Product Design Process

By Team Strider

Table of Contents

• Introduction • Customer Needs • Benchmarking • Programming Concepts • Structural/Lift Concepts • Propulsion Concepts • Concept Integration • Gantt Chart/Conclusion

Introduction

• Ultimate goal Design and fabrication of an autonomous hovercraft • Product Development Process Two phases completed Benchmarking & Customer Needs Concept Generation

Introduction (continued)

Benchmarking & Customer Needs Results: – Several existing models assessed – Company owner interviewed

Introduction (continued)

Concept Generation: • Hovercraft subsystems divided into three groups • Structure and Lift • Propulsion and Power • Instrumentation & Control

Introduction (continued)

Assessment: • Pugh Matrix • Concept scoring matrix

Customer Needs

By Team Strider

Customer Needs Evaluation

• Consulted Bryan Phillips, owner/operator of Amphibious Marine, a commercial hovercraft manufacturing company • Amphibious Marine builds hovercraft used in industry as well as recreation, for private and government customers.

Important • Basic functionality • Reliability Relatively Unimportant • Costs • Adaptability

Benchmarking

By Team Strider

The Benchmarking Process

• Evaluate our competition to obtain knowledge • Comparative analysis of competitors products.

• Process, methods, and service performance against competitors.

Existing Products Product Griffon 2000TDX Figure 1 Reference 1 Description RC Hovercraft Models developed this model with the help of Griffon Hovercraft Ltd, a company for real size hovercrafts. It is a fully operational replication of a full sized craft at 1/30th scale. This model has the ability to independently control lift and thrust. It operates on two channel radio, which enables the thrust motors to be controlled with full forward or reverse thrust at the same time while maintaining throttle control of the lift motor (with the help of a specially built ILC model). The craft has the ability to operate on ice, water, snow and land, and has a water proof body panels and skirts [1].

Specifications

Power:

4.8 to 8.4 volt 600mA/Hr and greater capacity (mA/Hr) NiCad, MiMH or Lipoly batteries.

Runs on 4, 6, or 7 cell batteries.

Propellers:

Thrust:

3 inch (0.0762 m) ducted fan

Lift:

3 inch (0.0762 m) ducted fan

Motors:

280 size

Skirt:

Black Rip-stop Vinyl

Operating Surface:

Water or Land (will float off of hover and return to full hover) Will transition from water to land

Radio Requirements:

2, 3 or 4 channel land based RC systems ( as used in RC cars and boats)

Speed Controller Requirements:

5 Amp 7-8 cell Electronic Speed Controller (ESC). Can use ILC model for 2 channel control with forward/reverse thrust

Craft size:

Length: 18 inches (0.4572 m) Width: 8 inches (0.2032 m) Height: 5 inches (0.127 m)

Craft Weight:

17 ounces (0.481941893 kg) loaded with battery, ESC and radio equipment (as in our combo)

Max speed:

30 km/h (8.33 m/s)

Range:

¼ mile (402.33600 m)

Product SR.N5

Figure 2 Reference 1 Existing Products Description The SR.N5 is a very detailed craft with elevator moldings and a detail engine intake. It has a rear storage bin, puff ports, bifurcated exhaust, and cabin lines. This craft is a fast craft. The SR.N5 has forward and reverse thrust capabilities, and it goes backwards just as fast as it goes forward. It has super lift power and outstanding handling. It features high efficiency twin motors for optimum lift and thrust. The Sr.N5 is known for its efficiency and its durability [1].

Specifications

Craft size:

Length: 26 inches (0.6604 m) Width: 20 inches (0.508 m) Height: 11 inches (0.2794 m)

Craft Weight:

2.4 Pounds (1.08862169 kg) loaded with battery and radio equipment (as in our combo)

Power:

7.2 or 8.4 volt 1700mA/Hr and greater capacity (mA/Hr) NiCad RC car battery.

Motors:

400 size

Propellers:

Thrust:

6 inch (0.1524 m)

Lift:

4 inch ducted fan (.1016 m)

Skirt:

Black Rip-stop Vinyl

Operating Surface:

Water or Land (will float off of hover and return to full hover) Will transition from water to land

Hover Height:

1.5 inches (0.0381 m) (no additional load other than kit as built with 6 cell NiCad)

Speed:

10-25 MPH (4.4704 - 11.17600 m/s) depending on terrain and operating conditions

Radio Requirements:

2 or 4 channel land based RC systems ( as used in RC cars and boats)

Speed Controller Requirements:

Electronic Speed Controller (ESC) 20 Amp 7-8 cell

Product HoverDart Figure 3 Reference 1 Existing Products Description The HoverDart is a racing craft design that has the ability to perform under excruciating course conditions. It is said to be an extremely fast craft. It accelerates from a standing start to full speed in an extremely rapid manner. The HoverDart is easy to maneuver, and it loses very little speed due to turning friction. The HoverDart operates on land, snow, water and ice with a two channel control system, and it is suitable for any type of motor although it contains a powerful RC motor for outstanding performance. The HoverDart has a proportional RC throttle on lift and thrust which gives it exceptional power [1].

