Mechanical Design Engineering Portfolio

1. Mechanical Engineering
Design Portfolio
Nikhil Kulkarni -MS Mechanical Engineering
Arizona State University
[email protected]
[phone]

2. CONTENTS
SL No TITLE PAGE NUMBER
1.Introduction and About me. 3
2.Jigs and fixture for ERU crutch fairing [Intern –HAL]. 4
3.Structural assessment and analysis of TVC hydraulic 8
system flight filter manifold.
4.Design for Autodesk. 15
5.Automatic basketball machine. 17
6.Automatic surveillance vehicle. 20
7.Orange picker. 23
8.Human powered paper bike. 25
9.Transfer wheelchair. 28
10.Miscellaneous. 31

3. Introduction:
Welcome,andthankyoufortakingthetimetoviewmyportfolio.MynameisNikhilKulkarni.Iamcurrentlyafinalyeargraduatestudent
majoringinMechanicalengineeringwithfocusonproductdesignandsimulationatArizonaStateUniversity.Theaimofthisportfolioistoprovide
youwithadeeperinsightintomydesignskillsandexperiencesthatIhaveacquiredoveraperiodoftime.TheMastersdegreehashelpedme
developsufficientfoundationofknowledgesoastostampmydominanceinmyfieldasaleadingprofessional.
Aboutme:
Thewordmechanicalresembledamagicalworldtomeinmychildhooddays,butanunseenforcewhichmadetheworldaroundmework,the
passivityofacircuitandyetachievingtasksthatotherwisewouldhaveinvolvedalotofphysicallabor,resembledalandofArabiannightsforme
afairytaleinthemaking.Maybethechildinmestilllivesonbutthecuriosityofdiscoveringthisseeminglyintangibleworldofmechanical
engineeringremains.TrueIexcelledinallmysubjectsduringmyschoolyearsandcouldhavejustbeenanequallysuccessfulfinancialanalystor
journalistbuttheprospectsofthoseprofessionsneverstimulatedmypassionorimagination.AndIbelievewithoutpassionandadreaminones
fieldofwork,itstaysjustthat,work.Itwasinmydueinterestofmechanismsofgadgetsaroundmeespeciallymotorbikes,mechanical
componentsoftoys,mechanicaldeviceswithwhichIhavegrownupwiththatfueledmetopursuemybachelorsandnowmastersinMechanical
engineering.Havingrealizedthattheworldisincreasinglybecomingadigitalworldtodayandeventhesimplestofadvancementsinthisfield
affectsourday-to-daylives.Moreimportantlyanylatestbreakthroughsinthefieldofinformationtechnologyorthetelecommunicationworld
areadirectconsequenceofdevelopmentsoftheDesignfront.Thusmydesiretobeinvolvedwithtechnologicaladvancementsatthegrassroots
leveloratalevelthathasfarreachingimpact,hasmademekeentotakemyspecializationinProductDesignandsimulation[CAE]attheMasters
level.BesidesmyfocusonacademicexcellenceImadeitapointtohaveamorethoroughunderstandingofmysubjectsascomparedtomypeers.
WheneveropportunitieshavecomemywayIhavealwaysmadeitapointtomakethebestuseofthemandinvolvedinmanyimplanttrainings
like“HindustanAeronauticsLimited-ResearchandDevelopmentDepartment”whichisoneoffthetopaerospacecompanyinIndiaduringmy
undergraduatetogetaninsightintothepracticalnuancesofthetheorylearntintheclassrooms.Theprojecton“DesignandFabricationofDrill
JigandFixturesforaFighterJetAircraft”washighlyappreciatedandwasevenselectedtobesponsoredbyHindustanAeronauticsLimited.The
richestofalltheexperienceshasbeenworkingonthedesignprojectsduringmygraduatestudies.
Now that I am about to graduate and will be soon awarded my masters degree, I am looking forward towards having a successful career in
Mechanical design engineering. If given an opportunity I promise you that not only will I give my best, but strive to become an asset.
Introduction and About me
3

