FINAL PRESENTATION UNIVERSITY OF CINCINNATI MUTHAR AL-UBAIDI, PHD 04/20/17

1. FINAL PRESENTATIONUNIVERSITY OF CINCINNATI MUTHAR AL-UBAIDI, PHD 04/20/17

2. Agenda • Team Introductions • Problem Statement • Project Objectives • Design and FEA Analysis • Fabrication • Hydraulic Circuit • Hydraulic Components • Fabrication • Testing • Cost Analysis • Lessons Learned • Conclusion

3. Muthar Al-Ubaidi, PhDTeam Advisor

4. Dorian Durant

5. Ray Frank

6. Bill Hayes

7. Tyler Tavalero

8. Paige Weaver

9. Problem Statement Design, build, and test a human powered vehicle utilizing hydraulics as a means of power transmission. The vehicle will compete in three events: • Sprint Race • Durability Race • Efficiency Challenge The following design parameters must be observed: Must accommodate a single rider who can enter and operate the vehicle unassisted Comply with all appropriate safety codes Vehicle cannot leak any hydraulic fluid Vehicle must have multiple, fully active, independent brakes Guards must be used to protect the rider from unsafe moving components No chains or belts can be utilized in the design

10. Project Objectives • Reduce the overall weight relative to the 2016 prototype • Eliminate electronic components • Shorten hose lengths as much as possible • Minimize number of fittings • Change the input gear ratio leading into the pump • Use a two-wheeled bicycle frame

11. Design and FEA Analysis

12. Design and FEA Analysis Two wheeled 2.3L Reservoir inside bike frame geometry 1:3 Gear ratio 1L Accumulator

13. Design and FEA Analysis Cont’d • 200lb Rider • 4,978psi Max • 50,000psi Yield strength • .005” Max displacement

14. Design and FEA Analysis Cont’d • 200lb Force • 9,270psi Max • 51,000psi Yield strength • .0003” Max displacement

15. Hydraulic Circuit • 2 Phase • Charging accumulator • Accumulator discharge & direct drive • Ball Valve Actuated • Pressure Relief Valve

16. Hydraulic Components • Parker 1 liter, 4000 PSI piston accumulator • Prince RV4H 3000 PSI Pressure Relief Valve • Set to 2800 PSI • Anchor AE2 3000 PSI Hydraulic Ball Valve • Pump: ACNAL02ACA0040000000000A • 26002-LZD • 8.2 cc • 3/4" keyed shaft • Rear Ports • Motor: ADMAR04ACA0100000000000A • 10.2 cc • 5/8" keyed shaft • Side Ports

17. Fabrication • 19 Fabricated parts • 4 Subassemblies • Plasma cut • Welding • Milling • Lathe

18. Testing • Initial Testing • No nitrogen charge • Ran at lower pressures than anticipated • Tested at Different Gas Pressures • Between 2000 PSI Nitrogen and 500 • Lowered pressure in 100 PSI increments • Tested to find optimal balance between charged volume and direct drive capability • 1000 PSI performed best on smooth, level concrete

19. Cost Analysis Parameters were put in place as a guide through the costs for the overall fabrication of the bicycle. They are listed below: • Labor: $60/hr • Average Cost of Steel: $4.00/lb • Efficiency of Production: 95% • Yearly production: 500 units • Life Volume: 5000 units The total cost of the 2017 University of Cincinnati’s prototype was $1012.09. Including labor costs, the total cost of the prototype is $40,012.

20. Cost Analysis (cont.)

21. Lessons Learned • Practical Hydraulics Applications • RPMs are important • Small components are surprisingly capable • Design with Manufacturing in Mind • Multiple Ways to Approach Machining • The Simplest Solution is Often Best • Rely on Your Team

22. Conclusion • Design Goals Achieved • Weight Reduction to 100 Pounds Maximum • Reliable Circuit Performance • Consistent Speeds and Take-offs • Build Quality • Possible Improvements • Regenerative Braking • Lower Fluid Requirements • Precharge Stability • Lower Center of Gravity