MECH 2412 Mini Design Project

Winter Term (Jan – Apr 2020)

Friday, April 10, 2020

Final Report

Team Name: Elon’s Musk

Team Number: 1

Prepared by:
Nicholas Di Scipio (216294712), Hisham Amer (216520637), Idris Colpan
(215922222)
Table of Contents

List of Figures 3

List of Tables 4

1.0 Team Statement of Participation 5

2.0 Executive Summary 6

3.0 Planning and Clarification 7

3.1 Background 7
3.2 Design Specifications 8
3.2.1 Requirement List 9
3.3 Functional Structure Diagram 11

4.0 Conceptual Design 12

4.1 Morphological Analysis 12
4.2 Conceptual Design Selection 14

5.0 Embodiment Design 16

5.1 Preliminary Layout 16
5.2 Design Analysis 17

6.0 Design Implementation 18

6.1 CAD Modeling 18
6.2 Prototype Analysis 19
6.3 Final Design 21

7.0 Conclusion 23

8.0 References 24

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List of Figures

Figure 1: Functional Structure Diagram showing go-kart functions and their

interactions 11

Figure 2: Preliminary layout of design 15

Figure 3: Orthographic View of Gearbox 18

Figure 4: Orthographic view of Fully Assembled Prototype 19

Figure 5: Results of Frame Analysis 20

Figure 6: Results of Critical Gear Analysis 20

Figure 7: Top View of the Gearbox 21

Figure 8: Orthographic View of the Final Design 22

Figure 9: Mass Properties of the Final Design 22

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List of Tables

Table 1: Requirements Table with descriptions and testing methodologies specified

ranked in importance 9

Table 2: Morphological Chart showing possible concept configurations 12

Table 3: Decision Matrix used to evaluate viability of each concept 14

Table 4: Excel solving system of equations given by FBDs 17

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1.0 Team Statement of Participation

As a unified group, we set out to put as much effort into every component of this project to

ensure the end result would be one that we all deemed successful and reflective of the work

contributed by each of us. As a result of this collected group effort, the project yielded a very

successful outcome and the prototype created was a viable solution for this design project. Our

group is very content with the results and finds the outcome quite reflective of the effort put

into achieving this goal.

Written and approved on behalf of,

Nicholas Di Scipio - 216294712

Hisham Amer - 216520637

Idris Colpan - 215922222

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2.0 Executive Summary

One of the most compelling challenges humanity is facing is climate change. Many approaches

and strategies have been developed throughout the years on how to combat this challenge and

eventually overcome it. One such strategy is the United Nations (UN) Sustainable

Development goals (SDG). In regard to this project, the group has been tasked with addressing

the problem of climate change by creating an electric go-kart for Canada’s Wonderland in order

to spread awareness on the subject as well as increase the number of park patrons.

The group has spent the duration of this project conceptualizing and designing a prototype

capable of fulfilling the needs of Canada’s Wonderland, the UN and the project requirements.

To address the aforementioned project needs, the group proposes the implementation of the

prototype created as it has been designed and tested to address all the requirements of this

project.

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3.0 Planning and Clarification

3.1 Background

This project was driven by the need to create an electric powered go-kart for Canada’s

Wonderland. In addition, these go-karts powered by an electric motor will not only be a fun

attraction, but an eco-friendlier and more sustainable one. By delivering on this need, the group

will be able to meet the United Nations’ ‘Climate Action’ sustainable development goal.

To better assist the project, the conclusions drawn from the research and findings conducted

has allowed for a suitable problem statement to be made:

“As the push for more eco-friendly and sustainable technology progresses, large companies

such as Canada’s Wonderland seek to incorporate this into their businesses. Thus, electric go-

karts that are safe, fun, user-friendly, and durable must be created for Canada’s Wonderland,

to be leisurely driven by children in the hopes of increasing the number of visits to the park.

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3.2 Design Specifications

The design process taken to conceptualize the final prototype involved a lot of ingenuity as

well as trial and error. By creating a requirement list, the project needs became very clear, and

it gave the group the ability to prioritize the more important needs when designing the

prototype. Through devising a comprehensive requirement list, the group was able to ensure

all the needs of the stakeholders were met before creation of any concepts. Thus, there were no

errors made in creating the requirements for the project and this was confirmed by having the

requirements reviewed by the Teaching Assistant. The group spent extensive time researching

pre-existing electric go-kart models and designing ways to improve upon these models to better

meet the project requirements. In addition, multiple concepts were created to explore various

possibilities of what a final prototype could be. The final design selected to become a prototype

was selected because it had the capability to meet all the requirements of the project. In

addition, it included all the design objectives chosen prior to the creation of the concepts. By

thoroughly analysing and ensuring that the design met the design objectives and requirements

at every stage of the project, the group was able to confirm that the prototype was a viable

solution based on procedures followed.