Specifications

Craft size:

Length: 24 inches (0.6096 m) Width: 16 inches (0.4064 m) Height: 9 inches (0.2286 m) Craft Weight: 2.3 Pounds (1.04326245 kilograms) loaded with battery and radio equipment (as supplied in our combo)

Power:

7.2 or 8.4 volt 1700mA/Hr and greater capacity (mA/Hr) NiCad RC car battery. Can also be used with LiPoly and NiHM battery packs.

Motor:

480 size

Propellers:

6 inch (0.1524 m), Ducted

Skirt:

Black Rip-stop Vinyl

Operating Surface:

Water or Land (will float off of hover and return to full hover) Will transition from water to land

Hover Height:

1.5 inches (0.0381 m) (no additional load other than kit as built with 6 cell NiCad)

Radio Requirements:

2 channel land based RC systems ( as used in RC cars and boats)

Speed Controller Requirements:

Electronic Speed Controller (ESC) 20 Amp 7-8 cell

Issues with Current Products • • • • Speed – Products rarely exceed the 30 – 35 km/h barrier – Can be overcome by: • Increasing Size and Number of Fans • Minimizing the Weight/ Size of Product Maneuverability – Reduced Performance in Reverse – Can be overcome by: • Implementing a Dual Fan Propulsion Assembly Safety – Exposed Fan Blades – Can be overcome by: • Protective Screens Placed at Ends of Ducted Fans Durability – Brittle and Vulnerable Components – Can be overcome by: • Additional Layer of Rubber Applied to the Body

Project Specifications • Circular Base: • Height: • Weight: • Payload Capacity: • Volume: • Footprint: • Top Speed: 13 inches 3.5 inches < 2.5 lbs.

> 5 lbs.

618.5 cubic inches 176.71 square inches 30 km/h

Programming Concepts

Hovercraft Programming Concept Design By Team Strider’s Programming Team

Introduction to Concept Generation

• • • • • • • • Navigation: Most important. The hovercraft’s ability to navigate the course based upon sensor location and types of sensors accounts for 25% of the weight. It is most important that the hovercraft be able to navigate the course and complete the main objective Sensitivity: Weighted at 20%.

Without perfectly functioning sensors, there would be no hovercraft, being that malfunction in the hovercrafts sensors would create a significant handicap in its mobility. It would interfere with the programming and therefore, make the hovercraft incapable of follow commands. Durability: Weighted at 20%, it focuses on the durability of the sensors. It is imperative that the sensors are durable for the reasons mentioned above. So when selecting the final concept we had to account for the placement of the sensor that will allow them to last and not to be exposed to collisions. Ability to be integrated: Integration was weighted at 15%.

When selecting a concept we analyzed which concept would have the ability to facilitate our integration phase without interfering in any way with other subsystems.

Introduction to Concept Generation

• • • • • • Versatility: Versatility was weighted at 10%.

We had to focus on those concepts that would enable us to make the programming of the hovercraft system more versatile. We are mainly searching for versatility in the programming section that makes the craft adaptable. This versatility will somewhat depend on the sensors placement on our hovercraft. Sensor balance: The sensor balance accounts for 5% of the weight. The sensor balance deals with equal distribution of the sensors placement accounting for every side of the hovercraft. Though ballasts could be used to counter any weight inconsistencies, it is preferable not to need them and keep weight down. When we focused on the criteria, we focused on the concept that would provide us with the most balance.

Sensor stability: The stability of the sensor also accounted for 5% of the weight. It is important that the sensors are positioned on the hovercraft on a spot where they would not fall off or be subjected to movement, and risk the chance of being ruined, or displaced.

Concept Generation

Concept #2 Concept #1

The Concepts (continued)

Concept #4 Concept #3

The Concepts (continued)

Concept #6 Concept #5

The Concepts (continued)

Concept #7

Weighted Criteria

Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6 Concept 7 Sensor Balance (5%) 6 1 5 3 2 4 7 Durability (20%) Sensitivity (20%) Versatility (10%) Sensor Stability (5%) 3 4 1 6 7 5 2 7 3 2 4 5 6 1 7 3 2 4 5 6 1 3 1 1 6 7 5 2 Ability to be Integrated (15%) 1 Navigation of Course (25%) 4 5 6 1 2 4 3 3 6 2 7 7 5

Pugh Chart

Balance Durability Concept 1 Concept 2 Concept 3 Concept 4 Concept 5 Concept 6 Concept 7 * * 0 + 0 + 0 + - 0 - 0 - + Sensitivity Versatility Stability Compatibili ty * * * * - - + - - - + - - - + - 0 + 0 0 + + 0 0 + + 0 0

Concept Selection

*Images care of Microsoft Office Clipart

Concept Selection (continued)

CONCEPT XY!!!!

