CapstoneProjectMasterFile2.12.15.docx
JMACAIRRIDE SEAT KIT
A Capstone ProjectSubmitted to the Faculty of theNational
University, School of Engineering and Computingin partial
fulfillment of the requirements for the degree ofBachelor of
Science in Manufacturing Design Engineering
Prepared By:Miguel GonzalezJosh SoltChristopher BispingAshley
Moreno
National UniversityMarch 2015CAPSTONE PROJECT APPROVAL FORM
We certify that we have read the project of Miguel Gonzalez,
Josh Solt, Christopher Bisping, and Ashley Moreno entitled JMAC
AirRide HPV Seat, and that, in our opinion, it is satisfactory in
scope and quality as to the capstone project for the degree of
Bachelor of Science in Manufacturing Design Engineering at National
University.
Approved:
________________________________________________________________________Prof.
Randall Hartman, M.S. P.E.DateFaculty, Department of Applied
EngineeringNational University
________________________________________________________________________Prof.
Michael Buckley, M.S., M.B.ADateFaculty, Department of Applied
EngineeringNational University
________________________________________________________________________Dr.
Shekar Viswanathan, Ph.D. P.E., M.B.A. Supervisor and Lead
FacultyDateFaculty, Department of Applied EngineeringNational
University
ABSTRACTBluevelo, the Canadian based company that designs human
powered vehicles, has requested that a new seat assembly and
cushion be designed to improve the adjustability and comfort of the
Velomobile. The Velomobile is a recumbent bike assembly encased in
an aerodynamic and lightweight composite shell. JMACs innovative
design incorporates functionality and manufacturability with the
intent to satisfy a wider range of desired adjustability for
customers. This design integrates Industry standards and best
practices as related to Design for Manufacturability and Assembly
(DFMA) guidelines, Lean Six Sigma principles, and Total Quality
Management (TQM) Requirements. JMAC utilized a design approach that
took into consideration existing concepts and products available,
and through the employment of manufacturing best practices and the
application of risk management techniques, developed an operational
and cost effective assembly that meets all of the requirements set
forth by Bluevelo.The JMAC AirRide design is manufactured for ease
of assembly and installation as a replacement for the pre-existing
seat assembly provided by Bluevelo. The design incorporates the
composite seat and provides adjustability for riders with heights
ranging from 66 to 72. and weights ranging from 150 lbs. to 220
lbs. Furthermore, the JMAC AirRide seat assembly has been designed
to provide comfort and ease of adjustability. All of the seat and
cushion adjustments, for instance, require only the use of simple
pneumatic valves. The design includes front and rear brackets with
a pendulum action lever levied with a pneumatic cylinder
accompanied by an inflatable seat cushion for additional safety and
ergonomic benefits. Because of the lightweight design of the
reinforced composite, the seat and all components do not exceed a
weight of 10 lbs., with the cost remaining under $1000 USD to keep
the product marketable and competitive.
Table of ContentsList of FiguresList of
Tables1.SCOPE12.INTRODUCTION AND PROBLEM DEFINITION22.1.HPV Quest
Seat Problem Statement22.2.JMACs AirRide Design
Delimitations22.3.General Considerations32.3.1.Pneumatic
Considerations32.3.2.Frame Considerations42.3.3.Safety
Considerations42.3.4.Reliability Considerations52.3.5.Manufacturing
Retail Considerations52.4.HPV Seat Industry Design
Research53.BACKGROUND AND LITERATURE REVIEW93.1.Variable Analysis
of Seat Design93.1.1.HPV Aerodynamic Feature
Analysis93.1.2.Structural Frame Design Variables103.1.3.Seat
Adjustability Analysis103.1.4.Seat Cushion Variables
Analysis113.2.Variable Analysis of Materials for Seat Frame and
Cushion Manufacturing113.2.1.Sustainable Materials
Variables123.2.2.Seat Cushion Material Variables123.3.Variable
Analysis of Manufacturing Strategy143.3.1.Manufacturing
Variables143.3.2.Production Variables143.3.3.Ease of Assembly
Variables153.4.Variable Analysis of Quality Assurance and Control
Strategies153.5.Background Research Variables Summary154.JMAC
DESIGN METHODOLOGY174.1.JMAC AirRide Seat Kit Design174.2.JMAC
AirRide Seat Position Considerations174.3.JMAC Seat Inflation
Design Requirements194.4.JMAC 3-Way Valve Considerations204.5.JMAC
Lumbar Support Cushion Considerations204.6.JMACs Air Chamber
Cushion Requirements204.7.JMAC Air Cushion Material
Considerations214.8.JMAC Vehicle Stability
Considerations214.8.1.Directional Stability
Considerations224.8.2.Rollover Stability
Considerations224.8.3.Table and Graph of Lateral Forces to initiate
rollover234.9.JMAC Air Ride Weight Considerations265.JMAC AIRRIDE
DETAILED DESIGN AND RISK ASSESSMENT295.1.JMAC AirRide Components
and Subassemblies295.1.1.JMAC Front Subassembly Design305.1.2.JMAC
Rear Bracket Subassembly Design315.1.3.JMAC Seat Subassembly
Design325.1.4.JMAC Air Cushion Design325.1.5.JMAC Air Manifold
Subassembly Design335.2.JMAC Bill of Materials355.3.JMAC Cost
Analysis365.4.JMAC Weight Analysis395.5.JMAC Risk Mitigation and
Considerations405.5.1.FMECA Development415.5.2.Risk Priority Number
Development435.5.3.Corrective Action Identification456.CONCLUSION
AND RECOMMENDATIONS46REFERENCES AND WORKS CITED49APPENDIX A:
ACRONYMS52APPENDIX B: GLOSSARY OF TERMS53APPENDIX C: SUBASSEMBLY
MANUFACTURING DATA56
List of FiguresFigure 1: Bluevelo Quest7Figure 2: Windcheetah
Sport Compact7Figure 3: Angletech Challenge Seiran SL107Figure 4:
Tri-Sled Rotovelo Carbon7Figure 5: Beyss Go-One7Figure 6: Butterfly
Gel Cushion8Figure 7: Orthopedic Gel Cushion8Figure 8: Ventisit
Seat Pad8Figure 9: Hobie Mirage Seat Pad8Figure 10: Genuine Corflex
Medic-Air Seat Cushion8Figure 11: JMAC DESIGN18Figure 12: Center of
Gravity Elevation Formula23Figure 13: Tire Side Forces at
Rollover23Figure 14: Rollover Lateral Force Chart25Figure 15:
Center of Gravity (cg) Elevation Shift25Figure 16: McCraws Weight
Study Formula27Figure 17: McCraws Formula for Time Saved or
Added27Figure 18: Seconds Per Pound Analysis28Figure 19:
Subassembly Detail29Figure 20: Front Bracket Subassembly30Figure
21: Rear Bracket Subassembly31Figure 22: AirRide Cushion
Design32Figure 23: Cylinder Assembly with Locking Bar34Figure 24:
Bill of Materials35Figure 25: Purchased Parts Cost36Figure 26: Make
Parts List37Figure 27: Manufacturing Cost38Figure 28: Buy Parts
Weight Summary39Figure 29: Functional Flow Diagram (TOP LEVEL),
FUNCTION41Figure 30: Functional Flow Diagram (Second Level)42
List of TablesTable 1: Industry Design HPV Analysis
Examples7Table 2: Industry Design Seat Cushion Analysis
Examples8Table 3: Comparison of Main Types of Cushions (Karp,
1998)13Table 4: Rollover Lateral Force24Table 5: Risk Priority
Analysis44
iv
SCOPEJMAC Engineering Company (JMAC) has been selected to design
an ergonomic seat for an existing Human Powered Vehicle design as a
result of their innovative yet practical ready to manufacture
design reputation. The information presented in this project
provides the purpose of the design, an overview of seat concept
considerations, analysis of industry techniques and best practices,
evaluations of HPV seat standards, an explanation of design
methodology, and detailed design characteristics of the ready to
manufacture product. The final portion of this project summarizes
the design and reaches the conclusion that this design meets
Bluevelos expectations along with any additional requirements set
forth.
