Final Report - Calvin College
Contents
1. Cost Simplicity Camber Travel Durability Suspension Type Weight 8 6 4 4 7 total MacPherson Strut 9 8 5 6 6 206 Double Wishbone 8 7 9 7 7 219 Trailing Arm 7 6 5 4 5 163 The team has decided that a double wishbone type suspension will be the most effective solution In order to keep costs low the team fabricated A arms from 1 in square steel tubing The arms are designed so that the front and rear wheels of the vehicle are in line The rear shocks from a Chevy Caviler are used for the front suspension Because the arms are narrow the team decided it was most important for the travel of the front tires to move upward The shocks are mounted so that the vehicle rides with a normal load of a couple of passengers sitting in the front with the A arms at a slight downward angle The front suspension design can be seen in Figure 13 below 19 Figure 13 Front Suspension 3 6 2 Rear The vehicles rear suspension is the leaf springs from the donated Ranger pickup Ranger leaf springs are rated for as much if not more weight than what we will be using it for The mounts for the springs were highly rusted so the team decided that replacing them was necessary 20 to provide a safe product for our customer The rear shock absorbers from the ranger had lost most of their damping power and were rusting out as well so the team also replaced these which can be seen in Figure 14 below Figure 14 Rear Suspension2. Alternative Farming Solutions Vehicle Seth Weaver ME Reuben Swinkels ME Matt Hoogstrate ME Jon Goorhouse ME Ben Byma ME FINAL REPORT ENGINEERING 340 SENIOR DESIGN Copyright 2012 Team 7 and Calvin College Abstract This report summarizes the research and design of a small utility vehicle Alternative Farming Solutions Vehicle also known as Team 7 has chosen the senior design project of building a small low cost durable vehicle for developing countries Team 7 contacted the CRC World headquarters in search of a contact that could act as a customer for the project Davis Omanyo was notified of the opportunity and replied with an immediate need in his hometown in the Samia District of Kenya Davis had a need for a small vehicle that could plant plow and transport produce Team 7 designed and constructed this vehicle with his needs in mind to develop a prototype that will be useful for a particular customer The goal was to design and build the vehicle with parts that are readily available as well as cheap and durable Table of Contents ENGINEERING 340 SENIOR DESIGN wiitesvesssssssivsiincssscencdsccsasveavavessversveatanctassatsscnabieaversssnssintitvacstesaunenss Cop LA lr E Abstract ge eseeteseeeeeeetb ttsancrewaereswalccuataiatusacesitun uch aaavawncauaiedtenuhavauwibcesdeibelevseeuandeanvbeusnaieand iwedntes i Table Re E CN ii Table OF te iv RA T E E A v W ii tt EE 1 1 1 The E td 1 1 1 1 Problem De
3. 3 7 Steering The steering system from the Ford Ranger was initially going to be used for the utility vehicle After the assembly began the team realized that the spindles from the Ford Ranger will not work as planned Therefore the front steering from the Ranger will also not work After front spindles from a Chevy S 10 were acquired the remaining system needed to be designed The steering linkage was designed in autoCAD Different linkages were drawn and constrained to determine turning limits and angles This design can be seen below in Figure 15 21 Figure 15 CAD Suspension Model A manual steering gear box was bought from a local junk yard Tie rod ends from the Chevy S 10 were reused to fit the S 10 spindles Linkages were then designed and built to connect the tie rod ends and the steering gear box The light weight vehicle allowed for the hydraulic booster to be left off The steering setup can be seen below in Figure 16 Ar Figure 16 Front Steering Diagram 22 3 8 Brakes The front brake system was initially going to be reused from the Ford Ranger but when the Ranger spindles were no longer going to be used different brakes were needed Since the new spindles came from an S 10 new calipers and brake pads were bought and attached to the new spindles A non powered brake cylinder was also purchased to power the hydraulic brakes The front caliper brake pads and rotors can be seen below in figure 17 Fig
4. He has also mentioned that a generator high ground clearance and good traction will be important Based on Davis comments for what would be important for a useful farming vehicle the team plans on constructing a vehicle which will abide by these requirements The goal is to construct a vehicle which can be used to drive to a town has a tilt bed will be able to plow and possibly seed will have a generator and will be durable enough to withstand the different environments in which it will be used 1 2 Design Norms 1 2 1 Cultural Appropriateness One of the team s primary concerns was making sure the design was appropriate for the culture in which it would be used This was done by considering what materials we used what fuel type we pick and what emissions we produce The parts and materials will need to be available in case repairs or replacements are necessary The fuel type must be readily available otherwise the design becomes inoperable The vehicle needs to be safe to drive and not produce hazardous emissions that will hard operators or bystanders 1 2 2 Integrity Trust Another important design norm the team considered was integrity throughout the design this was done by incorporating a simple yet useful design The utility vehicle will be easy to use without any issues This will help insure the trust between the recipient and donating organization The design will be tested to guarantee proper functionality of every compon
5. The completed schedule can be seen in Appendix section 7 2 The schedule for the final half of the project has a multi level approach so that multiple tasks can be worked on at the same time 2 2 Budget The team has been asked by our recipient for a few specific vehicle operations These vehicle operations include planting plowing and transporting produce Implementing these operations has caused the team budget to be higher than what was provided The team was initially given 500 for the vehicle and applied for a higher budget The approved budget was 2350 The current projected costs of the vehicle can be seen below in Table 1 Table 1 Vehicle Costs Frame Donated Tires Donated Drive Driven Clutch 327 85 Transaxle 375 00 Winch 99 95 Front Struts 209 19 Drive Belts 32 70 Plow 249 00 Bearings 20 00 Steel 2 x 2 83 74 Brake Cylinder 36 65 16 000 Lb Pulley 25 45 Golf Cart Seat 135 00 3 Project Specifications 3 1 Design Summary 3 2 Engine 3 2 1 Alternatives There were many different things that the team needed to consider when looking into an engine for the vehicle The main constraint for the engine was cost The goal for the team is to come up with a low budget utility vehicle Previous groups who actually entered into the BUV competition would be given a 10 horsepower diesel engine The team decided that since this particular vehicle was supposed to plow in addition to meeting most specifications of the
