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P14007: Wheelchair Assist: Detailed Design Review

P14007: Wheelchair Assist: Detailed Design Review. Che -An Lee – Industrial and System Engineer Dan Schuster – Mechanical Engineer Phil Medalie – Mechanical Engineer Tom Elliot – Electrical Engineer. Agenda. Project Overview Mechanical System Electrical System Assembly Plan

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P14007: Wheelchair Assist: Detailed Design Review

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  1. P14007: Wheelchair Assist: Detailed Design Review Che-An Lee – Industrial and System Engineer Dan Schuster – Mechanical Engineer Phil Medalie – Mechanical Engineer Tom Elliot – Electrical Engineer

  2. Agenda • Project Overview • Mechanical System • Electrical System • Assembly Plan • Test Plan • Risk Assessment • Project Timeline

  3. Project Overview • Assist manual wheelchair users on slopes • Mechanical system • Ratchet system • Brake system • Electrical system • Charging system • Expected outcome • Functional prototype • Engineering design experience • Basis for future senior design project

  4. Overview

  5. Total System

  6. Brake Disc w/Shaft

  7. Chair Mount

  8. Pawl Mount

  9. Ratchet and Pawl Interaction

  10. System w/ Washer

  11. System w/ End Plate

  12. Shaft

  13. Electrical Components

  14. Attachment to Shaft

  15. Critical Component Analysis • Shaft • Bearing Block Bolts • Ratchet Tooth

  16. Shaft Analysis

  17. Shaft Results

  18. Ratchet Tooth Analysis S = 60200 psi F = 0.25 in Y = 0.431 for 72 teeth DP = 24 V  Disregard for low speeds W = 270 lbf of allowable tooth load (will see ~115 lbf)

  19. Bolt Analysis • Bolt Shear • Sy = 70 ksi • Ssy = 40 ksi

  20. Detailed Electrical Generator Design

  21. Bill of Materials

  22. Buck-Boost Regulator Circuit 5V with 80% Efficiency *Ordered Premade*

  23. DC Generator • Motor 2.7W • 24V • 30RPM

  24. Battery with Battery Protection • 10,000mAh @ 5V Outputs up 2ADraws up to 1A • Dimensions: 2.9" x 1" x 4.9" / 72mm x 24mm x 125mm • Weight: 300g • 80% Efficient

  25. Simulation

  26. Breadboard Proof of Concept • Used a Linear Regulator which is less then 50% efficient • Used a Hand Crank motor • Used a 3.4V Battery

  27. PCB Board Design

  28. PCB Product Ready to Be Ordered Top Bottom

  29. Electrical Energy Harvesting Overview • Battery = Average 80% Efficiency • Buck-Boost = Average 85% Efficiency • Motors = 2.7W each = 5.4W at 30RPM • 3.456 W generation at 30RPM • 691.2 mA generation at 5V, at 30RPM

  30. Benefits to design • Easily can covert to AC Motor if Needed. • PCB Fits on top of the Buck-Boost Regulator therefore saving space. • Battery can be charged by a wall charger too. • Arduino boards and other electronics can also be power by battery therefore opening up further applications and not limiting it to phone charging.

  31. Cable System

  32. Bill of Materials

  33. Bill of Materials

  34. Target vs. Actual

  35. Assembly Plan

  36. Test Plan • Test Equipment • Plywood base • Car Jack • Cables • Tape Measure • Scale • Multimeter • Fish hook scale or similar • Circuit simulation software • Phase of Testing • Component • Ratchet System • Circuit Design • System • Mechanical System • Electrical System • Usability Testing

  37. Risk Assessment

  38. Project Future

  39. Comments/Questions?

  40. Updated Engineering Requirements

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