INTRODUCTION AND PROBLEM DEFINITIONBluevelo, the Canadian based
company that designed the Velomobile, has approached JMAC
Engineering Company with the request to create a seat design that
will improve the mobility and comfort of the user. HPV Quest Seat
Problem StatementAlong with the exponential growth rate in
technology, the standards of human powered vehicles are having no
trouble keeping pace. The development of more lightweight, durable
materials has opened up endless possibilities for even the most
prehistoric designs. Even without the use of electronics within the
vehicle, bicycles are becoming more aerodynamic, comfortable and
economically pleasing. As the transition period from fossil fuels
to sustainable sources steals the spotlight, the HPVs are stealing
the hearts of the daily commuter across the globe with their
economical and environmentally friendly benefits. This design
includes not only the frame, but the components therein which must
be as equally as lightweight and ergonomic to support its mounting
host. A required application of the HPV Seat outlines the need to
provide ease of adjustment for the mainstream consumer.JMACs
AirRide Design DelimitationsThe main limit imposed on this study is
working within the design and space restrictions set forth by the
Bluevelos model Quest HPV, a composite reinforced structure that
houses a recumbent bicycle. The Quest has limited fixed frame
mounting points within the structure along with a weak floor that
puts the weight bearing responsibility of the operator solely on
the seat assembly. Because of the cone like front end design,
height restrictions can limit the potential drivers while the
distance from the seat to the pedals severely limits the available
leg span of the operator. The customer requires the use of air as
the main medium to provide the adjustments required in order for
the seat to accommodate specified rider characteristics, consisting
of a height between 66 and 72, and a weight range of 150 lb. - 220
lb.s. This design must also provide the optimum performance, safety
and comfort without the use of any electronic systems. A safety
limitation requires that the seat adjustments be accessible at all
times while maintaining a line of sight that is both comfortable
and non-hazardous to the driver or other vehicles during operation.
Because of the lightweight design of the reinforced composite, the
seat and all components are not to exceed a weight of 10 lbs. The
cost limitations designate a maximum cost of $1000 USD to keep the
product marketable and competitive. General ConsiderationsThe
purpose of this study is to propose a human powered vehicle seat
design ready for manufacturing that meets the specific performance
and reliability requirements set forth in this research paper. This
paper will detail a cost effective, lightweight and safe design
that accommodates a wide range of users while maintaining comfort
and accessibility to the driver and conformance to industry best
standards for manufacturing. Pneumatic Considerations An important
aspect of this design includes using air as the fluid to provide
different levels of adjustment to accommodate ergonomic needs and
physical characteristics of the user as well provide some utility
as a safety device. Due to the weight requirements, using air to
generate the pressure needed for the seat cushion and for the seat
adjustment will ensure the riders ability to utilize the vehicle to
its full potential. The major finding of the research experiment
involving the wheelchair cushion study were that the increase in
leg volume caused by wheelchair sitting was attenuated by using the
dynamic air cushion, but not the static cushion. (Murata, J.,
Murata, S., Ohyama, M., Kogo, H., & Matsubara, S., 2014) These
results suggest that the dynamic air cushion relieved the leg edema
induced by wheelchair sitting. Frame ConsiderationsThe seat will
have a single fixed frame design that is installable in a
pre-existing human powered vehicle and will allow for accordion
type adjustments. The solid frame is necessary to assist in
achieving the power output and to support the weight of the rider
during physical activity. Safety ConsiderationsThe seating angle
should recline enough to provide a comfortable ride for the
recumbent human powered vehicle while still allowing the driver a
full, safe view of the road and surroundings. While bicycles are
generally not considered to have blind spots, the Quests recumbent
style frame setup combined with the composite casing has the
potential to create them should the seat not provide sufficient
height. For this seat design, the HPV is analyzed as a road vehicle
where blind spots can mean the difference between life and death
decisions in maneuvers. There is a trade-off between occupant
protection and all-round visibility. Drivers need to make sure that
improvements in their safety do not compromise the safety of
others. (Millward, 2011)Reliability ConsiderationsThe life cycle of
the seat frame will be equivalent to that of the vehicle, with a
focus on the shelf life of the inflatable portion of seat based on
the material outlined in this document. The seat portion of an HPV
will need to be built such that it can withstand daily use, as the
target market is the daily commuter. This seat cushion should be
water and tear resistant, and the brackets and cylinders have a
life span that supports the HPV User throughout the vehicles
lifespan.Manufacturing Retail ConsiderationsBecause the HPV design
already exists, the best approach is to provide the seat as part of
a kit, which will serve as an upgrade to the stock configuration.
The Stock Bluevelo Quest comes equipped with a pre-existing seat
and adjustability options, but because this design is an upgrade,
it will be manufactured as a ready to install kit that the user can
easily install in the vehicle. To ensure ease of installation, the
design should utilize a quick disconnect mounting option wherever
possible. The kit should include all tools and hardware required
for installation to existing mounting points to serve as an upgrade
to the stock seat. The kit should also include instructions with
simple illustrations. HPV Seat Industry Design ResearchAlong with
internal research, JMAC has conducted extensive research on
commercially available HPV seat design. To allow for a more
comprehensive understanding of seat cushions, this research
includes seat cushions for wheelchairs. The commercially available
Seat designs are identified in Table 1. The commercially available
seat cushions are identified in Table 2. This information provides
a collaborative view of various characteristics, both aesthetic and
ergonomic, used by JMAC in the generation of the most efficient
seat design for the Quest HPV Model. In these tables, JMAC has
identified several commercially available seat designs, and
detailed the notable characteristics and approaches that were
utilized in the designs of these seats. Through a complete analysis
of the designs identified in Tables 1 and 2, JMAC has identified
model features to better evaluate the characteristics that will be
utilized in the generation of an optimum HPV Quest Seat Kit
Design.
Figure 1: Bluevelo QuestThe Quest Model from Bluevelo comes
equipped with a carbon fiber seat bucket and Ventisit Comfort Seat
Cushion. Tee mesh Ventisit cushion is the highlight of this seat
assembly, however the adjustability of the seat frame leaves
something to be desired. Adjusting the seat to fit the desired
users height and weight requires a manual adjustment that includes
disassembly, adjustment and then reassembly.
Figure 2: Windcheetah Sport CompactAngletech Cycles Windcheetah
Sport Compact comes standard with the Ventisit comfort seat, along
with its seat that has carbon leaf spring mounts. The main
disadvantage of the carbon-reinforced composite leaf springs is
that they have been limited to low-volume production models.
Figure 3: Angletech Challenge Seiran SL10The Challenge Seiran
SL10, an Angletech Cycle, boasts a Tiefliegersitze, which is
considered one of the most comfortable shell seat designs on the
market. This model also contains the Ventisit Comfort seat pad.
Figure 4: Tri-Sled Rotovelo CarbonThe Tri-Sled - Rotovelo Carbon
design contains a carbon seat bucket with a foam seat pad. This
seat model extends the carbon fiber seat upward and behind the
riders head. Its just enough to hold your head up but allows some
movement if hit any bumps or pedal squares. Tri-Sled covers their
super seat (headrest included) with a very thick and comfortable
layer of open cell foam.
Figure 5: Beyss Go-OneThe Beyss Go-one standard seat is designed
for a certain height, and many use reviews claim the seat had to be
replaced with a user designed option in order to utilize the
vehicle properly.
Table 1: Industry Design HPV Analysis ExamplesFigure 6:
Butterfly Gel CushionThe Butterfly Gel Cushion boasts a high-tech
gel. This gel is both nontoxic and recyclable. It has shock
absorption and insulation from vibration and rebound, while
providing maximum dissipation of pressure points with a relaxed
feel. Its channeled/ribbed design maximizes protection of soft
tissues, allows ventilated comfort and conforms to the user.