4. Jigs and fixture for ERU crutch fairing
HindustanAeronauticsLimited
IworkedasanDesignengineeringInterninToolingdepartmentat
HindustanAeronauticsLimited,Bangalore,India.Theprojectassignedtook
about8weekstocompleteofwhich4weekswasspentatHAL.
Objective:Todesignandanalysisjigsandfixtureforejectorreleaseunit
[ERU]crutchfairingtoimprovetheaccuracyofmachining,todecreasethe
costandtimeconsumedformanufacturingandtohaveinterchangeability.
Assemblyrequirements:
•Thepositionof4holestobedrilledontopoftheERUcrutchfairing
musthaveconstantpitchmaintainedbetweenthem.
•RivetingontheERUcrutchfairingmustbedoneinproperpositionsat
16*4places[asshowninthedrawing].
•ThebulkheadsmustbepositionedcorrectlyinsidetheERUcrutch
fairing.
•The2positionsforthesupportarmsmustbemaintainedcorrectlyusing
locatingpins.
•Fairingskinmustbeproperlyandaccuratelytrimmedsothatwhen
attachedwiththepylonhousingitfitsperfectly.
4

5. Jigs and fixture for ERU crutch fairing
Setup1:
Todrill4holesof14mmdia.atdifferentlocationsontheskin/fairing
usingthedrilltemplate.
Thedrilltemplatesarefastenedontothebaseplateofthefixtureatthe
firstlocation.Thenthedrillingoperationiscarriedout,thecenterofthis
drilledholeareensuredtobeinlinewiththeaxisoftheholepresentin
thebulkhead.Thebushesprovidedonthedrilltemplateactsasguidefor
themovementofthedrillingtool.Thedrilltemplatesareremovedfrom
theirplaceonlyaftercompletionofdrillinginthatlocation.After
removingthedrilltemplateitisfittedonthenextconsecutivelocation.
Thisprocedureisrepeatedtillallthe4holesof14mmdia.aredrilled.
Thedrilltemplateisremovedfromthefixture;thenthefixtureassembly
iscleanedensuringthatthereisnowastechippresentonthefixture
assembly.
5

6. Jigs and fixture for ERU crutch fairing
Setup2:
Topositionandclamptherivetholetemplatesandtocarryoutdrilling
pilotholesof2mmdia.thenenlargethisholesizeto3.2mmdia.
Therivetholetemplatesarefastenedontothebaseplateofthefixtureat
thefirstlocation.Thedrillingofpilotholesarecarriedoutoneafterthe
other,totally16holesaredrilledatthislocation.Sincethepitchdistance
betweentheholesaresamethedrillingoperationiscarriedoutusingthe
sametemplate.Thedrilltemplatesareremovedfromtheirplaceonly
aftercompletionofdrillinginthatlocation.Afterfinishingatoneplace
thetemplateisfastenedontoanotherlocation.Henceatotalof64holes
aredrilledusingthistemplateontheERUfairing.
Thesepilotholesarethenincreasedindiameterto3.2mmusingseparate
drillingtoolotherthantheonechosenearlier.
6

7. Jigs and fixture for ERU crutch fairing
Setup3:
Usetheendcontourblocksasreferencetomarkthetrimminglineson
thefairingusingheightgaugeandtrimtheunwantedparttofinishall
operations.
Thetemplatesareremovedfromthefixture,theheightgaugeis
mountedonthetable.Takingtheuppersurfaceofthestopperblockas
referenceatrimminglineisdrawnthroughoutthefairingusingthe
heightgaugeassembly.Thetrimmingoperationatthismarkedlineand
thedeburringoperationiscarriedouttofinishalltheoperations.
Results:
•AtotalcostofmachiningtheERUassemblyforanaircraftwasreduced
byof600$.
•Dimensionalaccuracy,repeatabilityandinterchangeabilityof
assemblewasachieved.
•Cycletimewasimprovedby40%
7

8. STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST
VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT
FILTER MANIFOLD
TheprojectwasapartofMAE546:AdvanceCAE.
Objective
Toqualifytheassemblyasanaerospacecomponentbyperformingpressureanalysisfornormal
operating,proofandburstpressurecases,accelerationandrandomvibrationsanalysisinX,YandZ
directionssoastoobtainthemarginofsafetyandcalculatingfatiguedamageratio.Also,the
projectssecondaryobjectivewastooptimizeinnerradiusofthefilterusingparametricstudy,
responsesurfaceanddesignofexperimentssoastominimizethemaximumstressinsidethefilter
bowl.
TheanalysiswasperformedinANSYS16.0andforthefiltermodelDesignmodelerwasused.
ModelPreparation
Afilletradiusof0.475inisconsideredinthebeginningtostudyiftheassemblyqualifiesasan
aerospacecomponent.Thefittingsinthemodelwerereplacedwithasolidwithnegligibledensity.
TocompensatefortheirmassespointmassesareappliedattheCGofthefittings.Thishelpsin
minimizingthecomplexityofthegeometry.Also,thepointmassesisaneffectivemethodtobalance
thepressureloadsthatarebeingactedontheassemble.Toaccountfortensionintheboltsthatfix
thefilterassemble,fixedsupportboundaryconditionisappliedtocircularregionsunderthe
manifoldsurface.Thefluidthatappliesontheinnersurfaceofthefilterisnotmodeled,butthe
massofthefluidistakenintoaccountbyadding2/3
rd
ofthemasstothemassoffilterbowland
1/3
rd
ofthemasstothemassofthemanifold.Appropriatecontactsurfacesarealsoadded.
Fixed support
TVC filter manifold assembly
8

9. STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST
VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT
FILTER MANIFOLD
Convergencestudy
Aconvergencestudyissuccessfullycarriedoutontheassemblytojustifythatthelocationofthemaximumstressbylocallyrefiningthefacesof
thevalvemanifoldandthefilterbowlwherethemaximumstressisobtainedwhentheassemblyismeshedat0.2incheselementsize.The
followingdataprovidestheconvergencestudywhereinthemaximumvon-misesstressconvergesatalocalmeshsize0.0125incheswithan
errorpresentoflessthan4%asperthespecifications.Thematerialissafeasthemaximumstressinducediswithintheyieldstrengthofthe
materialproperties.Theimagesshowtheareawherethemeshislocallyrefined.
0.025 in mesh size -Manifold
TVC Filter Manifold Assembly
Finite Element Mesh
Convergence Study -Manifold
Mesh sizeManifold StressCombined Stress% Error
0.2 20600 20673
0.1 21944 27925 6.12%
0.05 24318 29918 9.70%
0.025 24615 31025 1.20%
Convergence Study -Filter
Mesh sizeFilter StressCombined Stress% Error
0.2 20673 20673
0.1 29673 29673 5.77%
0.05 27960 27960 9.30%
0.025 30860 30860 0.30%
Convergence Study
0.025 in mesh size -Filter
Manifold
Pressure
Filter
Pressure
9

10. STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST
VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT
FILTER MANIFOLD
Forcebalancing
Duringthestaticcases,forcereactionischeckedbyapplyingareactionprobeatthefixedsupportoftheassemble.Forceimbalanceisobserved
intheY–directionduetothegapsandanomaliesinthegeometryofthemodelassemblyarisingduetothemodelmodificationdoneinitiallyto
simplifythesimulationoftheTVCfilterassembly.Reactionprobeappliedatthefixedsupportsdepictstheforceimbalanceintheassembly.The
totalreactionforceinalongeachcomponentofthedirectionisrequiredtobelesserthan5lb.Asperthespecifiedrequirements.Therefore,
thisimbalanceintheforceisbalancedbyapplying96psiofadditionalpressuretotheinnertosurfaceofthefilterbowltoobtainthenet
reactionforcewithinthespecifiedrequirements.Themaximumvon-misesstressinducedinthesysteminthenrecordedforthequalificationof
theassemble
TestSpecification
Pressurecases RandomVibration
•Normaloperatingpressurecase:3200psi Longitudinal:X-direction
•Proofpressurecase(1.5*NOP):4800psi Tangential:Y-direction
•BurstPressurecase(2.5*NOP):8000psi Radial:Z-direction
Accelerationcases
+1gaccelerationappliedinX,Y,Zdirections.
ScalingfactorforMSandFDRcalculations
•6.22xResultforX–directionalanalysis
•2.00xResultforYandZ–directionalanalysis
NOTE:Alltestsrequirematerialtobe
Characterizedatmaximumflight
environmenttemperature:135degC
Random Vibration requirements
10

11. STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST
VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT
FILTER MANIFOLD
Margin of safety for flight acceleration –Longitudinal flight axis
Margin of safety for flight acceleration –Tangential flight axis
Margin of safety for flight acceleration –Radial flight axis
Margin of Safety for Assembly Components under Proof Pressure
Margin of Safety for Assembly Components under Normal operating
pressure
Margin of Safety for Assembly Components under Burst Pressure
11

12. STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST
VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT
FILTER MANIFOLD
Maximum Von-Mises Stress –Normal Operating Pressure
Maximum Von-Mises Stress –Proof Pressure
Maximum Von-Mises Stress –Burst Pressure
Maximum Von-Mises Stress –Axial (X) Acceleration
Maximum Von-Mises Stress –Lateral (Y) Acceleration
Maximum Von-Mises Stress –Lateral (Z) Acceleration
12

13. STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST
VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT
FILTER MANIFOLD
Results: Random Vibrations
3 sigma stress in Z direction
3 sigma stress in X direction
3 sigma stress in Y direction
13

14. STRUCTURAL ASSESSMENT AND ANALYSIS OF THRUST
VECTOR CONTROL (TVC) HYDRAULIC SYSTEM FLIGHT
FILTER MANIFOLD
Clockwise from top right to left: Mode shapes 1
to 6 for Random Vibration analysis
Response Surface plots for
fillet optimization
Margin of safety and FDR ratio
calculations
Conclusion
TheTVCfiltermanifoldassemblyachievedalltherequiredmarginofsafetyaspositivevaluesandallfatiguedamage
ratioswerelessthanthedesignlimitof1.
Therefore,theTVCfilterqualifiedasanaerospacecomponent.
14

15. Design for Autodesk
DesignforAutodeskisaprogrambyAutodeskdesignacademywhichencouragesstudentstolearnandmodelintheirlatest
CADsoftwareFusion360.
Projectrequirements:
1.ProjectmustbecreatedexclusivelyusingAutodeskFusion360.
2.Projectmustinclude15+individualuniqueparts(thisdoesnotincludefastenerssuchasnuts,bolts,screws,etc.).
3.YoumustbethesoleowneroftheprojectandallmaterialssubmittedtoAutodesk,andnothirdparty(includingyour
school)shouldhaveanyrightsofanymaterialsyousubmit.Projectssponsoredorfundedbythirdpartiesmaynotbe
used.
4.Allindividualcomponentsofyourmechanismmustbemodeledbyyou.YoucannotimportexistingCADdataintoyour
design.(StandardpartsmaybeaccessedthroughtheMcMasterCarrlibrary.)
5.Youmustcombinethemechanismpartsintoanassembly.
6.Theprojectrequiresthemodelingoftheexternalsandinternalsofthemodel/assembly.
7.Prismaticshapedmodelssuchasboxedfurnitureorarchitecturewillnotbeaccepted.
IhavesuccessfullysubmittedoneofmyCADmodelsandIamintheprocessofcompletingmysecondCADmodel.Thedesign
programhelpedmegainavaluableopportunitytolearn3Dmodelinginonemorenewsoftware.
15

