Metal Motion Vehicle

Design and manufacture a three-wheeled vehicle.
The vehicle will be manufactured from steel rod, sheet metal, and three inline skate wheels (~ 3"). The vehicle must be capable of covering a distance of 35’ down a ramp, relying solely on gravity for propulsion.

The vehicle will be evaluated on the following issues:

  • Distance: The vehicles will start at the top of the Creative Arts building ramp and travel as far as possible into the common area.

  • Speed: The traveling speed will be evaluated (35) feet in (4) second

  • Control: Design and manufacturer the vehicle to travel in the straightest possible line down the ramp.

Materials:

¼ inch steel rod 10’ long

16"x6" sheet metal 20-22 gauge

Rivets, bolts & nuts, washers, paints, wax, bondo filler

Three Inline polymer Wheels and bearings

Project Timeline

Phase 1: Research and Analysis

April 4st

Understand Testing Environment

Research examples of past projects

Phase 2: Ideation

April 11th

5-10 Concept Sketches

Seek Feedback and design direction from Professor

Phase 3: Prototype

April 18th

Create Foam Core Mockup

Design 3D Cad model

Final design Approval from Professor

Phase 4: Fabrication and Testing

April 25th

Compile Materials

Identify tools needed for fabrication

Conduct trial runs and make adjustments where necessary

Phase 5: Results and Deliverables

May 2nd

Competion Results

Final Presentation

Findings and Takeways

  • After understanding the purpose/goals of the project, scope, timeline, and availabile resources; the next phase is to conduct research.

    Analyze the conditions and influences affecting the use of gravity force in the design.

    Considerations: Distance, Control, Speed, gaps between concrete slabs, debris, alignment angles, where to apply load, low profile chassis, extended wheelbase, and application of suspension.

Test Environment: Fine Arts Building Ramp

Ramp angle: ≈30°, Ramp length: ≈60’

Shifting your weight to the back of the car before starting, gives you more potential energy. This extra energy, when converted to kinetic energy, makes the car go faster down the ramp. Both cars start at the same speed, but the one with weight at the back gets a boost and accelerates for a longer distance on the flat part of the track.

Distance and Speed: (Dragster)

The length helps keep the car stable under high speeds.

  • It all begins with an idea.

    Conceptual Design: Develop 5-10 design concepts considering the materials and criteria specified.

    Design Considerations: Aerodynamics, testing environment, gaps between concrete slabs, chassis design.

  • foam core mockup, 3D model

    Challenges: Corrupt CAD files

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Fabrication

  • Cut and bent steel rod/ initial measurements

  • visualization

  • Grinded and Reverse threaded 1/2” flat steel bar. Used for lower mount of shock suspension.

  • 1/2” Pipe, vertically milled for axle inserts.

  • Created jig for welding A-Frame together. Bent 1/2” flat steel bar to 53°

  • Finalized A frame suspension

  • Used Metal Lathe to horizontally mill bronze bushings.

  • Added rear suspension, bronze bushings, and set collars to chassis.

  • Attached wheels and measured resting height of axles.

  • Welded sections of upper cage

  • Aligned and welded upper suspension mounts

  • Added Reinforcement rods

  • Grinded excess welds and gave it a matte black finish.

  • Fabrication Challenges:

    - Weak welding

    - Learning on the Fly (No prior knowledge of welding)

    - Fitment and Material Challenges

    - Safety (Grinding metal, situational awareness for others

  • After fabrication was completed, multiple runs were conducted and alignments angles were adjusted accordingly to ensure straightest possible descent.

  • Farthest vehicle travelled with distances of 140’ +

    weight: ≈ 4lbs

    Speed: 0-35’ in 3.1 seconds

Learning Outcomes:

Save files often and make copies

Mig Welding, Creating Jigs

weight distribution

How to create technical Drawings/ List of Materials

List of Materials