6. 9 Research Engine Possibilities 2 days 11 3 2011 11 4 2011 8 8 00 17 00 10 1st Verbal Presentation O days 10 21 2011 10 21 2011 8 00 8 00 11 Make Project Website 8 days 10 17 2011 10 26 2011 8 00 17 00 12 Project Website O days 10 26 2011 10 26 2011 8 00 8 00 13 Preliminary Designs Computer 6 days 10 19 2011 10 26 2011 8 00 17 00 14 Research Generator Heads 5 days 10 31 2011 11 4 2011 8 00 17 00 15 Research Design Plow Idea 5 days 10 31 2011 11 4 2011 8 00 17 00 16 Research Design Bed Lift System 5 days 10 31 2011 11 4 2011 8 00 17 00 17 Industrial Consulting Meeting 9 days 10 26 2011 11 7 2011 8 00 17 00 18 Updated Project Poster O days 11 9 2011 11 9 2011 8 00 8 00 19 Rough Stress Strain Calculations 3 days 11 7 2011 11 9 2011 13 14 15 16 8 00 17 00 20 Cost Estimate Calculations 5 days 11 7 2011 11 11 2011 9 14 15 16 8 00 17 00 48 21 Preliminary Cost Estimate O days 11 11 2011 11 11 2011 8 00 8 00 22 Determine Frame 3 days 11 10 2011 11 14 2011 19 5 15 16 8 00 17 00 23 Design Gearing Mechanisms 3 days 11 10 2011 11 14 2011 5 14 8 00 17 00 24 Write PPFS Rough Draft 10 days 11 1 2011 11 14 2011 8 00 17 00 25 PPFS Rough Draft O days 11 14 2011 11 14 2011 8 00 8 00 26 2nd Verbal Presenation O days 11 30 2011 11 30 2011 8 00 8 00 27 Further Necessary Calculations 10 days 11 15 2011 11 28 2011 24 8 0
7. complete details of frame stress calculations A summary of the maximum stresses and safety factors for given scenarios can be seen in Table 4 28 Table 4 Summary of Stress Calculations Scenario Max Stress Safety psi Factor Distributed Load across 3ft 33750 1 067 Distributed Load across 2ft 22500 1 6 Typical Load across 3ft 10120 3 556 Typical Load across 2ft 3000 12 The team s design called for much of the frame to be welded together at various points In order to ensure that the welds are strong enough to support the payload of the vehicle the team did weldment calculations The same assumptions were made as previous about dynamic loading The team also assumed an unrealistic worst case scenario for the weldment calculations to be sure that the welds would meet the design specifications The assumption was the entire load acting on a single beam in a cantilever type arrangement and includes torsion Based on published data by the American Welding Society AWS specific to the chosen material and the calculations performed the welds can be no smaller than 1 8 wide and can go up to 2 7 wide Again the upper limit is unrealistic but shows that the material selected is strong enough for the application Complete calculations for the weldments can be found in Appendix7 1 2 3 11 Plow 3 11 1 Alternatives Harrows are another type of plow Many times tractors pull many of these at once In man
8. gauge the vehicle s capabilities as built With the winch only tacked in the lift system was tested to determine if it would sufficiently lift the bed While the winch was strong enough to lift the bed the team confirmed previous thoughts that the mounting hardware should be stronger After an FEA analysis of an alternative mount yielded better results this new system was implemented Once the vehicle was constructed to a point where it could roll on the ground a test drive was completed in the parking lot behind the Engineering Building This test helped to determine some minor adjustments that must be made for the vehicle to operate properly The team noted that the belt connecting the jackshaft to the transmission was slipping quite dramatically To solve this issue the team ordered a chain and sprockets that would provide better driving The vehicle traveled slower than anticipated as well This was somewhat attributed to the slipping of the belts To help with this the sprockets that were ordered will allow the vehicle to travel slightly faster Some of the completed tests are 36 Plow Test The plow test was done in order to ensure correct plowing depths and overall usefulness of the plow The vehicle was brought to a field with different soil types to test the functionality of the plow The first plow test was done in soft soil The test went really well as the plow was able to overturn the dirt as necessary When the plow was put into
9. hydrostatic transmission was not used for much of the same reason Hydrostatic transmissions run off hydraulic fluid which gets pressurized from a pump which would be run off the engine power Again maximum power was needed by the engine to drive the vehicle The team also wanted to minimize problematic options on the vehicle Having hydraulics on the vehicle would increase the probability of problems A hydrostatic transmission can be seen in Figure 8 11 http http adaptiveblue img s3 amazonaws com topics p manual_transmission small 12 PF oO Ep o o D Lo a O a gt O o Oo 3 oO Ep p ao ES Lo LA O Lo d i j O Q E EN er S y Lo 3 Lo 2 O 3 oO E E 1 4 Oo la SC Figure 8 Hydrostatic Transmission Other utility vehicles were also looked into Many of these transmissions are continuously variable The team did not use this type for many reasons Overall the cost was the determining factor that led the team to reject this type of transmission 3 3 3 Cost 3 3 3 1 Lawn Mower Transaxle The cost of a lawn mower transmission varies greatly depending on the year size hours of use and model of transmission Most lawn mower transmission cost between 150 and 400 3 3 3 2 Car Transmission Car transmissions vary in price due to mileage and type Most of these transmissions vary from 300 to 2000 3 3 3 3 Hydrostatic Transmission Hydrostatic transmissions vary
10. in price due to the year size hours of use and model These transmissions vary from 175 to 200 http www fordfalcon2000 com cgi bin pic p id T52 13 3 3 4 Transmission As requested by Davis Omanyo the utility vehicle will be used to plow plant and transport produce To do this a transmission will be required to transmit power in different gear ratios for the different applications A low gear will be required for plowing while higher gears are required for driving at higher speeds To plow at 2mph a total reduction of 30 1 will be needed To drive at 20 mph a reduction of 3 1 will be needed The range of gear ratios required has been hard to find These calculations can be seen in Appendix 7 1 4 The team looked into many different transmissions and finally found that the best transmission for the project is the type used by a riding lawn mower These transmissions are typically 5 or 6 gears along with a reverse gear This transmission can be seen below in Figure 9 The chosen transmission was a Peerless transmission with 6 forward gears and a reverse gear It is designed for 18 horsepower engines and will thus be strong enough for our 15 horsepower engine Figure 9 Lawn Mower Transaxle The final gear ratios along with corresponding speeds will be determined after exact components are bought Ideally the vehicle will plow at 2 mph and will carry produce at 20 mph 14 http www onlineauction com index php p
11. previous BUV teams a bigger engine would be desirable The first thing that was researched was fuel availability The findings were that both gasoline and diesel fuels were fairly readily available in most of rural third world countries This opened up the potential for either engine Since diesel engines are known for producing more torque this was the first possible option the team looked into This was a good option for the vehicle because the engine would produce more torque than the gas equivalent engine which is beneficial for plowing as well the diesel fuel is slightly more easily accessible The primary diesel engine of interest was the Kohler KD425 2 seen in Figure 1 Figure 1 Kohler KD425 2 18 8 Horsepower Diesel http robotics caltech edu mason ramblings dieselTorque html gt http www kohlerengines com onlinecatalog productDetail htm productNumber KD425 2 6 The KD425 is an 18 8 horsepower diesel air cooled engine This engine was in the desired horsepower range and was diesel which was important because of the torque assumption previously made In order to determine the type of gearing needed for plowing and for the generator the team needed to find the actual torque the engine created The power curve for this engine can be seen in Figure 2 Figure 2 Power Curve for Diesel Kohler Engine The torque of the engine with respect to engine rpm can be seen in the red MN line This shows that a