16. Design for Autodesk
6 Speed -BLENDER
16

17. Automatic Basket Ball Machine
ThisdesignchallengeprojectwasapartofMAE540:Advanceproductdesignmethodscourse.
Challenge
Foramateurplayersmostofthepracticetimeisspentretrievingthebasketballafteritgoescareeningofftherimorbackboardor
afteritfallsthroughthebasket.Asaresult,therewasaneedtoallowplayerstomaximizeshootingtimebyminimizingthetime
spentretrievingbasketballs.
Thedesignchallengewastodesignasystemthatreturnsathrownbasketballtotheplaceoftheshooterwithoutmanualrotationof
theshootingreturndevice.Thetargetedplayerswerein10-16yearsofage.
Theshootercouldbeasfarawayas24ft.Thesystemdesignedmustnotblocktheshooter'saccesstothebasket.Itmustbeeasily
setuponahoopandcourt.Itmustfitanykindofhoopthatayoungplayermighthave(e.g.,hoopsthataresetuponhomecourts,
garagesorarefree-standing).Itshouldbeeasilytransportableandstorableinasmallspace.Itshouldbeaffordablebytheaverage
family.
Design
Mydesignwasratedthehighestintheclassandwasregardedasanuniqueidea.Iwassuccessfulinanalyzingtheproblemand
designingadevicethatmetalltherequirements.ThedesignprocessimplementedtosolvethechallengewaslearntintheMAE540
class.Also,duringthedesignprocessIlearntandused2newsoftware's,toformulatetheproblemstatementandobjectivetreeI
used‘Problemformulator’developedatArizonaStateUniversityandforideagenerationIused‘Ideation-space’.
TheCADmodelswascreatedusingSolidworksandCatiaV5.
Designprocess
Problem
formulation
Objective Tree,
Requirements,
User scenario,
Function decomposition
Brain storm,
Morph chart,
Concept sketches
Modeling and
Analysis
Documentation:
CAD models,
simulation,
BOM
17

18. Automatic Basket Ball Machine
Morph chart
Concept sketches
18

19. Automatic Basket Ball Machine
Final Design
Collection -The basketball thrown towards the basket hoop is collected using a net frame. The net frame was designed
large enough so as to account even for air ball [ if the ball misses the basket board that is behind the hoop]. Once the ball is
detected in the net frame a linear actuator stops the ball from entering into the return mechanism.
Sensing/Detection -The second stage makes use of 2 main sensors, an IR motion sensor that detects user position on the
court and an ultrasonic sensor that detects the distance of the user from the return mechanism.
Return -Based on the inputs from the 2 sensors the return mechanism rotates and aligns itself to the user position. Now
the linear actuator releases the basket ball into the return mechanism. The 2 rollers in the return mechanism rotate at a
certain speed based on the distance data from ultrasonic sensor.
Figures showing basketball collection and return 19

20. Automatic surveillance vehicle
ThiswastheseconddesignchallengeprojectwhichwasapartofMAE540:Advanceproductdesignmethodscourse.
Objective:Todesignandbuildafunctionaldevicethatiscanautomaticallysteerandsurveystwobuildingsin‘8’patternand
thenstopsatthemidpointin-betweenthetwobuildings.
Problem
formulation
Objective Tree,
Requirements,
User scenario,
Function decomposition
Brain storm,
Morph chart,
Concept sketches
Modeling and
Analysis
Documentation:
CAD models,
simulation,
BOM
1 2
96”
48”
48”
Requirements
•Thevehiclemuststartatandstopatornearthereferenceindicatedinthediagram.
•Thevehiclemustfitwithina6x6xl2inchbox.
•ThevehiclemustbepoweredbyoneortwoRadioShackDCmotors(partnumber273-223,
258or047)andcompatiblebatteries.Nootherenergysourceshallbeincludedwithinthe
vehicle.
•Thevehiclemusthaveanindexmarkwhichistobeusedtopositionthevehicleinthe
startingpositionandwillbeusedtomeasurethedistancebetweentheindexmarkandthe
referencewhenthevehiclestops.
•Withinoneminutethevehiclemustbeplacedinthestartingpositionandmotioninitiated
bya"switch"onthevehicle.Oncestarted,nocommunicationofanykindshallbe
transmittedtothevehicle.
•Thevehiclemusttravelaroundbuilding1,crossthereferencepoint,andtravelaround
building2,thencometoastopatornearthereferencepoint.
•Micro-controllersoranytypeofCPUisNOTallowed;howevernon-programmableelectronic
orelectricalcomponentscanbeused.
•YouareNOTallowedtoplaceanyguidechutesortracksontheplywoodoutsidethe6x6x12
envelope.
Design process:
20

