TechnoPush 2008

1. TechnoPush 2008 Sheriffs Angels Year 7 Ungarie Central School

2. Design Briefs Our task is to design and construct a push cart to participate in a series of performance challenges. Participating classes will bring our vehicles to the KDC-NRMA TechnoPush Challenge for a joint celebration, where we will demonstrate and trial them in action. Our Design Brief For our design brief the push cart will be constructed of timber for the frame. The front wheels will be 220mm pneumatic steel 110kg and the back wheels will be 275mm pneumatic plastic 120kg. The steering will be designed with a steel mechanical design. All safety aspects will be covered with a roll bar, seat belts, brakes and a bumper bar. The overall design of the cart will aim to be constructed light for easy pushing and increase speed and quick assembly.

3. Research We researched some photos to get an idea on what our pushcart could look like.

4. Internetand other search We looked at books in the library and found a traditional and simple design Billy Cart Innovative ideas for constructing our Billy Cart When considering how we might build our Cart we wondered if used Aluminium cans could be used. But after looking at how this could be done, it was decided to much time was needed to try and achieve this. Trent successfully joining two cans that would have been part of the Aluminium frame if we had gone ahead with the Aluminium idea.

5. Researching ideas for the different Billy Cart components We looked at last years “Bushrangers” Billy Cart for a steering wheel idea, but one of the team members, Chase came up with the great idea of using a old chain from a piece of farm machinery. PLACE A PICTURE OF STEERING WHEEL Last years two Carts used retractable seat belts. Talking to students from last years teams, they told us how these were terrible and lost them valuable time in the change over of drivers and pushers. Josh testing out the retractable

6. After investigating other seat belts we decided on a racing type belt. Caitlin and Jesse working on the folio. Looking at last years bumper Our 2008 bumper

7. (Left) “Bushrangers” steering column and steer system, ours will be similar. Last years “Little Cow” used an old plastic seat, we decided this would fit with our support for recycling. These are pneumatic tyres, tyres that require air. We are going to put them on the front and the black tyres below on the back our Cart. This brake system was what the “Bushranger’s” and “The Little cows” used on their carts last year. Speaking with the members of those teams, they were not happy with how the brakes stopped the carts.

8. Safety For safety a few areas needed to be considered. • Safety aspects of the Billy Cart The safety aspects of the Cart needed to consider stability and braking. • Safety of the drivers, pushers and others For safety of drivers, pushers and others the carts needed the roll bar to be 100mm above the tallest driver, sharp edges removed, seat belts, working brakes, covered in floors and a bumper. • Safety in making the Billy Carts In the making of the Billy Cart many things needed to be known about to protect the student and others during this construction. We worked with Mr Sheriff to better gain this knowledge by doing a on risk assessment. (See following page slide).

11. Construction of Billy Cart After researching different designs and discussing between the team and with Mr Sheriff about a design for our Cart, we decided to go with a similar design as last years “Little Cow”, using as much recycled material as possible. The main chassis would be made from wood and metal. Any bolts or steel parts needed for the cart would at least be good recyclable material. Below shows the basic design we would go with. Right, De-nailing old hardwood for the frame Mr Sheriff discussed the idea of mortise and tenon joints being strong for the construction of the frame. Everyone agreed, and Mr Sheriff cut the depth of the mortises on the drop saw for us. Chiselling out the mortises required a team effort.

12. Marking out for the tenons. While the Mortise and tenon join would be strong. Some of the team assisted in making corner brackets for extra strength. Completed mortise and tenon joints Frame assembly and fitting corner brackets. Cutting out mortises for the roll bar

13. After deciding to construct the same steer system as last years carts, Mr Sheriff showed us how to do 3 dimensional drawings for us to copy Marking out of metal parts using steel rule, square and scriber Making part of the steering required helping Mr Sheriff heat the steel with the Oxy-Acetylene then bending it in the vice

14. This slide shows the process taken to construct the new brake system. After researching last years carts our design was discussed with Mr Sheriff and we decided to go a very different way. The main braking system was mounted under the chassis and worked by a centre brake handle that pushes forward. To lock the brake into a set position, two old springs were set into the design. The arrow shows where the springs have been set in to keep the handle locked in place.

15. Testing out our Cart (Below) Realising our roll bar was not high enough above the tallest driver. We had to add an extra piece of timber to the top of our roll bar. Practising assembly Test pushing the cart

16. Evaluation I like the way we have recycled nearly everything on the cart that is why I like it. Because I am little and light, that means the cart will have lightning speeds. “Chase” I think that the steering system is a bit hard to use because of the steering wheel (which is a bit uncomfortable) and the actual steering system (which when turning is really sudden for the person who is pushing the cart and the steering system is hard to turn at times) I’ve had fun making the cart with everyone else, mainly because it has given me the chance to learn more and experience more. I learnt a painful experienced, that is, don’t fool around in the workshop! But I’m certain I’m going to have a lot more fun at Eastern Creek. “Callum” I like the way it drives and the way we made it using recycled timber and metal. Our brakes didn’t work when we tested them so we had to make brake pads. I also enjoyed working at night and at school on the Cart. “Brock” I enjoyed making the Cart, especially working on Tuesday nights at the work shop. I like how the brakes work now. And how it runs and how light it is. “Josh”

17. My favourite things on the Cart are the brakes and the steering because you hardly have to move to use it. “Caitlin” When we first test drove the Billycart, we noticed that the bottom of the back wheels started to draw closer towards the cart. We replaced the back wheels with thicker wheels. Because we changed the wheel we had to make the brake pads, so we put leather on for better stopping, this made them work better. Everyone agrees that since we changed the wheels, the billycart has been easier to push. “Renae” I liked driving and pushing the cart, I have always wanted to help make something like this. ”Jesse” Good – Our construction time, our seat belt, night time workshop. Bad – steering needs greasing/oiling and the back wheels (slant) OK – our experience, our safety equipment. “Trent”