Figure 7: Orthopedic Gel CushionThis high density foam pad
conforms to the users contours. Inside the foam pad is a generous
layer of soft, supporting liquid gel. This design is intended to
banish fatigue and discomfort once and for all. Soft polyester
fleece cover removes for washing. Measures 18"W x 13.5"L x 3
1/2"H.
Figure 8: Ventisit Seat PadThe Ventisit is a Netherlands design.
The open weave design is loaded with venturi to bring ultimate
airflow to the ride. The Ventisit is available in 2
formats/thicknesses, the Classic at 2 cm thick and the Comfort at
3cm thick. Unlike the reticular foam, Ventisit design does not
compress permanently over extended use.
Figure 9: Hobie Mirage Seat PadThe Hobie Mirage Seat pad can
replace the standard foam seat pad. It can easily adjust the seat
to the desired comfort by adding or replacing air pressure. There
is an internal valve that allows it to inflate and deflate as
needed.
Figure 10: Genuine Corflex Medic-Air Seat CushionThis seat
cushion provides stress free sitting with a gentle layer of air.
The air assists in eliminating pressure points. This design
provides adjustable density by adding or subtracting air. Maximum
weight 300 lbs. 15 1/2" x 17 1/2.
Table 2: Industry Design Seat Cushion Analysis
ExamplesBACKGROUND AND LITERATURE REVIEWSince the nineteenth
century human powered vehicles have played an important role in
sports, transportation, and industrial practices. As stated by
Rosen in the Encyclopedia of 20th Century Technology, many
inventors and industrialists such as Henry Ford and the Wright
brothers began their careers as bicycle mechanics. Because of the
simplicity in design, bicycles to this day continue to be used in
innovative ways to test new materials and industrial processes
(Rosen, 2005). This simple design is once again a contender as a
daily commuter and with the right design features and
characteristics could catapult the HPV into the daily li.ves of
citizens across America. Variable Analysis of Seat DesignThe
following research material has led the JMAC team to the generation
of the latest advancements for the Bluevelos Model Quest HOV Seat.
The variables, which are the cornerstones of JMACs AirRide design
to support a person between 150 and 220lbs, with a maximum height
of 6, and who utilize the vehicle 5 days a week as a daily commuter
are noted in the following section. HPV Aerodynamic Feature
AnalysisAccording to Lei, Trabia, and Too, the design of
human-powered vehicles prior to 1993 was solely focused on
aerodynamic characteristics (1993, p. 115). In past endeavors, many
innovative designs were tested and proved through competition. In
the 1930s, recumbent bicycles were used to break speed and distance
records, causing them to be banned in competition to keep other
models from being invalidated. It wasnt until the 1970s when
recumbent designers and enthusiasts made their own sporting designs
for competition that reached speeds up to eighty miles per hour
(Rosen, 2005). While Bluevelos Velomobile struggles to reach the
speeds of the competition recumbent bikes, it still meets the
requirements and expectation of a viable alternative to a
gas-powered vehicle. With the right design and features, this
recumbent bike could work its way into mainstream commuting. 3.1.2
Structural Frame Design VariablesIn order to better evaluate how
the seat frames angles will affect the human operator, the
following sections describe the considerations of the Seat
adjustability analysis and the seat cushion variable analysis.
Careful considerations are given during the development of the
JMACs AirRide seat design to ensure the most ergonomic and reliable
options are incorporated.3.1.3 Seat Adjustability AnalysisThe
research regarding the use of pneumatics as the pressure system to
engage the seat adjustments proved useful in overall design
consideration. A pressure system must employ an energy source, a
transmission path, control, a load device, and possibly one or more
indicators in order to function. (Fardo, 2008) The energy source in
question would be a variation of the energy transformation from
mechanical energy through the handheld pump, the load device, to
the energy created in the cylinder. The Transmission path is the
hose that connects the load device to the adjustable valves. All of
the system aspects are carefully taken into consideration in the
adjustability design.3.1.4 Seat Cushion Variables AnalysisThere are
a wide variety of cushions available on the market, and research
into active cushions versus passive cushions provided valuable
insight to the effect of pattern of inflation and deflation. In a
study done by Mahender Arjun Mandala at the University of Kansas,
two custom active cushions were developed based on the Roho Quadtro
passive cushion design. The inflation and deflation pattern of the
first cushion was checkerboard (CHK) and the second was column
(COL). The study concluded that the active seating system with
column based pattern of inflation and deflation (COL) exhibited the
best mechanical performance with regards to the parameters
calculated. (Mandala, 2011) 3.2 Variable Analysis of Materials for
Seat Frame and Cushion ManufacturingThe analysis of the materials
used in the manufacturing of the HPV Seat design demands careful
consideration due to the wide range of materials that are available
today. When utilizing Design for Manufacture and Assembly (DFMA)
Principles, the careful selection of materials is detrimental to
the optimization of the seat design. The following sections outline
the process of material choice and other available options such as
material sustainability as it applies to the HPV Air Ride Seat
design. According to the research outlined in this project, designs
have included space-age materials such as molded thermoplastics,
fiber composites, and titanium. The material selection criteria are
organized in order of importance: Availability Sustainability Price
Sustainable Materials Variables3.2.1 Sustainable Materials
VariablesAluminum is one of the most abundant metals available;
however it requires significant amounts of energy in order to
process the ore into purified and alloyed forms. Aluminum is a
versatile metal which may be used for a variety of applications.
Recycling allows the recapture of over 1.7 billion pounds of
aluminum per year, resulting in major savings in the use of
electricity used in the processing of aluminum oxide ore into
purified aluminum (Das 2011)Carbon fiber does not benefit from the
ease of recycling that aluminum does, and can be as energy
intensive to produce as aluminum from its ore, however the inherent
durability and versatility of carbon fiber makes it a solid choice
when light weight, high strength and unusual molding is required
(Mehta 2010). A benefit of recycling carbon fiber is that no
solvents or chemicals are required in order to process scraps back
into a product suitable for re-use, but rather the scraps are
subjected to high pressures and temperatures without any other
environmental impact. (Kunz 2013)3.2.2Seat Cushion Material
VariablesWhen selecting the material for the seat cushion,
consideration needs to be taken to account for the additional
localized pressure applied to the seat when the driver is entering
and exiting the vehicle and must stand on the seat bottom. Research
on a honeycomb type cushion is an essential material design
requirement. A good design should utilize abrasion protection for
honeycomb cushion while reducing friction against the drivers
clothing and allowing ease of ventilation during driving. Table 4
outlines the four basic materials that are used to manufacture seat
cushions in the industry. Research on a urethane honeycomb mesh
proved efficient air travel and more protection against skin
breakdown due to a cooler temperature and minimal moisture level
during use. Because there are many individual cells--like a
beehive--these cushions are able to distribute weight evenly, but
there is no risk of leaking gel or of an air bladder being
punctured. (Karp, 1998). Cushion typeAdvantagesDisadvantages
FoamInexpensive.Very lightweight.Comes in range of
densities.Holds shape (memory).Provides even support.Can be cut to
relieve sores.Nothing to leakWears out faster.Loses its shape.Old,
compressed foam could lead to a sore.
GelExcellent pressure distribution.Very comfortable.May have
supplemental inserts to stabilize legs.Heavy.Chance of leakage.Less
able to absorb impact.Some designs allow gel to push out to
sides.
Air floatationLightweight.Even pressure distribution.Will not
bottom out if properly inflated.Can be modified to relieve pressure
sores.Some models inflate to user's specific needs.Waterproof.Less
stable.Chance of puncture/leakage.High maintenance: need to check
pressure frequently.
Urethane honeycombVery lightweight.Low profile in
appearance.Distributes weight evenly.Good support.Absorbs
shock.Keeps skin cooler.No risk of leakage.Machine
washable/dryable.Relatively new, so not much of a track record
yet.
Table 3: Comparison of Main Types of Cushions (Karp, 1998)
3.3 Variable Analysis of Manufacturing StrategyThe details in
the following paragraphs provide a high level overview of the
manufacturing strategies utilized based on literature available.