12. the possibility of using this engine The specific engine is the Kohler CH15 and can be seen in Figure 4 Figure 4 Kohler CH15 15 Horsepower Gas Engine This 15 horsepower gas engine was slightly different than the previous engines It obviously had slightly less horsepower and was only one cylinder instead of two The weight and dimensions were similar to that of the CH620 This engine produced a peak torque of 24 8 ft Ibs at 2400 rpm Although this was less than the 18 horsepower engine the team decided that with the correct gearing and the slow speed at which plowing is done that amount of torque would be more than adequate The final engine selected for use was the Kohler CH15 It was selected because it fit the criteria needed for an engine discussed above The fuel type gas was readily available in most rural places the torque would be sufficient for plowing and transportation and most importantly the cost was minimal 3 3 Power Transmission System 3 3 1 Clutch To transmit power from the engine to the transaxle a centrifugal clutch will be used There are many different types of centrifugal clutches available to the public The most common of these clutches are Comet Clutches The team has decided to use a series 40 Comet Clutch These clutches are designed for 8 18 horsepower engines The comet 40 series clutches engage at 1600 rpm s which will fit the Kohler 15 horsepower engine perfectly This clutch system
13. 0 48 Update Team Description for Banquet O days 4 13 2012 4 13 2012 8 00 8 00 49 Plumb Brake Lines 2 days 4 10 2012 4 11 2012 47 8 00 17 00 50 Build Seat Frame 3 days 4 18 2012 4 20 2012 38 8 00 17 00 51 Attach Steering Box 2 days 4 12 2012 4 13 2012 49 8 00 17 00 52 Attach Steering Column 2 days 4 16 2012 4 17 2012 51 8 00 17 00 53 Attach Seat 1 day 4 18 2012 4 18 2012 52 8 00 17 00 54 Draft Design Report O days 4 23 2012 4 23 2012 8 00 8 00 55 Mount Gas Tank 3 5 days 4 23 2012 4 26 2012 50 44 8 00 12 00 56 Construct Plow System 3 days 4 27 2012 5 1 2012 55 8 00 17 00 57 Submit Poster O days 4 30 2012 4 30 2012 8 00 8 00 58 Testing 8 days 4 23 2012 5 2 2012 8 00 17 00 59 Optimizing 2 days 5 3 2012 5 4 2012 58 8 00 17 00 60 Senior Design Night O days 5 5 2012 5 5 2012 59 8 00 8 00 61 Reworking 5 days 5 7 2012 5 11 2012 60 8 00 17 00 50 6 4 Suspension Parts Part Number 32296 Print this page Close View larger image Product Specifications Subject to Change Without Notice Compressed rengn em y GE Dust shield Extended Bumper Stop Extended Hydraulictockot 1 y Compressed Hydraulic lockout to Compressed Bumper top he 51
14. 0 17 00 28 Write PPFS Final Draft 5 days 11 29 2011 12 5 2011 24 27 8 00 17 00 29 PPFS Final Draft O days 12 5 2011 12 5 2011 8 00 8 00 30 Work on Design Memo 7 days 12 1 2011 12 9 2011 8 00 17 00 31 Preliminary Design Memo O days 12 9 2011 12 9 2011 8 00 8 00 32 Aquire Parts 60 days 11 9 2011 1 31 2012 8 00 17 00 33 Deconstruct For Vehicle Parts 5 days 1 9 2012 1 15 2012 8 00 17 00 34 Construct Frame 10 days 1 16 2012 1 27 2012 33 8 00 17 00 35 Begin Vehicle Assembly 20 days 1 30 2012 2 24 2012 34 8 00 17 00 36 Construct Gearing Mechanism 10 days 2 27 2012 3 9 2012 35 8 00 17 00 37 Various Tasks 10 days 3 12 2012 3 23 2012 36 8 00 17 00 38 Basic Vehicle Construction complete O days 3 26 2012 3 26 2012 8 00 8 00 39 Cut Drive Shaft Build 3 days 3 26 2012 3 28 2012 38 8 00 17 00 40 Cut Drive Shaft Adapter 1 day 3 26 2012 3 26 2012 38 8 00 17 00 41 Cut A arms 1 day 4 2 2012 4 2 2012 8 00 17 00 42 Assemble A Arms Mounts 3 days 4 3 2012 4 5 2012 41 8 00 17 00 43 Make Shift Lever 1 day 3 26 2012 3 26 2012 36 38 8 00 17 00 44 Construct Lift Bed System 10 days 3 26 2012 4 6 2012 37 49 8 00 17 00 45 Exectuvie Summary For CEAC O days 4 4 2012 4 4 2012 8 00 8 00 46 Attach Winch 2 days 4 4 2012 4 5 2012 34 38 45 8 00 17 00 47 Attach Brake Booster 2 days 4 6 2012 4 9 2012 42 8 00 17 0
15. age auction view_item amp auction id 1040252 14 3 4 Final Drivetrain Design The final design for the drivetrain can be seen in the following image Figure 10 Mounted Drivetrain The comet clutch detailed above was connected to the driveshaft of the engine via the driving clutch which was keyed and bolted in place This connects to the driven clutch via a V belt The driven clutch is mounted on a jack shaft that spins on two bearings The driven clutch is keyed in the jack shaft and is held in place with collars Also keyed onto the jack shaft is a sprocket which is connected to a sprocket on the transaxle via a chain see below picture for chain updated chain drive discussed above A better view of this connection can be seen in Figure 11 below 15 Figure 11 Mounted Transaxle and Driveshaft The power is then transferred from one of the axles of the transaxle to the driveshaft of the old ford ranger reduced in size A plate was machined and welded onto the axle to connect the driveshaft The other axle coming out of the transaxle was held in place using a collar and welding it in place From the driveshaft the power goes through the Ford Rangers rear differential and two the wheels 3 5 Tilt Bed One of the very useful options desired for the vehicle was a dumping bed Many commercial vehicles feature this type of system and its possible applications are highly desirable for agricultural use Most modern systems featu
16. connected through the key switch so they are always on when the vehicle is running and the brake bulb is connected through a switch on the brake pedal http www kohlerengines com onlinecatalog pdf tp_2402_a pdf 26 Aan keyswitch Ss 2 ENE starter 12Vdc Figure 21 Wiring Diagram for Lights 3 10 Frame The frame of the bed rests on the existing frame of a donated Ford Ranger The rear half of the Ranger frame is used for the project as seen in figure 22 and the front was recycled The front frame section was custom fabricated from 2 x 2 square steel tubing with 1 8 thick wall as was the bed frame This material was selected because of its availability strength and ease of fabrication The floor of the bed was made from 6 x 34 wooden planks to keep weight low and will measure 6 x 5 27 Figure 22 Rear Frame The design goal for payload was 1500 pounds of static loading In the calculations a dynamic load was estimated to be at least twice the static load for example going over a large bump and the entire load bouncing up and coming down the calculations used a dynamic loading factor of 2 5 The calculations show several worst case of the full load distributed to one frame member of two different lengths and as a cantilever type loading for the same two lengths to demonstrate safety factors The final calculations show safety factors for a more typical loading See Appendix 7 1 1 for
