The Design, Construction and Testing of a Human-Powered Moonbuggy Faculty Advisor: Dr. Paul Shiue Industry Advisors: Dr. Paul Shiue Christian Brothers.

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The Design, Construction and Testing The Design, Construction and Testing of a Human-Powered Moonbuggyof a Human-Powered Moonbuggy

Faculty Advisor: Dr. Paul Shiue

Industry Advisors: Dr. Paul Shiue Christian Brothers University

January 31, 2000January 31, 2000

Moon Buggy SquadMoon Buggy Squad

Katie Baxter

Thomas Malone II

Teretha Blackburn

Rob Hartelust

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NASANASA - Authority in Space Research

NASA is deeply committed to spreading the unique knowledge that flows from its aeronautics and space research….

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NASA Sponsors

• High-school and college students develop a human-powered moonbuggy.

• Competitors engineer solutions to similar problems faced by NASA with the lunar rover.

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The Race Is ...

• At Marshall Space Flight Center in Huntsville, Alabama

• On April 8, 2000 (college division only)

• 1/2 Mile in Length with 15 obstacles

5MBMBThe Course Has 15 Obstacles Around The Course Has 15 Obstacles Around

the Space Centerthe Space Center

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Race Conditions Simulate Lunar Surface

• Course consists of a rocky, dusty terrain with 180o

turns.

• Surface may include one or more of the following at each obstacle: – “Craters”

– “Lava” ridges

– Inclines (up to 30o)

– “Lunar” soil, crushed limestone gravel, sand or grass

7MBMBNASA Presents

Design Constraints for Moonbuggy

• Max dimensions unassembled: 4’ X 4’ X 4’

Lunar Rover

• Maximum dimensions assembled: 1.) 4’ width

2.) 15” clearance from passenger to ground

8MBMBThe Moonbuggy Constraint List

Continues

• Maximum allowable turning radius: 20ft

• Seat restraints for each passenger

• No sharp edges or protrusions

• Features: – Simulated T.V. Camera

(2”x3”x6”)

– Simulated electronic controls-radio & display console (1 cubic ft combined)

– Two simulated batteries (4”x6”x8” each)

– 2’ satellite dish

– U.S. flag

– Moon dust abatement device(s)

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Ergonomics Is Addressed

• Combined weight of racers = 350 lbs.

• Max carry capacity per person = 75 lbs.

• Vehicle weight alone = 150 lbs. max

GoalGoal: :

Max combined weight of moonbuggy + racers = Max combined weight of moonbuggy + racers = 500 lbs.500 lbs.

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Scattered Puzzle Pieces

• Chassis Structure

• Drivetrain

• Steering

• Pedals & Seats

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Frame and Chassis Must be Simple but Effective

• Easy to Assemble and Take Apart

• Gear and Drive Train Protection

• Maintain Structural Integrity

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Chassis Material Specified

• Performed static and dynamic loading on chassis component under highest stress (seat support)

• Determined that 2” x 2” x 1/4” 6061-T6 aluminum square tube can withstand these stresses with a safety factor of 10

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Folded Moonbuggy Fits Volumetric Constraint

• After viewing footage from previous races, the necessity of quick race time construction became apparent.

• Moonbuggy squad has developed a way for the chassis to fold in two.

• Caused some design modifications.• Will limit race-time construction to unfolding and putting together chains.

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Internally Geared Hub Chosen Over Derailleur Style Gear

• Internal Hub– chain length remains constant

– housed gears are not exposed to the environment

– easier to mount

– possible to attach brake to exterior of hub

– can shift at a standstill

• Derailleur system– gears are exposed to environment

– chain alignment is very important and difficult to maintain

– interferes with ground clearance

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Total Cost Estimate

• Parts : $1800• Chassis Material : $300 (6061 T-6 Al)

• Labor : $50/hr (2hr w/ certified welder)

• Travel Expenses : $700• Total Cost : $3000

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Short Term Goals Set

• Seek more sponsors• Continue to acquire parts • Finish modeling prototype in ProEngineer• Acquire aluminum tubing and begin chassis

construction

17MBMBTimeline Is Intact For 2000

MonthWeek 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

Gain Corporate Sponsors

Prototype Design & Evaluation

Parts Acquisition & Construction

Working Prototype Evaluation

Prototype Modification

Final Presentation Creation

Race Preparation

Competition Day

Poster

Report Apr 25

April 17

January February March April

April 8

Mar 25

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For Updates on The Moonbuggy Squad

Go to the following url:

1.) http://www.cbu.edu/~tmalone/moon.html

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Any Questions or Suggestions?