These will be incorporated into the design of the JMAC AirRides
Seat design Kit. 3.3.1 Manufacturing VariablesThe planning and
execution of the manufacturing process will be largely controlled
by the following variables: selection of material types, material
forms, tolerances, design and shape. Material types and forms will
be chosen based on ease of machining and forming as well as
minimizing the amount of waste. Processes which yield a reduction
in the amount of time required to achieve the final geometry
required are also a major consideration. The design should allow
for a generous degree of tolerance without compromising performance
and function in order to reduce machining setup time and maintain
first pass yield. Implementation of DFMA from initial design to end
product will result in reduced number of parts and manufacturing
cycles in order to minimize material cost and production cost.3.3.2
Production VariablesWhen developing the production plans for the
assembly kit, the focus will pertain to part handling, designing
for inserting and fastening, and defining which components will be
provided pre-assembled and which components will require the
consumer to install into the vehicle itself. Packaging is another
main component of getting the product kit ready for retail, along
with shipment options for the consumer.3.3.3 Ease of Assembly
VariablesNot only should the design incorporate ease of
manufacturing at the factory, but for the consumer it should
provide easy assembly at home as well. To better serve the
consumer, this design will be provided in a kit with simple
instructions detailing the installation required. Because of the
kit approach JMAC is taking, Design for Assembly (DFA) Principles
were carefully considered when designing this product for ease of
Assembly. DFA is also a vehicle for questioning the relationship
between the parts in a design and for attempting to simplify the
structure through combinations of parts or features, through
alternative choices of securing methods, or through spatial
relationship changes. (Design for Assembly, 2004)3.4 Variable
Analysis of Quality Assurance and Control StrategiesIndustry
Standard Practice Manufacturing Strategies all adhere to stringent
quality engineering principles such as Six Sigma and Total Quality
Management (TQM) methodologies to ensure manufacturing success and
product optimization. These systems allow the design and
manufacturing companies to remain competitive in the consumer
market by providing the most efficient product at the best possible
price. The culture requires quality in all aspects of the companys
operations, with processes being done right the first time and
defects and waste eradicated from operations. (Hashimi, 2014)3.5
Background Research Variables SummaryUtilizing a combination of
existing technology and new designs, this study will demonstrate an
improved design for providing seating to the operator of a Human
Powered Vehicle which enhances the comfort, safety and individual
customization to the drivers physical characteristics and
preferences, all while conforming to the requirements,
specifications and limitations provided. The study has analyzed the
amassed knowledge relevant to the subject matter and delineated the
methods, design features and manufacturing technologies that will
be utilized to bring this product to market.
JMAC DESIGN METHODOLOGYJMAC strives toward creating an efficient
design that incorporates best practices into functionality and
material selection to guarantee customer requirements are met and
ensure all manufacturing needs are addressed. 4.1 JMAC AirRide Seat
Kit DesignJMAC has utilized the Five Principles of Design to better
evaluate and meet the outlined requirements. The five principles of
design taken into consideration are form, function, quality,
sustainability, and low price. The AirRide Seat kit is provided
complete with all manufactured and purchased parts, along with a
simple installation manual. 4.2 JMAC AirRide Seat Position
ConsiderationsTraditional designs of HPVs have typically focused on
aerodynamics as the most important characteristic to consider when
determining proper seat position. The seat position is adjusted to
meet size and shape of the HPV as opposed to optimizing power
output. While aerodynamics is very important of the overall
performance of the HPV, sacrificing performance to meet the
aerodynamic shape could become counterproductive to achieving
maximum efficiency. With efficiency in mind, the focus shifts to
identifying and setting the HPV seat to the proper position,
allowing the rider to maximize power output while exerting minimum
energy. Many factors have to be considered when determining the
best seat position and different riding styles require a different
seat position. Seat position is generally defined and represented
through a series of measurement including seat angle (Figure 1,
Reference A), the distance from the back of the seat to the pedals
(Leg length), (Figure 1, Reference B), and the minimum height
required to maintain proper line of sight to the road (torso
height), (Figure 1, Reference C).
Figure 11: JMAC Design
Reference A - Seat angle is obtained by measuring the angle
created at the base of the seat in relation to the top of the seat
and the center of the pedal crankshaft. Proper seat angle can range
from 110-150 degrees and usually is adjusted based on the specific
application intended for each HPV (Reiser II, Peterson, Broker,
2011). Riders looking for a better position for climbing a hill may
choose a greater seat angle than a flat surface rider. The seat
position can affect the power output both directly and indirectly.
It can affect the power directly through the optimized use of leg
power, whereas it can indirectly affect the power by providing a
comfortable, relaxed seating position that allows for proper
alignment of the body to maximize air intake while the rider
breathes. Reference B - The leg length is measure from the base of
the HPV seat to the center of the pedal crank and is most important
in determining the rider height range, which the HPV can
accommodate. Proper adjustment of leg length is also an important
factor in maximizing power output.Reference C - The torso height is
measure from the base of the seat to the minimum point in which the
rider can maintain an unobstructed view of the road and surrounding
area. This measurement in combination with the leg length is used
to determine the rider height range.The JMAC AirRide takes into
account the option of changing riders and allows for proper seat
adjustment for riders ranging from 52 to 62. This adjustment is
made through the use of an air-operated cylinder and JMACs original
pendulum seat mounts. The pendulum mounts allows for two directions
of travel simultaneously allowing shorter rider to move both,
closer to the pedals and higher in the cockpit to maintain a proper
view of the road. 4.3 JMAC Seat Inflation Design RequirementsThe
JMAC AirRide will feature an inflatable seat design which will
provide the vehicle operator with the ability to customize support
points, seat height, and distance to the vehicle controls which
accommodate different body types within the height and weight range
specified by the customer. Inflation will be accomplished utilizing
a hand-operated pump, which will supply air to a set of
strategically positioned chambers. Each chamber will be adjustable
through the use of a smart valve system. This smart valve system
will regulate adjustability, and also prevent over pressurization.
Seat inflation is accomplished utilizing an ambidextrous
hand-operated pump located on the JMAC Air Manifold subassembly and
designed to allow two-handed operation, allowing the driver to
produce the most amount of mechanical energy with the least amount
of physical exertion. The pump is connected to an air supply system
that feeds into a 3-way valve that can be switched between two
positions. 4.4 JMAC 3-Way Valve ConsiderationsThe first position
supplies air to a pneumatic cylinder mounted to the vertical
support post connected to the seat frame. This pneumatic cylinder
provides back and forth movement to the seat by pushing the seat
forward, and also provides vertical movement to the seat by pushing
upward.The second position supplies air to a manifold with 6
outlets, each of which connects to a check valve. The check valve
controls the pressure at each of the 6 chambers throughout the
inflatable seat. Each check valve can be adjusted by the driver to
the desired pressure in order to control both the firmness of the
seat and also to provide additional control to the height of the
seat for the purpose of providing a clear line of sight for the
driver. The chambers include the following in order to provide
support to key areas: backrest, lumbar, seat height 1, seat height
2, seat height 3, and seat surface.4.5 JMAC Lumbar Support Cushion
ConsiderationsBackrest and lumbar chamber inflation allow the
driver to adjust optimized support to the back and shoulder area
independently from the chamber providing lumbar support. This is to
allow customization to the unique physical characteristics of the
driver.4.6 JMACs Air Chamber Cushion RequirementsThe JMAC Air
Chamber Cushion will consist of 17 connected tubes which have been
separated into chambers, Upper-Back, Lumbar and Waterfall. Each of
the 3 chambers will be individually controlled through a regulator
allowing the rider to set each of the chambers to their preferred
setting. Control of the air cushion will be accomplished through a
manifold assembly containing air regulators. The mini air
regulators attached at the manifolds are calibrated to inflate
within 1 psi of the desired pressure setting. Excess air supplied
to various chambers will be expelled by the relief valve, which
prevents over pressurization and resulting damage to the seat. The
air pump has a high pressure low volume stage and a low pressure
high volume stage. Changing between stages is accomplished with a
simple twist of the handle. 4.7 JMAC Air Cushion Material
ConsiderationsSeat materials were selected to account for the
additional localized pressure applied to the seat when the driver
is entering and exiting. The honeycomb cushion will be protected by
a Ventisit comfort cushion screen mesh cover providing abrasion
protection to the honeycomb cushion while reducing friction against
the drivers clothing and allowing ease of ventilation during
driving. The Ventisit is the cushion provided with the Bluevelos
Velomobile stock assembly.4.8 JMAC Vehicle Stability
ConsiderationsThe stability of a vehicle is largely determined by
center of gravity and the response of tires to applied forces,
specifically the relationship between lateral acceleration,
longitudinal acceleration, and control characteristics. Driver
input in the form of braking and cornering, and the resulting
forces resulting from both actions as they occur simultaneously
affect center of gravity of the vehicle, and its stability.