17. ections This does not account for any horizontal forces that get applied to the bed frame or mounts If the vehicle hit a tree or rolled sideways the bed could crack the mounts if they are not strong enough The mounts need to be analyzed in different forces also The last item that team 7 would like to suggest is that the design for the whole vehicle should be done before the construction is started Many changes in team 7 s design needed to be changed as a result of starting to build before the design was done Many of the drawings of the 39 vehicle also needed to be changed because of this Specifically the front end of the vehicle was changed many times due to this fact If the entire design was done for a specific region of the vehicle before construction started the process would have gone much smoother 5 2 Final Prototype The team worked hard throughout the year researching designing and building By doing these three things and combining all the design decisions together the team is proud of the prototype that was built The vehicle can be seen in Figure 29 below Figure 29 Final Prototype 5 3 Conclusion With the design of the vehicle complete and a final prototype fully constructed the team is happy with the work that was achieved this year The team hopes the vehicle will find its way to a mission organization where the vehicle will be put to good use Details have not been finalized but the team has seen a lot
18. ent as well as include an operator s manual 13 The Team The team is composed of five mechanical engineering students Seth Weaver Ben Byma Reuben Swinkels Matt Hoogstrate and Jon Goorhouse All team members have different skills and backgrounds which gives a well rounded team Seth has a strong automotive background and will be a great contribution to the physical build of the vehicle Ben is very interested in design and calculations and will be a great contribution to the design and trouble shooting of the vehicle Reuben has a good knowledge in the concepts of what needs to go into a vehicle as well 2 as an interest in problem solving which will be useful in the design and build Matt has experience in electrical wiring and will be able to contribute to the necessary electric engineering and design associated with the project Lastly Jon is very well versed with computer engineering software He will be a good contribution to the design of vehicle the calculations involved and with maintaining and updating the project website 1 4 The Class This senior design project is the final project and capstone to the engineering program at Calvin College This design project is part of the Engineering 339 fall and Engineering 340 spring senior design classes at Calvin In addition to designing and building this vehicle the class has different lectures that prepare the team for the work that needs to be done on the project b
19. equently under extremely dusty dirty conditions 2Only required for Denso starters Not necessary on Delco starters Have a Kohler Engine Service Dealer perform this service Figure 30 Manufacturer Recommended Maintenance 6 1 1 2 Vehicle Components The vehicle should be checked over before each use to be sure it is in good operating condition The tires should be inflated to the pressure required on each tire The winch should be maintained using the following guidelines 1 BEFORE EACH USE inspect the general condition of the winch Check for loose hardware misalignment or binding of moving parts cracked or broken parts damaged electrical wiring corroded or loose terminals and any other condition that may affect its safe operation Examine the wire rope Do not use the winch if the wire rope is frayed kinked or damaged 2 AFTER USE wipe external surfaces of the winch with clean cloth 41 3 Lubricate the wire rope occasionally with a light oil 4 Every six months separate the Left and Right Shells 4 amp 60 to grease the Gears 19 23 28 36 Use any good quality waterproof gear grease 5 If the unit becomes wet during use separate the Left and Right Shells 4 amp 60 dry all parts then grease and lubricate as in steps 3 and 4 above 6 Do not pull battery wires against any surfaces which could damage them 7 If the winch is permanently mounted periodically remove and clean wire connections to the batte
20. ese types of vehicles need the power capabilities of a small tractor yet the traveling speeds of a small car These vehicles can be used on the farms bringing people back and forth from town or used to transport produce and materials Some of the important attributes these vehicles need to fulfill include integrating a small plow for use in the fields having a tilt bed for carrying produce etc and possible additional features such as seeding machinery Price size weight fuel and usability are some of the many constraining issues which the team faces The team is designing and fabricating a vehicle to meet the specifications and requirements determined from an actual customer 1 1 2 Customer Solution To find this customer the team went to the CRC Global Headquarters After a quick search of all the ministry areas there was a need found in Eastern Africa Specifically there was a need in the Samia District of Kenya Davis Omanyo is the main contact in that region Davis is the CRWRC team leader in Eastern Africa and has an immediate need for this type of vehicle He runs a small demonstration farm in his hometown of the Samia District of Kenya Here he currently teaches women how to plant maintain and harvest amaranth He would like to expand this operation to grow maize corn millet sorghum peanuts ground nuts beans and peas Davis has made it clear that he would like this vehicle to be able to plant plow and transport produce
21. has a primary driving clutch and a secondary driven clutch The secondary clutch will be mounted on a jackshaft which transmits power to other pulleys located on the jackshaft The power will then be transmitted to a transaxle The clutch setup can be seen below in Figure 5 8 http www kohlerengines com onlinecatalog productDetail htm productNumber Command 20PRO 20CH15 C H450 http www gokartsupply com 4044seri htm 10 0 Figure 5 Clutch System Setup 3 3 2 Alternative Transmissions The team also looked into other alternatives Some of these alternatives included transmissions from small cars and hydrostatic transmissions from lawn tractors other utility vehicles and golf carts go carts The main reason that none of these types of transmissions were used was size and cost The reason that a small automatic car transmission was not used was because of the power required to run an automatic transmission To be able to cover the needs of the vehicle there needed to be minimum power loss in the transmission The reason that a manual car transmission was not used was because of the clutch setup The team focused on ease of use Therefore teaching others how to operate a clutch was out of the question A picture of an automatic and manual transmission can be seen below in Figure 6 and Figure 7 respectively 1 http www hoffcocomet com EpiphanyWeb flexpage aspx ID 75 11 Figure 7 Manual Transmission A