21. Automatic surveillance vehicle
FinalDesign
Thesurveillancevehiclefabricatedmadeuseoftwomotors,oneforsteeringandotherforforwardmovement.The
devicecontained2clockswhichwasusedasswitchestoopenandclosethecircuits.Thedevicewaspoweredby27volt
batteries.
Precalculations:
•Thetimetakenbythedevicetogoaroundbuilding1.
•Timetakenbythedevicetocompletetheentire‘8’pattern.
•Theangleatwhichthefronttiresmustbeturnedtogoaroundthebuilding1andbuilding2.
21

22. Automatic surveillance vehicle
Turningmechanism:
Theprecalculatedtimetakenbythedevicetogoaroundbuilding1wasaround10sec,whichwassetonthefirstclock.
After10secondsthesecondhandontheclockmakescontactwithaswitchthatclosesacircuit.Thistriggersthefirst
motorandturnsthewheelswhichissetatananglesuchthatitmakesaperfectcirclearoundthebuilding2.
Stoppingmechanism:
Thesecondclockissetfor18secondswhichwasprecalculatedtimetakenbythedevicetogoaroundboththe
buildings.After18secondsthesecondhandontheclockbreaksthecontactwithaswitchthatopensthecircuit.
Therebythepowersupplytothesecondmotorthatisusedforforwardmovementisstopped.Sincethereisnobreaking
mechanismthepowersupplytothesecondmotorisstopped2secondsbeforeitapproachesthecenterpointinorder
toaccountforinertia.
22

23. Orange Picking Device
ThisdesignassignmentwasapartofMAE540:Advanceproductdesignmethodscourse.
Objective
Todesignaorangepickingdevicethatcanbeusedinabackyardtoharvestorangesfromlarge,thickandmaturetrees.
Finaldesign
Thedesignmadeuseofnestedpipestoreachouttotheorangesonthetree.Acupwithaninflatablerubbertube
holdstheorangeinplace.Thecupthenrotatestoplucktheorangefromthetree.Thenrubbertubedeflatesanddrops
theorangeinanet.Alltheorangesrollsdownthroughthenetandarecollectedatthebottom.Thedeviceiscontrolled
byajoystickprovidedatthebottom.
Morph chart Conceptual Designs
23

24. Orange Picking Device
Figures showing orange picking and collection
24

25. Human Powered Paper Bike
ArizonaStateUniversityisallaboutfindingneworinnovatedwaystoaccomplishatask.Thisdesignchallenge
wasapartofEGR535:EngineeringInnovationandentrepreneurship.
Satellite view of race path
for the paper bike race.
Challenge
The challenge for the paper bike race is to build a human-powered vehicle out of
paper products (e.g. cardboard, paperboard) to carry a rider and be pushed or
pulled by another team member. The bike must be built in a two week time frame
and the team will be racing against 5 additional teams. The race is played on a
circular path with two sets of two laps each (Figure 1). The goal is to win the race.
The race rules are as follows:
•The paper bike must fully support one rider during the race.
•The paper bike must be powered by a single puller or pusher.
•Race consists of two heats of two laps each.
•One or more team members can participate as the ‘power source’ or
‘passenger’ in one or more laps.
Functional Constraints
•Bike must support the weight of one team member.
•The bike must be powered by one team member.
•The rider and the driver must wear head protection
while operating the bike.
•Rider cannot operate the bike.
Physical Constraints
•The bike must fit within a 5’ x 3’ x 3’ box when fully assembled.
•The bike must be constructed with paper products and wood glue
only.
•Vehicle has a budget of $0. Therefore materials must be provided
or recycled from elsewhere.
25