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 3.2.1 Requirement List

The requirement list (see Table 1) is provided as a comprehensive guide as the main needs that

must be addressed by the concepts created for this project. Every concept evaluated must meet

all of these requirements in order to be considered a viable solution for this project [1]. The

table explores each requirement category and provides a brief description of that requirement

as well as it’s importance ranked from 1-8, with 1 being the most important and 8 being the

least. In addition, further information on why these requirements are needed for each concept

and how each will be tested is provided as well.

Table 1: Requirements Table with descriptions and testing methodologies specified ranked in importance

Category Description Requirement Source Need Testing

Importance Methodology
Sustainability Electric motor is only If the go-kart was An emissions test may be
source of power
1 powered by anything conducted however, with an
other than an electric electric motor, it is already
motor, it would fail to known that there will be no
meet a primary need of emissions
this project

Safety The outer body must not The go-kart would be Controlled crashes with
break down after a crash
2 unsafe for operation by various speeds
at 5 cm/s of speed children if safety was not
considered

Weight Capacity Must support 2 kg both The speed of the go-kart Test the go-kart with various
on an incline and
3 would be reduced if the scaled weights on various
horizontal surface load is too heavy levels of elevation

Speed At least 1 cm/s of speed If the go-kart is too slow, Test the speed on a 15-
on a 15-degree incline
4 it will not be an enjoyable degree incline
but still slow enough to ride for the park patrons
be fully controlled and if it is too fast, the
safety of the driver will
be at risk

Handling Turning radius of a The go-kart will become
minimum of 5 meters
5 unstable and may infringe
on the safety of the driver
if it turns too sharply
Testing of the steering can
be done to adjust the chassis
until it has a desirable
turning radius

Geometry Has to fit in a 20 x 20 x The size of the prototype Place completed go-kart in a
40 cm box.
6 would fail to meet one of 20 x 20 x 40 cm box
the technical

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 requirements as well as
reduce performance if too
big

Assembly Parts should be attached The time it takes to Create multiple concepts that
and detached easily and
7 handle the go-kart will be emphasize simplicity and
fast impacted negatively select the one that can be
assembled/disassembled the
easiest

Cost Only provided material The cost will increase if Multiple material producers
should be used
8 an outside material is can be reviewed to see which
used will provide us with the
necessary parts for the
cheapest price

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3.3 Functional Structure Diagram

The Functional Structure Diagram (FSD) provided a visualization of the expected inputs and

outputs going through the go-kart system (see Figure 1). It’s creation allowed the group to gain

a more clear understanding of the primary functionality of the go-kart and the subsystems to

account for. Unfortunately, the FSD lacked detail in some aspects, reducing it’s effectiveness

in these areas. For example, the FSD failed to elaborate on the process involved on how the

go-kart was expected to transition from one gear level to another. The diagram shows that the

rotating shaft causes the wheels to turn. However there are more steps in between, such as

adjusting the position of the main shaft and transforming its rotation axis using spur gears. The

steering system should have been added since it is an essential function of the project. Even

with the absence of the steering system, the group successfully accomplished all the functions

that were mentioned on the Functional Structure Diagram.

Figure 1: Functional Structure Diagram showing go-kart functions and their interactions

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4.0 Conceptual Design

4.1 Morphological Analysis

The Morphological table allowed the group to explore a range of options that could be

incorporated for the various functional components of each conceptual design (see Table 2).

The group strived to create diverse options that would allow the possibility to create a unique

range of concepts.

Table 2: Morphological Chart showing possible concept configurations

Option 1 Option 2 Option 3 Option 4

Driving Force
Electric Motor

Gear Shift
Buttons
Paddle Shifters
Singular Gear Shift
By Pedal

Wheels
4 Wheels (Big) 4 Wheels 3 Wheels
4 Wheels (Small)
(Racing style)

Body

Square Triangular Closed Body Oval

Drivetrain
All-wheel FWD RWD One Wheel Drive

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Handling
Handlebar
Standard Throttle
F1 Style

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4.2 Conceptual Design Selection

The main problem about our conceptual designs was not being specific enough. Only required

parts and their positions were shown in our designs. It was not mentioned how the transmission,

or the steering system would function. Considering the knowledge we gained throughout this

project, none of the conceptual designs would work fully as shown.

Conceptual design 1 had a complex outer body which would make it hard to sketch on

Solidworks and had problems on the positioning of the motor as well as the gearbox.

Conceptual design 2 didn’t have the right amount of space to store the whole transmission

system. Conceptual design 3 had a big body and wheels which would be a problem while

manufacturing the parts because of the constraint on the amount of 3D printed objects. Design

4 was the best one amongst them all. Its size was optimal, body design was nice and simple

and it had the most points on the Decision Matrix (see Table 3).

Even though the selected conceptual design was the design 4, changes needed to be made

throughout the designing process. It was required to have a system which allows us to change

the gears in the gearbox as easy and as fast as possible. That is why the top part became a closed

top which could be lifted. After adding the adjustable top, our new design looked like a mixture

of conceptual designs 1 and 2.