22. ia REENEN 14 Mounted Drivetrain EE 15 Mounted Transaxle and Driveshaft AAA 16 Winch Mounted to ROU Carece liniers lante 17 Front SUSPENSION ss ssecsetei ches lees eid ees ea ees Gen hee EE ee 20 Rear SUSPENSE AAA TA 21 CAD Suspension Model ies a eles eee EEN 22 Eront SteermeDiasraMiecnnistnd tii ENEE REESEN 22 ein ET EE 23 Rear Dium Brakes sde msn E EE E R EE EE E E E A E a a 24 Brake BOOsStO siii iria iaa li REEE EENES 25 Engine Wiring Di famM ini als 26 Waring Diagram tor Light mii A a A AAA Ed 27 Rear Frame nina A 28 HarrowPlo Wim lat 30 Potato Eloge eebe Le ee dee tee ee 31 Chisel A EEN Eier ieder 32 Single Bottom Plow Attachment icis enrenar neee E EE EO NEE EE RER 33 Pivoting Drop Seed Plate ui ea eel eet ee i ies 34 Engine Mount for Testing A A A A 35 Final ProtOt Persia A A lta SEA 40 Manufacturer Recommended Mantenance conan con ncrnnccnnc ns 41 Wanch Assembly and Partida id A id 42 iv Table 1 Table 2 Table 3 Table 4 Table 5 Table of Tables Vehicle Costs aoe e e Bet EN E eek a in 4 Decision Matrix for Bed Lift System neiii iis ee ei EEEE EREE REA eE 18 Decision Matrix of Front Suspension Option 19 Summary of Stress CalculationS oo oooooonocnocnnoccnrenonnenanccononno nono EERE RE EE E EEEREN TEE EERE ER 29 Work BreakdO Wisin iii 48 1 Introduction 1 1 The Project 1 1 1 Problem Definition In many third world countries there is need for small inexpensive all terrain vehicles Th
23. lations n 4 number of leaves E 1350 1bf L 25 in b 2 5 in width t 0 375 in thickness Tp 36 ksi bending stress 2 n b t Ty 65 ksi G r FS 1 806 Th 46 6 2 4 Driveshaft Calculations Drive Shaft RPM Calculations For Desired Speed User Defined Calculations Cire 3 14159 Diameter 78 54 Si a 63360 3 TireRPH een 242x 10 Circm TireRPH 3 La 3 TireRPM 403 36 dsRPM TireRPM gr 1 654 x 10 47 Wanted Miles Per Hour Tire Diameter In Inches Rear End Gear Ratio Tire Circumference In Inches Tire Circumference In Miles Tire Revolutions Per Hour Tire Revolutions Per Minute Drive Shaft Revolutions Per Minute 6 3 Work Breakdown Table 5 Work Breakdown Task Task Name Duration Start Finish Predecessors Number 1 Determine a Client Organization 3 days 10 17 2011 10 19 2011 8 00 17 00 2 Determine Location 3 days 10 17 2011 10 19 2011 8 00 17 00 3 Research Location 3 days 10 20 2011 10 24 2011 2 8 00 17 00 4 Determine Needs 5 days 10 20 2011 10 26 2011 1 8 00 17 00 5 Determine Vehicle Capabilities 2 days 10 27 2011 10 28 2011 4 8 00 17 00 6 Scheduled WBS O days 10 17 2011 10 17 2011 8 00 8 00 7 Research Fuel Availability 2 days 10 20 2011 10 21 2011 2 8 00 17 00 8 Determine Engine Requirements 3 days 10 31 2011 11 2 2011 5 7 8 00 17 00
24. lifted 6 1 2 3 Plowing In order to operate the plow the operator must attach the plow to the rear of the vehicle using the supplied attachments The plow should attach by two plates bolted to the square hitch receiver and to a piece of square tubing on the passenger side of the bed Insert pins in the end of the pipe to ensure that the plow does not detach itself during operation Detach the winch cable from the bed and let out enough line to allow it to be attached to the ring located at the top rear of the plow frame Use the winch to lift the plow above the ground while driving When ready to plow simply lower the plow using the winch until the line is no longer tight and begin driving forward The vehicle should be in first gear while plowing Once the end of the furrow is reached lift the plow out of the ground using the winch and turn the vehicle around to start the next furrow Repeat this process for all furrows 43 6 1 2 4 Planting In order to plant seeds with the vehicle the operator must attach the planter to the rear of the vehicle by inserting the base into the square hitch receiver While one person slowly drives the vehicle another person should sit in the bed and drop seeds into the opening near the top of the pipe while aiming the base of the pipe to the appropriate location 6 2 Calculations 6 2 1 Bed Frame Analysis Payload of 1996 Ford Ranger is 1654 Ibs Design ASFV for payload of 1500 lbs Using 2x2 in 1 8 i
25. maximum torque of 42 Nm or 31 ft lbs is obtained at roughly 2200 rpm This gave the team a good idea of what was to be expected out of a diesel engine around this size The next option the team looked into was a comparison to the gas engine The team looked into similar brands and similar horsepower engines to try to eliminate factors such as differences in quality builds in manufacturers that might give a bad http www kohlerengines com onlinecatalog pdf kd425_2 pdf 7 representation of the differences in engines For the gas engine the team looked at the Kohler CH620 gas engine seen in Figure 3 Figure 3 Kohler CH620 18 horsepower Gas Engine This 18 horsepower gas engine is very similar in size to the 18 8 horsepower diesel Kohler engine They both are air cooled horizontal drive and 2 cylinder engines The sizes are similar but the weights are slightly different This aluminum block engine weighs about 90 lbs which is about 50 lbs lighter than the iron block diesel engine P Although this difference in weight would have an overall effect on the vehicle it does not have a direct effect on the horsepower or torque the engines would put out The power curve for this engine could not be found however the peak torque was still given The gas engine put out 32 2 ft lbs at approximately 3600 rpm which is actually more than the diesel engine which had 0 8 more horsepower Although the engine would be running at a highe
26. ms were built and attached to the frame the team noticed that the short a arms didn t allow much suspension travel The suspension was also first assembled in a way that didn t allow the suspension to work properly In order for the double a arm configuration to work properly the length between ball joints and the length between pivot points on the frame needs to be equal This creates a parallelogram in which the tire can move straight up and down When the suspension was originally fabricated these lengths were not correct making the wheels have the wrong camber The next item that team 7 would suggest is chain clutches instead of belt clutches Even though the comet clutches fit the designed needs of the vehicle they are not sufficient for the uses of the vehicle On flat ground unloaded the clutches work well When the engine has any extra load the belts begin to slip Leaving the vehicle in a low gear helps decrease this problem On the other hand having chain clutches would rid this problem completely There are chain clutches that would fit our 1 inch OD shaft with a 1 4 inch keyway These clutches can also be configured to engage at 1600 rpm like the current clutches The chain clutches are also cheaper This change would allow the vehicle to operate with no problems while plowing driving in higher gears and climbing hills The bed also needs to be analyzed in different ways The only way the bed was analyzed was in vertical dir
27. n wall thickness square steel tubing Oy 36000psi Potatic 15001bf 3 Paynamic ZIP ratie 3 75x 10 1bf For 3ft distance between supports distributed load Lbeam3f 36in Paynamic lbf Fa oe E distributed3 ft Lbeam 3 an y 1 0in I 0 Sin 2 aan y ei max 3ft 8 1 3 375x 10 psi 1 067 44 For 2ft distance between supports distributed load Lpbeam2f 24in Paynamic lbf Egistributed2 y 156 25 beam21f in 2 CA y 2 25x 10 psi 8 1 Omax2ft 7 o 1 6 Notzt Omax2ft Typical Loading for 3ft Se Paynamic Farea S 0 868psi 30 7 2 9 4 es lbf Ge 3 ft ft 2 Ce eer y 8 1 Fiypical3f A Otypical3ft 1 012x 10 psi CO y 8 Ns Ftypical3 3 556 Otypical3 ft Typical Loading for 2ft 2 a B It 2ft z i 2 Cc y 8 1 Eiypical24 oe Stypical2f 3x 10 psi y _ 12 Otypical2f Ns Ftypical2f 45 6 2 2 Weldment Calculations Weld Size Tallowable 2 100 si Throat FR t 1 955in Tallowable Weld ibl ith all fi i le Worst possible case with all force exerted at point on the end of beam Not entirely a realistic scenario Based on these calculations and regulations published by the American Welding Society weld size should be a minimum of 1 8 in and a maximum of 2 765 inches 1 lt w lt 2 76 8 6 2 3 Leaf Spring Calcu