*Images care of Microsoft Office Clipart

Structural/Lift Concepts

Hovercraft Programming Concept Design By Team Strider’s Structural/Lift Team

Figure 1

• Frisbee-like circular base • Centrifugal fan

Figure 2

• Square, styrofoam base • Piston based air pump • Distributed arrangement

Structure/Lift – Figure 3

•Thin Metal or Balsa wood base with axial symmetry •Axial fan •Dispersed load

Structure/Lift Pugh Chart

Strength Durability Balance Ease of Construction Availability of materials Cost Safety Weight Size Payload assisting Sum +'s Sum 0's Sum -'s Net Score Rank Continue ?

No 2 2 6 -4 + + 0 0 0 0 0 0 10 0 0 0 0 0 0 0 0 0 + + 3 2 5 -2 0 + 0 0 0 0 4 6 -6 0 0 + 1 6 3 -2 0 0 0 0 0 0 + 2 5 3 -1 0 0 + 0 0 0 Yes No No No No Yes 0 0 0 0 10 0 0 0 0 0 0 0 0 0

Structure/Lift Pugh Chart

Strength Durability Balance Ease of Construction Availability of materials Cost Safety Weight Size Payload assisting Sum +'s Sum 0's Sum -'s Net Score Rank Continue ?

0 + 0 + + 4 2 4 0 + No No 0 + 0 + 0 3 4 3 0 + 0 0 + 0 + 2 3 5 -3 0 0 + 0 + 0 3 5 2 1 + 0 0 0 0 0 0 0 0 0 0 10 0 0 0 0 0 0 0 1 9 -8 0 0 0 0 0 0 0 0 10 0 0 0 0 0 0 0 0 0 0 4 6 -6 0 0 0 0 0 0 0 0 10 0 0 0 0 0 No No Yes No Yes

All-Terrain Vehicle

United States Patent 6845833 • Rectangular/trapezoidal shape with a main cabin • Lift engine supplies lift to the backside of the main body. Separate from propel engine.

• Incorporated various structural shapes in our concept generation.

• Assumed the lift engine to be separate from the propel engine.

Vehicle Assisting Fabric

United States Patent 6955192 • External fabric utilized to support vehicle in snow, sand, or mud.

• When using fragile materials, such as Styrofoam, for the base, rubberized spray can be applied to reinforce the structure.

Air Cushion Vessel

United States Patent 6672234 • Weight supported by varying elements such as surfaces, different volumes, air cushions, and pressure.

• Size/arrangement are designed to achieve the best effect for lift and motion.

• Incorporated concepts like size of volume and need for strong powered lift fan to provide air cushion.

• Recognized need for distributed arrangement to create balance for lift and motion.

Propulsion/Power Concepts

Hovercraft Programming Concept Design By Team Strider’s Propulsion/Power Team

Propulsion Concepts

Figure 4 Reference 2 Hovercraft Concept Design Rear mount Propulsion with rear mount steering fan

Propulsion Concepts (continued)

Hovercraft Concept Design Dual Propulsion/Steer motor Single lift motor Figure 5 Reference 2

Propulsion Concepts (continued)

Figure 6 Reference 2 Hovercraft Concept Design Dual Propulsion/Steer motors

Propulsion Concepts (continued)

Figure 7 Reference 2 Hovercraft Concept Design Dual Propulsion motors Single lift motor

Propulsion Concepts (continued)

Figure 8 Reference 1 Hovercraft Concept Design Rear Facing Propeller with Rudders

Propulsion Concepts (continued)

Figure 9 Reference 1 Hovercraft Concept Design Air Intake and Directional Expulsion System

Propulsion Concepts (continued)

Figure 10 Hovercraft Concept Design Dual Rear Angled Propellers

Propulsion Concepts (continued)

Figure 11 Hovercraft Concept Design Dual Front Mounted Pulling Propellers

Propulsion Concepts (continued)

Figure 12 Hovercraft Concept Design Multi-Directional Propellers That Pull

A. Dual Propulsion/ Steer Motor B. Rear Mount Propulsion w/ Rear Mount Steering Fan C. Dual Mid mounted Rotating Propellers D. Dual Fixed Mid-mounted Propellers

