shell Eco-marathon Urban Concept Vehicle Team is committed to reducing its impact on the
environment. We strive to improve our environmental performance wherever possible during
design and implementation of vehicle enhancements. We will comply with all applicable
environmental policies, prevent all pollution wherever possible, and continue to measure and
improve our environmental impact by setting goals to reduce these impacts.

7.6 Communication and Coordination with Sponsor

The team communicates with our sponsor in number of ways. A weekly progress report is
delivered to Ryan Moyer via email on Tuesdays in the form of a PDF. We also hold a weekly
teleconference on Thursdays at 11 AM EST to discuss project milestones and team concerns.

Sources
[1] Brady, James T. Car-door Latch and Opener. Patent US 1370515 A. 8 Mar. 1921. Print.
[2] "Brake Calculations." Engineering Inspiration. Engineering Inspiration, 2014. Web. 29 Sept.
2014. <http://www.engineeringinspiration.co.uk/brakecalcs.html>.
[3] Benjamin, Christopher H., Jr. Dual Master Cylinder for Hydraulic Automobile Brakes.
Christopher Jr Benjamin H, assignee. Patent US 2568220 A. 18 Sept. 1951. Print.
[4] Marchione, Joseph H. Automobile Door Hinge with Two-position Toggle Type Hold-open.
Atwood Vacuum Machine Co, assignee. Patent US 3370318 A. 27 Feb. 1968. Print.
[5] Oertel, Clemens, Heinz Neuburger, and Anton Sabo. "Construction of a Test Bench for
Bicycle Rim and Disc Brakes." Procedia Engineering 2.2 (2010): 2946-948. Sensor
Products Inc. Web. 29 Sept. 2014. <http://www.sensorprod.com/news/white-papers/201003_ctb/wp_ctb-2010-03.pdf>.
[6] Weiler, Rolf, Dieter Bieraugel, Karl Storzel, and Wolfgang Schiel. Floating Caliper-type Disk
Brake for Automotive Vehicles. Itt Automotive Europe Gmbh, assignee. Patent
Http://www.google.com/patents/US5860495. 19 Jan. 1999. Print.
[7] Werbach, Adam. "The American Commuter Spends 38 Hours a Year Stuck in Traffic." The
Atlantic. Atlantic Media Company, 06 Feb. 2013. Web. 16 Sept. 2014.
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Appendix A Gantt Chart

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Appendix B AHP Chart

AHP
Chart

Co
st

Appeara
nce

Ergono
mics

Weig
ht
(lbs)

Safe
ty

Efficie
ncy

Total

Weig
ht

3.3

0.5

0.2
0.2
5

0.67

0.33

0.5

2.00

0.3

1.5

0.33

23.5
11.1
33

0.5

17.5

0.05
64
0.03
08
0.16
65
0.12
76
0.27
89
0.13
21
0.20
77

Sum

84.2
6

Cost
Appeara
nce
Ergono
mics

1
0.
5

0.5

0.25

0.2

0.25

Weight

0.5

Safety

Durable
Efficienc
y

2
4

0.2
5
0.1
4

Dura
ble

0.5

0.25

0.25

0.25

4.75
2.59
29
14.0
33
10.7
5

Ranki
ng

6
7
3
5
1
4
2

Insert Information on how AHP was constructed

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Appendix C Brake Concepts

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Appendix D Hinge Concepts

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Appendix D (Continued)

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Appendix E Door Sealant Concepts

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Item # 1129A2 from

McMaster-Carr
Item #
#899DK23
12335A24
from
from McMasterMcMaster-Carr
Carr

Appendix F Initial Problem Clarification Chart

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Appendix G Resumes
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Appendix G (continued) Resumes

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Appendix G (continued) Resumes

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Appendix G (continued) Resumes

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Appendix H- Concept Scoring

Table 3: Door Sealant Concept Scoring

Appendix I Brake Analysis

The braking system also needs to create enough force to hold the car steady while on a 20 degree
incline. Assuming the car weighs the maximum allowable weight for the competition, 225 kg,
with a driver weighing in at 80kg, the cars mass is 305kg. The brakes must be designed, at
minimum to hold the car on a 20 degree incline. At a 20 degree angle, the gravitational force
from the car acting down the incline would be 1026 N. Therefore, the brakes must transfer the
Table : Hinge Scoring Chart

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necessary torque to the wheels to keep them from rotating. The wheel radius is 0.293m, and the
brake radius is 0.08m.
The calculation of force needed at the rotors is:
(Braking Force)*(Rotor Radius) = (Car Force Down the Incline)*(Wheel Radius)
(Braking Force)*(0.08 m) = (1026 N)*(0.293 m)
Braking Force = 3760 N,
Braking Force/wheel= 940 N
The 940 N force is the friction force needed to be actuated on each caliper. From the
specifications of the calipers and master cylinders we chose, the force required of them is well
within their abilities.

Appendix J Customer Needs Metric Matrices

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