28. nnion aiden aa 1 1 1 2 Customer S Oli a cdi 1 1 2 Design NOMI iran EEN 2 1 2 1 Cultural ee Lee NEE H 1 2 2 tec Trust dione A A AAS deet 2 L A ie ta ited ace Secale eee Sense peaches 2 WA The O E 3 1 5 Acknowledgements mmm 3 2 Project Management a A didnar dienin aiani siaaa anaran adnata 4 2 1 So is 4 SE A A e deduce bedosaslatdtecncvestecresieteenvbedeegtecdes 4 3 Project Specifications cnn a 3 1 DO UA laica A A AAA A A nn A 3 2 1 EK 3 2 2 Selected Em QM iirin 3 3 Power Transmission System nc 3 3 1 Oe E 3 3 2 Alternative Transmissions csssecscssssessessescesessessesessescesesseasesessensesesseaseiesseesesesseaseiesseaseiesseaseissneasenesneaseaes 3 3 3 Cda a a 3331 Lawn Mower Tras ale A a ci 3 3 3 2 Car Tra sMiSSi paikoin a ea i 3 3 3 3 Hydrostatic Transmission 3 3 4 BR EE EE 3 4 Final Driy train DO EE A ur Bed eek cea essed ech a a Ta d ee aaea ae a aae aa aa ai aiaa e a Oa aaaea eaan SA n E a AA 3 6 1 Epos 3 6 2 Restart Eeer EE 3 7 Steeriug eebe EENS EE SCH Brakes tee 3 9 Electrical Systems ee See eEeeh e EE ESEeEEEeE 3 9 1 Se Ke e 25 3 9 2 AA AA A eens orks 26 3 10 Frau ee EEN EE ee 27 S KWR PV EE 29 3 11 1 AMAIA ES Ee EE AE EEN 29 JIL Selected How EEN au 32 3 12 EU ECH 33 4 Testi aida 35 5S Project SUMMATY Eege e 39 5 1 Future SUS SOCSUIONS eege EEN 39 5 2 TEMA TOO a 40 5 3 Conclusion iaa dada 40 6 EDEGEM ea ee ne 41 6 1 Maintenance amp User Manual s ss
29. of interest from people in the community The team is glad that our design will be able to be put to use and hope that along with the operating manual it will have many years of service for a good cause Although there were many times throughout the year that it seemed like we would never make it to the end through hard work and dedicated team work our final design and prototype have come together 40 6 Appendices 6 1 Maintenance amp User Manual 6 1 1 Maintenance 6 1 1 1 Engine The engine of the vehicle should be serviced regularly Check the manufacturer s specifications for specific service recommendations and instructions The oil used for this engine is 10W 30 The following are a summary of but not complete list of regular engine maintenance Maintenance Required Fill fuel tank Daily or Before Check oil level Starting Engine Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary Every 25 Hours e Service precleaner element Every 50 Hours Check gear reduction unit Replace air cleaner element Every 100 Hours Change oil Remove cooling shrouds and clean cooling areas Change oil filter Every 200 Hours Check spark plug condition and gap Replace fuel filter Annually or Have bendix starter drive serviced Every 500 Hours Have solenoid shift starter disassembled and cleaned Perform these maintenance procedures more fr
30. power to pull through the ground Since the engine that will be used on this vehicle is only 15 horsepower only a single bottom plow can be used These types of plows are also called furrows Along with overturning the dirt furrows create a long narrow trench used for planting and irrigating This is the type of plow that was chosen to be used on the vehicle The single bottom plow that the team used was attached to the vehicle through a detachable 2x2 square tube mounted to the underside of the tilt bed The initial design for the plow lift system was for the plow to be engaged into the ground using the pivoting action of bed lift via the winch After testing 1t was determined the angle obtained from the bed was not sufficient and a different system had to be used Currently the system in place uses the same underside mount as well as a metal tube that connects to the hitch that the plow can pivot on The winch from the bed can then be detached and attached to the plow and used to lower and raise the plow A picture of this system can be seen in figure 26 below 2 http www ytmag com cgi bin viewit cgi bd ttalk amp th 409735 32 Figure 26 Single Bottom Plow Attachment 3 12 Planter The planting system was quickly mocked up as a demonstration of a type of seeding device that could be used Although the exact method of seeding that would be required was unknown the team developed a type of planter that could adapt to differen
31. pumped building up pressure The tires then slid on the ground which meant it had passed the braking test Payload Test This test was quite simple The goal of this test was to see if the vehicle and its bed could withstand its 1600 lb payload In order to do this 1600 lbs were placed on the vehicle which was then driven for a short period The results of the test showed that the vehicle was able to withstand the weight without any problems 37 e Bed Lift Test The bed lift test was designed to test the winch bar along with the winch and bed 1200lbs were evenly distributed throughout the bed When the bed was fully loaded the winch raised the bed to 35 degrees off horizontal The bed was then lowered back to the original position The winch and the winch bar along with the bed structure withstood the forces that were present This test passed With these tests performed the team is confident that the vehicle has passed the quality standards that we have set for the final prototype of the vehicle 38 5 Project Summary 5 1 Future Suggestions After building the alternative farming solutions vehicle Team 7 would like to give suggestions to any future team that might build something similar to this First off the front a arms must be longer The a arms were designed to keep the front and rear tires in line with each other The front frame was designed to come straight forward from the existing Ford Ranger frame Once the a ar
32. r rpm this showed the team that in these smaller engines the diesel engine did not necessarily produce more torque This was a 5 http www kohlerengines com onlinecatalog productDetail htm productNumber Command 20PRO 20CH18 C H620 http www kohlerengines com onlinecatalog productDetail htm productNumber KD425 2 7 http www kohlerengines com onlinecatalog productDetail htm productNumber Command 20PRO 20CH18 C H620 8 large surprise which took away a large factor of why the diesel engine would be more suitable for this project The last thing done to compare these engines was looking at the cost This ended up being the major deciding factor of what engine type was chosen Most new diesel engines around 15 20 horsepower would cost approximately 3000 5000 When looking into gas the team found that new engines of the same horsepower would range from 1500 2500 This was a significant difference in price that the team could not overlook However since the team only has an initial budget of 500 and is trying to make the vehicle as low budged as possible a different alternative was found 3 2 2 Selected Engine Based on the investigations of the diesel compared to gas engines it was clear that gas has no large disadvantage for this project Therefore when the team received the information that the Calvin College Engineering Department had a 15 horsepower Kohler gas engine that could be donated the team investigated