Generally speaking, when lateral forces from the center of gravity
are equal or greater than the forces of the vehicle mass at the
center of gravity, rollover can occur. As the center of gravity
elevates, the vehicle requires a greater amount of downward force
at the center of gravity in order to retain stability, or a greater
lateral distance between the center of gravity and the center of
the tires. (HS, 807 956)4.8.1 Directional Stability
ConsiderationsDirectional stability, also called Yaw or Heading,
depends on horizontal planar moments applied against opposing tire
forces. When driver input in the form of braking and cornering are
applied, the load of the vehicle is transferred from the inside of
the tires to the outside of the tires. When those forces exceed the
opposing forces of the tires, lateral acceleration will occur and
the risk of vehicle rollover increases. (HS, 807 956)4.8.2 Rollover
Stability ConsiderationsWhen the Center of Gravity (cg) is elevated
over one of the wheels, rollover can occur. Figure 11 illustrates
the change in elevation Delta h as the center of gravity cg shifts
from the center of the wheel axel to be directly over the center of
the tire in a lateral motion. The height and lateral position of
the center of gravity relative to the ground and wheel center
respectively determine how much of a change in cg elevation is
required for this to occur. The side forces exerted on the tires do
not have a high enough coefficient of friction to initiate a
rollover unless there are outside forces such as changes in the
road surface or physical obstructions on the road such as speed
bumps, contact with a curb or foreign objects which can change the
height of the side forces and cause a tripping event which leads to
rollover.
4.8.3 Lateral Forces Rollover AnalysisThe forces required to
initiate a rollover are dependent on the location of the center of
gravity, and the downward forces being applied by the weight of the
vehicle. Figure 11 and 12 reference the center of gravity elevation
formula and the side forces at rollover.
Figure 12: Center of Gravity Elevation Formula
Figure 13: Tire Side Forces at RolloverTable 4 and Figures 13
and 14 represent the effect of the shift of center of gravity as
the seat position is moved upwards. Zero position represents the
lowest seat position, and this position shifts upward as the seat
is elevated. Different weights of the rider are then applied
against this shifting center of gravity. As the rider weight
increases, so does the amount of lateral force required for the
vehicle to roll over.Zero + 5Zero + 4Zero + 3Zero + 2Zero +
1Zero
cg Elevation4.4014.0413.7273.4533.2123
Lateral Forces (ma) required for Roll-over
Zero + 5Zero + 4Zero + 3Zero + 2Zero + 1Zero
150118.402122.264125.839129.141132.188135
155122.349126.340130.034133.446136.595139.5
160126.296130.415134.229137.751141.001144
165130.243134.491138.423142.055145.407148.5
170134.189138.566142.618146.360149.813153
175138.136142.642146.813150.665154.220157.5
180142.083146.717151.007154.970158.626162
185146.030150.793155.202159.274163.032166.5
190149.976154.868159.397163.579167.439171
195153.923158.944163.591167.884171.845175.5
200157.870163.019167.786172.189176.251180
205161.817167.095171.981176.493180.657184.5
210165.763171.170176.175180.798185.0642189
215169.710175.246180.370185.103189.470193.5
220173.657179.321184.565189.407193.876198
Table 4: Rollover Lateral Force
Weight of Rider (lbs)Lateral Force Required to Roll
Vehicle(lbs)Figure 14: Rollover Lateral Force Chart
Seat Height SettingVertical Shift of Center of Gravity (in)
Figure 15: Center of Gravity (cg) Elevation Shift
4.9 JMAC Air Ride Weight ConsiderationsLightweight and HPV are
almost interchangeable when it comes to developmental and
competitive designs. The following sections define the weight
aspect as it pertains to the rider and the overall vehicle weight
in terms of both the operators performance and the vehicles
performance. Understanding the weight relationship between each of
these aspects will better determine the performance output of the
JMAC Air Ride seat kit design.When it comes to HPV and their
aerodynamic attributes, it is no surprise that weight will affect
overall performance. During the Tour de France, Lance Armstrong
switched his wheels, frame and components to a more efficient and
lightweight alternative during the mountain legs of the race. This
provided Armstrong with a lighter bike that provides less rolling
resistance, improved acceleration, and requires less power while in
an incline (Burke, 2014). According to Burke, it takes more power
to achieve the same speed of a lighter bike. Adding weight
increases the bikes inertia, thereby slowing down acceleration
rate, and increasing rotating friction on the wheels (2014).McCraw
discusses how the speed in an incline is influenced by the energy
the rider puts out versus the work that is required to overcome
inertia. Therefore the speed lost by adding the additional weight
from the improved seat design may be calculated using the following
formula (McCraw 2012).
Figure 16: McCraws Weight Study Formula
For this study, in McCraws formula the kilogram unit of
measurement was converted to pounds and the unit of speed was kept
as miles per hour. Thereby, using a rider that is 190 lbs., the
original bike weight at 77.16 lbs. for Bike 1, the new bike weight
of 87.16 lbs. for Bike 2, and using 12 mph as Bike 1s speed, Bike
2s speed can be calculated as 11.57 mph. Therefore the new design
is 0.43 mph slower than the original design. Taking into account of
the speed lost with the improved design, the time added to a 10
mile commute can be calculated using McCraws formula for time saved
or added in Figure 12.
Figure 17: McCraws Formula for Time Saved or Added
For this study, 10 miles was be used as the Distance for the
commute, and Speed 1 and 2 was utilized from the previous formula.
Therefore the time added to the commute by using the heavier design
is 111.49 seconds, almost 2 minutes more of a commute than the
original design (McCraw 2012). Figure 13 illustrates the time added
to a ten-mile commute for every pound added to the HPV. As each
pound is added, 38.88 seconds is added to the commute.
Figure 18: Seconds Per Pound Analysis5 JMAC AIRRIDE DETAILED
DESIGN AND RISK ASSESSMENTJMAC has taken an innovative design
approach to provide a more versatile option for Velomobile riders.
With the use of lean manufacturing principles, risk management
techniques and careful material selection JMAC has been able to
produce a design that meets the all of the customer requirements
and cost goals in a competitive market. 5.1 JMAC AirRide Components
and SubassembliesThe JMAC AirRide System is made up of five
subassemblies. The front and rear bracket subassemblies provide for
the mounting and pivot points for JMACs original pendulum driven
seat positioning system. The seat subassembly contains all the
necessary brackets to convert the original HPV seat bucket for use
with the AirRide system. The last subassembly is the Air manifold
subassembly providing all the controls to set the perfect seat
position. Figure 18 provides an overall view of the subassemblies
within the final assembly.
Rear Bracket(3) Seat Brackets(4) Seat Cushion( 1) Front
Bracket(5) Air Manifold (Not shown in this View)Figure 19:
Subassembly Detail5.1.1 JMAC Front Subassembly DesignThe front
bracket assembly consists of a mounting bracket which mounts
directly to the existing mounting holes for the current forward
seat brackets and JMACs unique pendulum drop arm. The drop arm
connects to pivot pins on both the mounting bracket and the front
corners of the seat subassembly. Figure 19 shows one of the two
front bracket subassemblies required.