26. Human Powered Paper Bike
Functional RequirementMetric Rationale
The bike must hold one
team member and they
may not aid the
movement of the bike.
critical
The base of the bike will
have a back support and
foot support for the rider
so he can sit comfortably
and not interrupt the
motion of the bike.
Only one team member
may push or pull the bike
and a different team
member must remain
stationary on the bike.
The bike must be able to
move swiftly.
Cardboard wheels of
sufficient thickness
(layers of cardboard) will
be latched on an axle
attached to the base.
Additionally the wheels
will be smoothened to
avoid friction.
By providing tape over
the circumference of the
wheels, friction will be
greatly reduced.
The bike must be able to
easily make turns.
Turn right at 90 degrees
within a few seconds.
The course around
campus only has right
turns
The bike must be able to
finish 2 heats (4 laps)
around the course
successfully.
critical
The course is a
rectangular course of
‘insert dimensions here’.
This is a requirement to
win the race.
The pusher must be able
to easily support the bike
with the passenger while
operating it.
critical
A third wheel will be
added to the back
support to help carry the
load.
There will be two runs
and the pusher will be
switched between races.
Therefore each member
must be able to operate
the bike with the lightest
rider.
Physical RequirementMetric Rationale
The bike must remain
intact (avoid failure)
while the operator
pushes/pulls during
the race.
The base of the bike
will be made with
several layers of
cardboard to ensure
strength and
reinforced with very
sturdy cylindrical
cardboard pipes as
the back support.
The strength to
weight ratio must be
high to ensure easy
push/pull and
completion of the
race.
Bike must be
constructed entirely
with paper products.
critical
Paper products are
products consisting of
at least 50% paper by
mass.
This is a paper bike
race, so the bike must
be made of paper.
One side of the bike
must be longer than
the other two. Much
like a dolly.
The back support will
be the chosen longer
side as this can allow
the passenger to lean
comfortably while
being pushed/pulled.
Bike must be able to
fit within a 5’ x 3’ x 3’
box when fully
assembled.
Bike must be
lightweight.
Bike still must be
strong and meet
requirements of the
race.
Provide easier control
of the bike and
requiring lesser effort
by operator.
Easy to build and
disassemble
Fewer than 5
separate parts.
Bike should easy take
apart when finish
racing
Functional Requirement Physical Requirement Critical Component
Onecriticalfunctionforourpaperbikeisto
beabletocontinuouslywithstandaminimum
payload(thehumanrider)ofroughly130
pounds.Inordertoaccomplishthisthebike’s
framemustbestructurallysound.Utilizing
materialfrompreviouspaperprojectswe
builtthebikeframeforourcriticalfunction
prototype(Figure).Thebottomplatformwill
supporttheriderandtheladderlikebacking
willaidtheriderinremainingstationaryon
thebikewhilethepusherisoperatingit.
26

27. Human Powered Paper Bike
Figures showing human powered paper bike
27

28. Objective
To help disabled person to transfer onto the bed from the wheelchair without anyone assisting the
user. To help the disabled person to become independent.
28
ProblemStatement:
Inourcurrentmoderntechnologicalworldthereareveryfewtransferdevicethathelpsdisabled
peopletotransferthemfromawheelchairtoanyotherseatingsurfaceslikebed,achairora
toiletetc.Themajorproblemsassociatedwiththesefewdevicesarethattheyareheavy,
expensive,complex,dependent,notuserfriendly,notergonomic.Thereforethereisanimmense
needforaninnovativedevicethatissimpleandinexpensiveandthatgetsthejobdone.
Alotofwheelchairusers[disabledpeople]havetheurgetodosimpletaskslikelyingdownon
thebed,usingtoiletorevenassimpleassittingonanyothersurfacetodoitontheirown,
withoutanyoneassistingthem.Thereforetheinnovativetransferdevicemustbedesignedthat
helpsmakethedisabledpeopleindependentandtherebyhelpingthemmaketheirlifebetter.
ThisisaninnovationchallengewhichismycurrentprojectIamworkingonasapartofEGR535:EngineeringInnovationand
Entrepreneurship.
Transfer Wheelchair

29. 29
Design thinking process
Morph chart
Business Model Canvas
Transfer Wheelchair
Requirements
https://canvanizer.com/canvas/wm696qEoAkQ

30. Transfer Wheelchair
30
Design Concept

31. Miscellaneous
Mouse
CatiaV5 surfacing design project
31