33. re a single hydraulic piston acting either directly on the bed frame or indirectly via a scissor lift frame Other possible systems feature a winch or crank system The major advantage of a hydraulic system was the amount of power it could deliver to raise the bed Its disadvantages were its overall cost and complexity The two winch systems considered were a tower boom type lift and a scissor lift The tower boom would feature a winch or crank mounted at frame level with cable running up to a pulley on the roll bar and then back down to the base of the bed Activating the winch or crank would cause the bed to lift 16 This system would be very simple and inexpensive but could pose some reliability and capability issues The other winch option considered would be similarly mounted but the winch cable would run to a scissor lift joint under the bed similar to those used in a hydraulic system Activating the winch or crank would cause the scissor to straighten and lift the bed This system is an in between on most criteria considered After considering several criterions and the importance each one held for the project the team decided to use the boom tower design Although it was not as impressive or as powerful as the hydraulic system it was more cost effective and had a simpler design Below is a photo of the winch system mounted at the base of the boom tower also acting as a roll cage Figure 12 Winch Mounted to Roll Cage The team felt
34. rpm and at maximum throttle approximately 5500 500 rpm This test was done using a digital tachometer model CDT 2000 from CHECK LINE The tachometer sends out an optical signal and records the amount of times it is reflected back in a specific time frame A reflective piece of tape was placed on the output shaft which allowed the tachometer to take a reading The tachometer was calibrated using a mixing head digital output device The mixing head rpm was set to various rpm and the tachometer was tested on each rpm and matched each rpm exactly The uncertainty in the rpm at idle speed comes from the slight change in idle speed from the engine The large uncertainty in the rpm at high speed is due to the fact that the throttle was difficult to maintain at a constant speed The throttle was being pressed in by a finger and the spring made it difficult to keep it pushed all the way in Through this testing the team also determined that the governor can be set at different levels to ensure the engine does to operate at too high of a speed during use At different stages of building the project the quality of craftsmanship and materials or parts was tested Generally this involved applying forces both static and dynamic to parts of the vehicle and then observing the behavior of the parts Although this method was not very precise it gave a good indication of how the vehicle would behave under loading Other performance tests were also used to
35. ry Corrosion will reduce performance or may cause a short 8 Secure and cover the winch when not in use Figure 31 Winch Assembly and Parts 42 Before operating any part of the vehicle ensure that all systems are securely fastened and in proper operating condition 6 1 2 Operation 6 1 2 1 Driving In order to drive the vehicle the operator should first ensure all vehicle components are in proper operating condition Before starting the engine shift the transmission into neutral If the engine is cold starting switch the choke lever into the choke position Turn the ignition key until the engine begins to turn over When the engine begins to start switch off the choke lever Starting the vehicle may require pumping the throttle slightly while turning the key Once the vehicle is running select the appropriate gear and slowly press the accelerator pedal Do not shift the transmission while pressing the accelerator At times the brakes may need to be pumped in order to build up enough stopping power This is due to the manual brake booster that is used to run the brakes 6 1 2 2 Dumping Before operating the dump bed the operator should ensure all components are in proper operating condition Connect the winch controller to the winch and the cable to the base of the bed Use the controller to reel the cable in until the desired height is reached Do not overload the bed or over lift the bed Do not drive the vehicle with the bed
36. susussununnssnnusuunununnnnununnnnunnnunnununnnnannnnnnununnnnnnnnnnnnnannnnannnnnnanannnn annann 41 6 1 1 Mea inten NEC ica CLA E e 6 1 1 2 Vehicle Components 6 1 2 Operation Aia EE DN ue Val QUE DA ol 6 1 2 3 Plowing 6 1 2 4 Planting 6 27 Calculations idos 6 2 1 Bed Prame Analysis ts 6 2 2 Weldment Cal cal sat EEN ESA EE 46 6 2 3 Leaf Spring Calculators iia 46 6 2 4 Driveshaft Calculations iii ea 47 6 3 Work Break Own oa 48 6 4 Suspension E 51 lil Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Table of Figures Kohler KD425 2 18 8 Horsepower Diesel 6 Power Curve for Diesel Kohler Engine cee eeeeseesceeseecnseceseceseceseceseeeseeeseeseneeeneeeseeenaeenaes 7 Kohler CH620 18 horsepower Gas Engine ce eesceseceseceseceseessceeeeeseneeeseeeseecaaecaecaeenaecnaeen 8 Kohler CH15 15 Horsepower Gas Engine coooconocccoconococonoconononcconncnnnnnan cono nono nono ncnn nono n conan cn nccnnenns 9 Cluteh System Setipiccc ieina aeea ne o EE e e OEE E E EEEE EER 11 Automatic Transmission iia teen did 12 Manual Transmission A EES 12 Hydrostatic Transmission suicide dd 13 Lawn Mower Transaxle nvid
37. t seeds and could be mounted to the back of the vehicle via the square hitch It could also adapt for multiple different tubes for seeds to be dropped down The tubes can swivel and pivot up and down to allow the user to direct the seeds wherever necessary A picture of the planter can be seen Figure 27 below 33 Figure 27 Pivoting Drop Seed Planter 34 4 Testing The team has done many different tests concerning the utility vehicle These tests have covered the main aspects of the vehicle most importantly the engine and the frame Since the engine had been sitting for over a year and the status of it was unknown the team decided to run a few tests First off the team made sure the engine was in running condition A testing mount for the engine was manufactured so testing could be conducted The engine mount can be seen in Figure 28 Engine Mount for Testing Figure 28 Engine Mount for Testing The engine was started and the components of the engine were analyzed and were determined to be functioning properly from idle to max speed However during this test it became clear that a new exhaust system will be necessary for better noise reduction A new 35 exhaust system be fabricated using the old muffler if it is still useable along with new piping In addition to testing the engine operation the team decided it would be important to test the output shaft speed The team found the shaft speed at idle to be 1460 40
38. that this choice best reflects the design norms focused on for the project Cultural appropriateness would dictate that the vehicle be simple and reliable enough to be used consistently and repaired easily by the user This also ties directly in with trust Below is a decision matrix that illustrates how the team selected the type of lift system to be used for the vehicle 17 3 6 3 6 1 suspension of the vehicle must have enough travel while still controlling damping The team has looked at several different types of suspensions and created a decision matrix comparing them which can be seen in Table 3 below The two designs that are found to be most desired are the double wishbone and the MacPherson strut The design aspects which are most important in choosing the best suspension type are the cost and durability of the design The cost was most heavily weighted because the major limiting factor of the vehicle is cost It must still be reliable Table 2 Decision Matrix for Bed Lift System Factor Weight Winch tower Winch Scissor Hydraulic cost 5 5 4 2 ease of design 2 5 3 2 ease of use 4 4 5 5 ease of build 3 4 3 3 maintenance 3 4 3 3 capability 4 3 4 5 Suspension Front In order to transport riders and cargo safely and comfortably along roadways the front however so durability was also heavily weighted 18 Table 3 Decision Matrix of Front Suspension Options