Figure 20: Front Bracket Subassembly
5.1.2 JMAC Rear Bracket Subassembly DesignFigure 21 conveys the
rear-mounting bracket that bolts directly to the existing rear
mounting holes and provides mounting points for the rear pendulum
drop arms and the air cylinder. The rear pendulum drop arms connect
to a pivot pin at the top of the rear mounting bracket and to the
back of the existing HPV seat via the provided mounting bracket. A
second pin connects the air cylinder to the bottom of the
rear-mounting bracket.
Figure 21: Rear Bracket Subassembly5.1.3 JMAC Seat Subassembly
DesignThe JMAC AirRide Seat uses the existing carbon fiber seat
bucket. As part of the installation kit, templates are provided to
drill and mount the AirRide brackets. The Seat subassembly has a
total of four brackets providing pivot/mounting points for the
pendulum drop arms and the air cylinder.5.1.4 JMAC Air Cushion
DesignThe JMAC air cushion is comprised of three separate chambers:
Upper-Back, Lumbar and Waterfall. Each chamber can be inflated to a
specific pressure, allowing for fine tuning of seating position.
Figure 21 demonstrates the 17 different sections of the cushion as
it fits on the existing carbon fiber seat. The JMAC AirRide logo is
also included as part of the cushion design.
Figure 22: AirRide Cushion Design
5.1.5 JMAC Air Manifold Subassembly DesignThe Air Manifold
subassembly houses all the pressure controls for operation of both
the air cushion and cylinder. The subassembly is made up of two air
manifolds, a three-way valve, mini air regulators and a hand pump.
The components of the subassembly are attached to the mounting
bracket that is bolted directly to the carbon lip formed by the two
halves of the HPV body. The three-way valve directs air to one of
the two air manifolds, each containing mini pressure regulators for
fine-tuning the seat position and a small needle valve for easy
deflation. The air pump has a high-pressure low volume stage and a
low pressure high volume stage, changing between stages is
accomplished with a simple twist of the handle. The operation
starts with a three-way valve that directs flow from the air pump
to either the air cushion or the air cylinder. Stage one of setting
proper seat position is accomplished by setting the three-way valve
to the downward position, directing airflow to the air cylinder.
Using the air pump, air is utilized until proper seat height is
obtained. Stage two is accomplished by moving the three-way valve
to the forward position, directing airflow to the air cushion
manifold. Figure 22 references an image of the cylinder assembly
and the locking bar.
Figure 23: Cylinder Assembly with Locking Bar
The air cushion manifold provides airflow to the three chambers
of the JMAC air cushion. The air cushion manifold contains a
combination mini Air regulator and relief valves for each chamber.
Pressure can be set and adjusted for each chamber by setting the
relief valve to a set pressure to allow for maximum comfort.
Individual riders can also record their preferred pressure setting
for each chamber for a faster set-up during subsequent rides.
Deflation is accomplished by slowly opening the two needle valves
until seat has returned to original position.
5.2 JMAC Bill of MaterialsA comprehensive parts list has been
generated in Figure 23 that outlines all of the materials needed to
manufacture and assemble the JMAC AirRide Seat.
Figure 24: Bill of Materials5.3 JMAC Cost AnalysisFigure 25 is a
detailed Bill of Material with Cost information for the purchased
parts of the JMAC Air Assembly.
Figure 25: Purchased Parts CostFigure 26 is a detailed Bill of
Material for all of the Make Parts in the JMAC Air Assembly.
Figure 26: Manufactured Parts List
Manufacturing processes costs were a subject of consideration
based on the suitability of the process for the part geometry and
the resulting cost of manufacturing. Cost analysis is based on
processes utilized by machine shops in estimating costs for
performing cutting services, bending, machining and welding. The
estimated costs for the various manufacturing services and
processes are detailed in Figure 26. This cost was arrived at by
considering several factors such as cut inches for cutting services
and the number of bends for bending operations. Given a bulk order
of 1000 assemblies, the estimated price for all custom manufactured
parts is $342.22.
Figure 27: Manufacturing Cost
5.4 JMAC Weight AnalysisJMAC AirRide weight considerations were
calculated using the Solid Works Files material properties and
weight calculation features, coupled with a summary of Buy Parts
Weights as outlined in Figure 28. The total weight output from the
Assembly is 4.96 lbs. The Total weight of the Buy parts is 4.79.
This creates a total Assembly kit weight of 9.75 lbs.
Figure 28: Buy Parts Weight Summary
5.5 Risk Mitigation and ConsiderationsRisk Mitigation strategies
and considerations must take into account a variety of factors when
analyzing potential sources of failure and difficulties in the
product design and manufacturing process. An evaluation of product
and process technologies which are going to be utilized in the
system must be undertaken. Technologies which are new and untested
are especially in need of special consideration when performing a
risk assessment. The allocation of development team resources and
the supply chain are also important points which may affect the
successful development and manufacture of the product. (Montgomery
2011)Mitigating these risks for each of the systems and subsystems
is a critical step during the product design phase. Development of
a Failure Mode, Effects and Criticality Analysis (FMECA) is
instrumental in this regard. (Blanchard 2011)
5.5.1 FMECA DevelopmentThe Failure Mode, Effects and Criticality
Analysis will evaluate the design and function of AirRide. Figure
29 is a top level functional flow diagram. Figure 30 is the second
level functional flow.
Figure 29: Functional Flow Diagram (TOP LEVEL), FUNCTION
Figure 30: Functional Flow Diagrams (Second Level)
5.5.2 Risk Priority Number DevelopmentRisk priority factors are
derived as outputs based on these functional diagrams. These risk
priority factors are evaluated utilizing three criteria: severity,
occurrence, and detection. Each component is assigned a score from
1 to 10, from lowest to highest level of priority. A Risk Priority
Number (RPN) will be determined by multiplying the scores for each
component, yielding the order by which corrective actions may be
taken to mitigate those risks. (Blanchard 2011) Table 5 details a
comprehensive Risk Priority Number Analysis.
Table 5: Risk Priority Analysis
5.5.3 Corrective Action IdentificationThe most commonly observed
potential sources for failure were related to the use of air as the
medium for seat adjustment and seat comfort. The inherent relative
weakness of air filled cushions combined with the need to manually
provide air to the system via a hand actuated pump create risks
which can be mitigated but not completely eliminated through the
use of mechanical support to the air system. The stop bar assembly
which provides additional structural support to the air cylinder
was implemented due to this observed and measured risk, and is
meant to provide an additional layer of safety and reliability
which cannot be as readily obtained through the use of the
pneumatic system and air cushions alone.
6 CONCLUSION AND RECOMMENDATIONSJMACs innovative design
successfully incorporates functionality and manufacturability with
the intent to satisfy a wider range of desired ease of
adjustability for customers. While the original design offered the
customer to specify his/her desired configuration when the vehicle
was first purchased, it was not easy for him to make adjustments
later as the process was cumbersome and require the use of hand
tools. JMAC utilized a design approach that took into consideration
existing concepts and industry products available, and through the
employment of manufacturing best practices and the application of
risk management techniques, developed an operational and cost
effective assembly that meets all of the requirements set forth by
Bluevelo. The JMAC AirRide seat assembly has been designed to
provide comfort and ease of adjustability, with all of the
adjustments made using simple pneumatic valves on both the seat and
cushion adjustments. The design includes front and rear brackets
with a pendulum action lever levied with a pneumatic cylinder
accompanied with an inflatable seat cushion for additional safety
and ergonomic benefits. JMAC intends to sell the new seat system as
an upgrade kit, utilizing the existing seat panel and mounting
points.Based on the research and analysis performed by JMAC in
creating a design that meets customer specifications, the following
recommendations are provided to increase assembly performance and
reduce cost. JMAC recommends the use of an electric pump instead of
a manual hand pump. A small battery operated electric pump would
decrease seat adjustment and cushion inflation time considerably,
reduce rider fatigue without adding a significant increase in
either weight or cost. Another suggestion is the use of a small
sealed hydraulic system. One of the main concerns when using a
pneumatic system is the compressibility of air which is less
efficient when using a liquid medium to actuate the cylinder. This
would only have a marginal effect on the overall weight but could
be provided as an option if the consumer chooses the upgrade.