Table 3: Decision Matrix used to evaluate viability of each concept

Factors: Safety Speed Handling Assembly Cost Total

Weights: 5 4 4 3 -1

Design 1 3 2 2 1 3 27

Design 2 1 2 1 2 2 21

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Design 3 2 3 3 3 1 42

Design 4 3 3 3 3 1 47

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5.0 Embodiment Design

5.1 Preliminary Layout

After determining the materials to be used for the Go-Kart and conducting the necessary

calculations, the preliminary design was created. The design was created to be hollow in the

middle to allow adequate space for the transmission and the housing unit for the battery and

motor. The cylinder atop the top frame is perfectly centred on the body of the go-kart in order

for the force of the mass being placed on it to be equally distributed between both axles.

Figure 2: Preliminary layout of design

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5.2 Design Analysis

The preliminary design relied on simplistic features to allow for the design to be as effective

as possible and reduce as much complexity as possible. By taking this approach, the group

encountered little to no obstacles and the design did not require any necessary redesigning. By

creating free body diagrams (FBDs) of each system and analysing them, there were no results

that implied necessary changes had to be made in order for the design to function properly (see

Table 4). All parts tested for structural integrity returned results that were more than capable

of withstanding the forces they were expected to bear. Although no necessary changes had to

be made, the group was able to improve upon the overall concept and optimize various features

in order to create the best prototype possible. These changes are reflected in the final prototype

as the model maintains the overall concept of the preliminary design but improves upon certain

features such as the top frame and front steering system.

Table 4: Excel solving system of equations given by FBDs

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6.0 Design Implementation

6.1 CAD Modelling

The modelling stage of the project greatly assisted in depicting what the final prototype would

look like, however, the group faced two specific challenges while assembling all the designed

parts of the prototype. The first issue was that the clutch was supposed to rotate only when it

was in mesh with a gear from a different level in order to engage that gear level. However, it

continued to rotate after returning to its initial position. Thus, the group decided to mate the

clutch differently for every individual gear level. This eliminated the problem that would be

experienced in a real world setting because the clutch would not rotate when it is not in contact

with a gear. The second problem occurred when connecting the main shaft to the rear axle.

Some portions of the wheels were supposed to be located below the base so that they could

touch the ground. However, after assembling the rear axle with the main shaft, wheels were

located above the base. To solve this problem, the differential connected to the rear axle was

lowered by using two additional gears and a shaft to allow all the components of the rear portion

of the drivetrain to be on the same plane (see Figure 4).

Figure 3: Orthographic View of Gearbox

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6.2 Prototype Analysis

The completion of the prototype in Solidworks led to the next stage of analysing and testing

the model created see (Figure 4). Based on the components determined to be high-stress

concentration areas from the initial assessment phase, the top part of the model as well as the

critical gear were subjected to structural analysis. These two components were selected because

the top part (see Figure 5) was expected to bear the added load on the go-kart and the critical

gear would be withstanding the highest level of torque from the motor (see Figure 6). By testing

these components, the viability of each could be evaluated to see whether they could withstand

the forces being presented upon them. Furthermore, the analysis confirmed the calculations

conducted during the embodiment phase were valid and each component had the necessary

yield strength to withstand the forces upon itself. This stage of the project allowed the group to

confirm the viability of the prototype and its components and was a very valuable tool in

determining if any changes to the prototype had to be made. Fortunately, the analysis confirmed

the structural integrity of the prototype which meant no changes had to be made but the analysis

provided the group with confidence in the model, nonetheless.

Figure 4: Orthographic view of Fully Assembled Prototype

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 Figure 5: Results of Frame Analysis

Figure 6: Results of Critical Gear Analysis

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6.3 Final Design

After analysing the prototype report, it was found that only a minor addition to the transmission

system needed to be made.

As mentioned in 6.1, it was required to add an additional shaft to allow all the components of

the rear portion of the drivetrain to be on the same plane. However, the additional shaft could

only be connected to one side of the gearbox which made that part vulnerable. The first option

to support the shaft was extending it through the other end of the wall. However, it was not

possible because it would conflict with one of the gears located in the gearbox (see Figure 7).

The second option was adding supports to both sides of the wall, supporting the shaft so that it

would not break. This option successfully supported the additional shaft and eliminated the

problem. Furthermore, the full prototype (see Figure 8) as well as its properties, can be

observed below (see Figure 9).

Figure 7: Top View of the Gearbox

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 Figure 8: Orthographic View of the Final Design

Figure 9: Mass Properties of the Final Design

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7.0 Conclusion

Through conducting the design process from the ‘Problem Definition’ stage to the ‘Prototype

Analysis’ stage, the group Elon’s Musk was able to design and create a prototype that addressed

all the defined project requirements and needs of the project stakeholders. This result could not

have been accomplished without the extensive evaluation and analysis conducted at every stage

of the project. By using the collective knowledge and expertise of each group member, the

group was able to generate a successful prototype with every member contributing greatly to

its success.

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8.0 References

[1] Elon’s Musk “Conceptual Design Report”

[2] Elon’s Musk “Prototype Report”

[3] Elon’s Musk “Problem Definition Report”

[4] Elon’s Musk “Embodiment Design Report”

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