39. the hard ground the plow would constantly pop out of the ground as it hit rocks This was a good find because it would release the pressure as the plow popped out Overall the plow test was a success Hill Climb Test The hill climb test was designed to test the vehicles ability to climb different hill gradients with no load When load was added to the bed the vehicle had a hard time with most gradients When the vehicle was unloaded it could climb many small gradients The vehicle would have an easier time when it was placed in a lower gear Overall it is suggested that the operator put the vehicle in a low gear for going up any gradients either loaded or empty Endurance Test The endurance test was simply a test to see if the vehicle could handle multiple hours of use at a time To do this test the vehicle was driven for 2 hours without many stops The first hour was driven on flat pavement or flat dirt The next hour was driven to the plowing test site and testing the plow The vehicle stayed running and functional the whole time Overall the endurance of the vehicle is very good Brake Test The brake test was taken from the BUV completion This test was created to see if the vehicle was safe for the users The test specified that the vehicle needed to be able to lock up the brakes meaning the tires needed to slide while moving For this test the vehicle was taken out to a field and driven at a medium speed The brakes were then
40. ure 17 Front Brake Calipers The rear drum brakes from the Ford Ranger were rebuilt and assembled to assure maximum safety The new parts included new pistons new pads new springs and new brake drums A picture of rear drum brakes can be seen below in Figure 18 23 Figure 18 Rear Drum Brakes The brake booster from the Ford Ranger will not be reused The old brake fluid will be taken out and will be replaced with new The new brake cylinder will be mounted into the correct position so that when the brake pedal is applied the brake cylinder will compress brake fluid in the lines and press the brake pads against the brake rotors This will also cause the rear brake pistons to expand and push the pads onto the drums in the rear A picture of a brake cylinder can be seen in Figure 19 below 24 gege ut vr Ee nel Figure 19 Brake Booster The brake lines from the brake cylinder to the calipers and drums will be totally replaced New brake lines will ensure the safety of the driver passengers and products being transported 3 9 Electrical Systems 3 9 1 Electronics The engine that the team decided to use on the vehicle has an electric starting system which requires a 12 volt battery rated at 32 amp hours and 250 cold crank amps The engine is also equipped with a charging system which is necessary in order to run electronic accessories such as lights The wiring diagram for the engine can be seen in Figure 20 The design
41. uses a key switch similar to the one seen in the diagram with five leads and a ground B is connected to the battery giving power to the switch S makes the connection at the solenoid to crank the starter R is running position and draws recharging power to the battery from the stator M is the kill position and A is optional accessories 25 Ground to Kill Lead White Violet Ignition Hoh Spark D Rectifier Module uy Plug Regulator EH a Keyswitch AC O pol MOL Flywheel 3 Optional O Stator Fuse Q Optional Optional Oil Sentry _ _ Froen D Optional Switch Oil Sentry Indicator Switch Light Shutdown O O Battery Solenoid Starter Figure 20 Engine Wiring Diagram 3 9 2 Lights In order to provide safe travel at any time of the day the vehicle is equipped with front headlights and rear running and brake lights The team used basic halogen headlamps which were determined to provide sufficient headlight for the vehicle spare bulbs are provided with the vehicle understanding that these are something that often fail and may be a hassle to find quick replacements Headlamps are mounted directly to the front frame and wired to the battery through a switch mounted near the seat a wiring diagram can be seen in Figure 21 below The rear lights are mounted on the bottom of the rear frame under the tail gate out of the way from falling objects when the bed is lifted the running light bulb is
42. ut also for the transition from school into full time employment The course aims to teach the students to perform in a realistic engineering working environment that integrates team design work computer usage documentation project management and supervision The team s goal for this design class is to design something that will help show our Christian backgrounds and have an overall positive effect on the world even if on a small scale 1 5 Acknowledgements Ned Nelson Project Advisor Phil Jasper Fabrication Mentor and Advisor Joel Lautenbach CRWRC contact Davis Omanyo Connection in Kenya and end user Patricia Fisher CRC Contact Ren Tubergen Industrial Consultant Mike Ohlman Berger Chevrolet Mike Kienast Donated tires Mark Kienast Donated Ford Ranger Doug Kok Tire mounting and painting Justin Hyma Bauer Truck Parts 1 https docs google com document pub id 13uHbBUCFovpt9do7 YmHZsh6HnYp WXjVMNVmqOWkHNO amp pli 1 3 2 Project Management 2 1 Schedule The team s approach to making a schedule involved a few steps Step one was to create a list including all of the assignments due dates for the first semester Step two was to create another list that included everything that needed to be completed for the project to be finished at the end of the school year Step three was to create a hierarchy of the tasks from the two lists based on which ones had to be done before others
43. y cases fields were bottom plowed and then left to dry Harrows are used to level and even out the dirt before planting Since this type of plow does not overturn the dirt the team will not be using this type of plow A harrow plow can be seen below in Figure 23 29 Figure 23 Harrow Plow A third type of plow that was considered was the potato plow A potato plow is used to overturn dirt similar to the single bottom Although this plow would be right for the need the power needed to pull this plow is much higher than the previous possibilities Therefore this plow idea was not considered further The potato plow can be seen below in Figure 24 16 http forums atvconnection com hunting trapping game management 291401 minimum engine size pulling plow html Figure 24 Potato Plow The final type of plow that was considered was called the chisel plow Chisel plows can be adjusted to till at deep or shallow depths These types of plows normally need 10 horsepower per shank to pull The issue with this type is that it does not overturn the soil This is the major design criteria determined by the customer A chisel plow can be seen below in Figure 23 1 http www robertsfarmequipment com Kodiak html si http www marketfarm com cfms chisel plow cfm 31 Figure 25 Chisel Plow 3 11 2 Selected Plow As requested the plowing device must be able to overturn the dirt A single bottom plow takes 15 20 horse
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