Although comfortable and efficient, the neoprene material can be
costly. JMAC suggests retaining the existing mesh seat cover in
lieu of the inflatable air cushion. The JMAC AirRide Seat Kit
allows for sufficient adjustability, making the neoprene cushions
focus mostly about comfort. Additional cost and weight savings
could be accomplished by retaining the use of the original mesh
cover that comes stock with the vehicle, since air would no longer
be necessary for providing the user full adjustability. The mesh
would also enhance user comfort as it naturally provides superior
ventilation and breathability as opposed to the inflatable neoprene
bladders used in the seat cushion assembly. The weight that was
introduced into the final design by the inclusion of the air
control system would be eliminated, thereby offsetting the marginal
increase in weight from the use of a hydraulic cylinder.The JMAC
AirRide design allows the use of air as a medium for providing
adjustability both vertically and longitudinally, while at the same
time reducing the amount of effort required by the rider to make
the necessary adjustments.
REFERENCES AND WORKS CITED
Blanchard, S. & Fabrycky, W. (2011). Systems Engineering and
Analysis. Upper Saddle River, NJ: Prentice Hall
Burke, E.R. (2014). The Effect of Weight on Speed. Retrieved
from
http://www.active.com/cycling/articles/the-effect-of-weight-on-speed.
Design for assembly. (2004). Manufacturing engineering handbook.
Retrieved from
http://ezproxy.nu.edu/login?url=http://literati.credoreference.com.ezproxy.nu.edu/content/entry/mhmeh/design_for_assembly/0
Fardo, Stephen W., and Patrick, Dale R.. Industrial Process
Control Systems (2nd Edition). Lilburn, GA, USA: The Fairmont
Press, Inc., 2009. ProQuest ebrary. Web. 10 February 2015.
Hashmi, K. (2014). Introduction and implementation of total
quality management (TQM). iSixSigma. Retrieved from
http://www.isixsigma.com/methodology/total-quality-management-tqm/introduction-and-implementation-total-quality-management-tqm/
Karp, G. (1998). Choosing a wheelchair: A guide for optimal
independence. Retrieved from
http://www.oreilly.com/medical/wheels/news/chair_cushions.html
Leil, Y., Trabial, M.B., & Too, D. (1993). Optimization of
the seating position in a human-powered vehicle. 11 International
Symposium on Biomechanics in Sports (1993), pp. 115-119. Retrieved
from
https://ojs.ub.uni-konstanz.de/cpa/article/view/1691/1593.Mandala,
M. A. (2011). Evaluating the effect of pattern of inflation and
deflation and cycle time on the pressure relieving characteristic
of a dynamic seat cushion using seat interface pressure
measurements (Order No. 1496880). Available from ProQuest
Dissertations & Theses Full Text; ProQuest Dissertations &
Theses Global. (884580382).
http://ezproxy.nu.edu/login?url=http://search.proquest.com/docview/884580382?accountid=25320
McCraw, D. (2012, June 19). Bike weight and performance.
Retrieved from
http://mccraw.co.uk/bike-weight-performance/#comments.
Millward, David. (2011). Blind spot crashes increase. The
Telegraph. Retrieved from
http://www.telegraph.co.uk/motoring/news/8779153/Blind-spot-crashes-increase.html
Montgomery, D., Jennings, C., & Pfund, M. (2011). Managing,
controlling, and improving quality. Hoboken, NJ: John Wiley &
Sons.
Murata, J., Murata, S., Ohyama, M., Kogo, H., & Matsubara,
S. (2014). Effect of a dynamic air cushion on the development of
leg edema during wheelchair sitting. Journal of Physical Therapy
Science, 26(6), 911913. doi:10.1589/jpts.26.911 Retrieved from
http://www.ncbi.nlp.m.nih.gov/pmc/articles/PMC4085220/
Raoul F. Reiser II, Micheal L. Peterson, Jeffrey P. Broker:
Anaerobic Cycling Power Output With Variations in Recumbent Body
Configuration, Journal of Applied Biomechanics, Vol 17, No. 3,
2001.
Rosen, P. (2005). Transport, human power. Encyclopedia of 20th
Century Technology. Retrieved from the Literati by CREDO Database.
Retrieved from
http://literati.credoreference.com.ezproxy.nu.edu/content/entry/routt/transport_human_power/0?searchId=d32f4209-7d76-11e4-a634-0aea1e24c1ac&result=0.
APPENDIX A: ACRONYMS
DFA: Design for AssemblyDFMA: Design for Manufacture and
AssemblyHPV: Human Powered VehicleMPPU: Machining Price Per
UnitPPA: Price Per AssemblyPPB: Price Per BendPPI: Price Per
InchPPM: Price Per MinutePPP: Price Per PiercePPU: Price Per
UnitPPW: Price Per WeldPSI: Pounds per Square InchTPPU: Total Price
Per UnitTQM: Total Quality Management
APPENDIX B: GLOSSARY OF TERMS For the purposes of this study,
the following terms will be utilized with the given definitions
below. (Defined terms to be inserted into this section as needed
during subsequent research)
Chamber: Each of the individually inflatable pockets within the
seat, which when grouped as a single entity form the entirety of
the inflatable component of the seat.
Cylinder A device that converts fluid power into linear
mechanical force and motion; consists of a movable piston,
connecting rod, and plunger operating in a cylindrical cavity.
Edema: An abnormal accumulation of fluid in the interstitium,
located beneath the skin and in the cavities of the body.
Honeycomb Cushion: The surface upon which the drivers bottom
will be resting. The honeycomb cushion is composed of a matrix of
inflated pockets maximized to provide the most surface contact with
the occupant possible.
HPV: A Human Powered Vehicle with a recumbent seat design
Leg Length: the measure from the base of the HPV seat to the
center of the pedal crank and is most important in determining the
rider height range which the HPV can accommodate.
Main Manifold: The distribution junction for air produced
utilizing the hand operated pump. Each manifold outlet will be
directed towards a chamber and will allow adjustability of air
pressure through use of an adjustable check valve.Smart Valve:
Adjustable valve which will allow the user to set the pressure
within a given chamber, thus controlling the height and
longitudinal position of the user under a given inflation
setting.
Seat Angle: the angle created at the base of the seat in
relation to the top of the seat and the center of the pedal crank
shaft. Proper seat angle can range from 110-150 degrees and usually
is adjusted based on the specific application intended for each
HPV.
Torso Height: the measure from the base of the seat to the
minimum point in which the rider can maintain an unobstructed view
of the road and surrounding area. This measurement in combination
with the leg length is used to determine the rider height
range.
Valve A device that controls fluid flow, direction, pressure,
and flow.
Vertical Support Post: the vertical aluminum post integrated
into the Quest HPV which provides a resting point for the upper
seat support bracket when the seat is in the full back position.
The Post features a bracket with three columns of holes which
function as mounting points for fasteners.
APPENDIX C: SUBASSEMBLY MANUFACTURING DATAThis appendix is a
detailed outline of the JMAC AirRide Seat Design, as represented by
detailed manufacturing drawings. Defined in this section is a
complete list of the subassembly Bill of Materials to indicate
which materials and components were utilized in each one of the
JMAC AirRide Subassemblies.
1.000 .500
.563
Spacer, Teflon
01DO NOT SCALE DRAWING
20-0010SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 2:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
Roundstock, 1ODx0.5IDx0.5625
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
7.500 1.000
1.000
1.000 R.500
.500
4x R.247
12.000 .250
Bar, Locking
01DO NOT SCALE DRAWING
20-0011SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:4 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
Flat Bar, 1x12.50x0.25
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
R.250
.200
.250
Ball, LockRelease Arm
01DO NOT SCALE DRAWING
20-0012SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 4:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
AluminumFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2
.500
R.250
R.625 R.500
1.000
5.000
1.750
1.250
.222
2x .100
1.813
.250
Pivot Arm
01DO NOT SCALE DRAWING
20-0013SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:2 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
Flat Bar 1.25x6.125x0.25
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
1.682
.460
4x R.105 1.250
1.472
.100 1.4
Spring, Pivot Arm
01DO NOT SCALE DRAWING
20-0014SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 2:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
Roundstock 0.10dia
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
2.500
.500
Pin, Locking Arm
01DO NOT SCALE DRAWING
20-0015SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 2:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
Roundstock, 0.5dia
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
R.250
.250
.200
Ball, LockRelease
01DO NOT SCALE DRAWING
20-0016SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 4:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
Aluminum
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2
JMAC AirRide Adjustable Seat Kit
01DO NOT SCALE DRAWING
Final Assem. 1SHEET 1 OF 2
2/22/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:12 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
N/A
N/AFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
ITEM NO. PART NUMBER DESCRIPTION Default/QTY.
1 10-0001 Rear Bracket Assembly Rear Bracket Assembly 1
2 10-0002 Front bracket assembly Front bracket assembly 2
3 10-0003 Seat Assembly Seat Assembly 1
4 10-0004 Locking Bar Assembly Locking Bar Assembly 1
5 10-0005 Pivot Arm Assembly Pivot Arm Assembly 4
6 35-0001-1 Cylinder, Air 1
7 35-0001-2 Piston, Cylinder, Air 1
8 20-0002 Pin, Rear Bracket Locking Bar Assembly 1
9 90302A482 90302A482 MCMASTER CARR 1
10 20-0009 Neoprene, Cushion Neoprene, 0.15in thk 1
11 20-0010 Spacer, Teflon Roundstock, 1ODx0.5IDx0.5625 2
12 33-0003 Washer, Teflon Washer, Teflon, 1ODx0.50IDx0.125 2
13 20-0015 Pin, Locking Arm Roundstock, 0.5dia 1
14 CR-RHMS 0.25-20x0.5x0.5-N Round Head, Screw 1/4-20x0.5 2
01Final Assem. 2SHEET 2 OF 2SCALE: 1:12 WEIGHT:
REVDWG. NO.
ASIZE
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3Drawing View4
Sheet3Drawing View5
4 1 2
56
7
3
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 Preferred Narrow FW 0.25 2
2 33-0003 Washer, Teflon Washer, Teflon, 1ODx0.50IDx0.125 4
3 33-0002 Washer, AluminumAluminum Washer,
0.68ODx0.25IDx0.125 2
4 CR-RHMS 0.25-20x0.5x0.5-N 4
5 20-0001 Bracket, Rear Bracket, Rear 1
6 20-0002 Pin, Rear Bracket Locking Bar Assembly 1
7 20-0003 Pin, Rear Bracket, Cylinder Pin, Rear Bracket,
Cylinder 1
Rear BracketAssembly
01DO NOT SCALE DRAWING
10-0001SHEET 1 OF 1
2/22/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:4 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
N/A
N/AFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3Drawing View4
53
4
2
1
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 20-0004 Bracket, Front Mounting Flat, Bar, 1x5x0.1875 1
2 20-0005 Pin, Front Bracket Round Stock, 0.5Diax0.6875 1
3 Preferred Narrow FW 0.25 1
4 33-0003 Washer, Teflon Washer, Teflon, 1ODx0.50IDx0.125 2
5 CR-RHMS 0.25-20x0.5x0.5-N 1
Front BracketAssembly
01DO NOT SCALE DRAWING
10-0002SHEET 1 OF 1
2/22/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:2 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
3 2
5
8
47
6
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 CR-RHMS 0.25-20x0.5x0.5-N 4
2 CR-RHMS 0.25-20x0.25x0.25-N 8
3 Seat 1
4 Seat2 1
5 20-0006 Bracket, Upper Seat 1
6 10-0006-1 Bracket, Front Right, Seat 1
7 10-0006-2 Bracket, Front Left, Seat 1
8 20-0008 Bracket, Cylinder to Seat 1
Seat Assembly
01DO NOT SCALE DRAWING
10-0003SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:12 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 20-0011 Bar, Locking Flat Bar, 1x12.50x0.25 2
2 20-0012 Lock Release Arm Bar Stock 0.20dia 1
3 20-0016 Ball, Lock Release Arm 1
Locking BarAssembly
01DO NOT SCALE DRAWING
10-0004SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:4 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 20-0013 Pivot Arm Flat Bar 1.25x6.125x0.25 1
2 20-0014 Spring, Pivot Arm Roundstock 0.10dia 1
Pivot ArmAssembly
01DO NOT SCALE DRAWING
10-0005SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:2 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
Bracket, FrontRight, Seat
01DO NOT SCALE DRAWING
10-0006-1SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:2 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3Drawing
View4Drawing View5
5 4 3
2
1
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 20-0007 Bracket, Seat Front Flat Bar, 1x3x0.1875 1
2 20-0005 Pin, Front Bracket Round Stock, 0.5Diax0.6875 1
3 33-0003 Washer, Teflon Washer, Teflon, 1ODx0.50IDx0.125 2
4 33-0002 Washer, AluminumAluminum Washer,
0.68ODx0.25IDx0.125 1
5 CR-RHMS 0.25-20x0.5x0.5-N 1
Bracket, FrontLeft, Seat
01DO NOT SCALE DRAWING
10-0006-2SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:2 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3Drawing
View4Drawing View5
4.000
.500
2x1/4-20 Tapped Hole 0.50"
Pin, RearBracket
01DO NOT SCALE DRAWING
20-0002SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
ALUMINUMFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
3.000
2x1/4-20 Tapped Hole 0.50" .500
Pin, RearBracket, Cylinder
01DO NOT SCALE DRAWING
20-0003SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
AluminumFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
5.000
.500 .250 .250 .500 2.500
4.250
.500 1.000
.188
Bracket,Front Mounting
01DO NOT SCALE DRAWING
20-0004SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONEFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Aluminum, Flat, Bar, 1x5x0.1875
Sheet1Drawing View1Drawing View2Drawing View3
.500
.688 .500
1/4-20 Tapped Hole
Pin, FrontBracket
01DO NOT SCALE DRAWING
20-0005SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 2:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
Round Stock, 0.5Diax0.6875
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
4.250
R.500 .250 THRO. ALL
1.875
3.000
1.000
1/4-20 Tapped Hole
Bracket, UpperSeat
01DO NOT SCALE DRAWING
20-0006SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:2 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
None
AluminumFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3Drawing View4
3.000
.500 THRU. ALL
.333 .500
.500 1.500
2.500
2x 1/4-20 Tapped HoleTHRU. ALL
.188
Bracket, SeatFront
01DO NOT SCALE DRAWING
20-0007SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:1 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
N/A
Flat Bar, 1x3x0.1875
FINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3
3.250
1.000
.750
2.750
R.500
1.125
1.000
2x .250
.750
4x 1/4-20 Tapped Hole
Bracket, Cylinderto Seat
01DO NOT SCALE DRAWING
20-0008SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:2 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
NONE
AluminumFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3Drawing View4
Neoprene,Cushion
01DO NOT SCALE DRAWING
20-0009SHEET 1 OF 1
2/15/15CJB
UNLESS OTHERWISE SPECIFIED:
SCALE: 1:12 WEIGHT:
REVDWG. NO.
ASIZE
TITLE:
NAME DATE
COMMENTS:
Q.A.
MFG APPR.
ENG APPR.
CHECKED
DRAWN
N/A
NeopreneFINISH
MATERIAL
INTERPRET GEOMETRICTOLERANCING PER:
DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE
DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015
APPLICATION
USED ONNEXT ASSY
PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY
OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN
PERMISSION OFJMAC IS PROHIBITED.
5 4 3 2 1
Sheet1Drawing View1Drawing View2Drawing View3