E. (Reference) Rear Facing Propeller with rudder

F. Air Intake and Directional Expulsion System G. Dual Rear Angled Propellers H. Dual Front Mounted Pulling Propellers I. Multi Directional Propellers Photos from Reference 1

Selection Criteria

Size Minimum Fan Output Maximum Fan Output Cost Ease of Integration Weight Aesthetics Variable Power Durability # of Fans (2 is best) Turning Radius A 0 0 0 0 -' 0 0 +' 0 +' +' B -' 0 +' -' -' -' 0 +' 0 -' 0 C 0 0 +' 0 -' 0 0 +' 0 +' +' 0 +' 0 +' 0 0 +' 0 +' +' D 0 Concepts

E 0

F +'

0 0 0 0 0 0 0 0 0 0

-' -' 0 -' +' +' -' 0 -' 0 G 0 0 +' 0 +' 0 0 +' 0 +' 0 H -' 0 +' -' -' -' 0 +' -' +' -' -' I 0 +' -' -' -' -' +' -' -' +'

Sum +'s Sum 0's Sum -'s A 3 8 1 B 2 4 6 C 4 6 4 D 5 6 1

E

0 12 0 F 4 3 5 G 4 7 1 H 3 2 7 I 3 1 8 Net Score Rank Continue?

2

3

Yes -4 7 (t) No 0 4 (t) Yes 4

1

Yes 0 4 (t) Yes -1 6 No 3

2

Yes -4 7 (t) No -5 9 No

Selection Criteria

Power Requirements Size Minimum Fan Output Maximum Fan Output Cost Ease of Integration Weight Aesthetics Variable Power Durability Number of Fans Turning Radius

Weight

Dual Propulsion/ Steer Motor

Ratin g Scor e

Dual Mid mounted Rotating Propellers

Ratin g Concepts - Propulsion Scor e

Dual Fixed Mid mounted Propellers

Ratin g Scor e

(Reference) Rear Facing Propeller with rudder

Ratin g Scor e

Dual Rear Angled Propellers

Ratin g Scor e

8% 10% 5% 5% 10% 10% 10% 5% 14% 5% 8% 10%

Total Score Rank 3 3 3 3 4 2 3 3 3 3 3 4

3.1

4 0.24

0.3

0.15

0.15

0.4

0.2

0.3

0.15

0.42

0.15

0.24

0.4

2 3 3 4 3 2 3 3 4 3 4 4

3.19

3 0.16

0.3

0.15

0.2

0.3

0.2

0.3

0.15

0.56

0.15

0.32

0.4

2 3 3 4 3 4 3 3 4 3 4 3

3.44

1 0.16

0.3

0.15

0.2

0.3

0.4

0.3

0.3

0.56

0.15

0.32

0.3

3 3 3 3 3 2 3 3 2 2 2 2

2.53

5 0.24

0.3

0.15

0.15

0.3

0.2

0.3

0.15

0.28

0.1

0.16

0.2

2 3 3 4 3 3 3 3 4 3 4 3

3.34

2 0.16

0.3

0.3

0.2

0.3

0.3

0.3

0.15

0.56

0.15

0.32

0.3

Dual Fixed Mid-mounted Propellers

Power Concepts

Power Concepts

Figure 13 Reference 4 Hovercraft Power Supply Design 4 "AA" Serial Battery Holders

Power Concepts (continued)

Figure 14 Reference 5 Hovercraft Power Supply Design "PP3" Serial Battery Holders

Power Concepts (continued)

Figure 15 Reference 6 Hovercraft Power Supply Design 7.2V Rechargeable Battery Pack

Power Concepts (continued)

Figure 16 Reference 7 Hovercraft Power Supply Design Solar Panels

4 "AA" Serial Battery Holders "PP3" Serial Battery Holders (Reference) Battery Pack Solar Panels Photos from Reference 4, 5, 6, 7

Selection Criteria

Power Output Size Weight Ease of Integration Cost Availability 4 "AA" Serial Battery Holders 0 '+' '+' '+' '+' +' Sum +'s Sum 0's Sum -'s Net Score Rank Continue?

5 1 0 5 2 Yes Concepts "PP3" Serial Battery Holders (Reference) Battery Pack +' +' +' 0 0 0 Solar Panels -' 0 0 +' +' +' 0 0 0 -' -' +' 6 0 0 6 1 Yes 0 6 0 0 3 Yes 1 2 3 -2 4 No

Selection Criteria

Power Output Size Weight Ease of Integration Cost Availability

Weight

10% 20% 20% 20% 20% 10%

Total Score Rank Continue?

4 "AA" Serial Battery Holders

Rating 3 3 4 Weighted Score

0.3

0.6

0.8

Concepts - Power

"PP3" Serial Battery Holders

Rating 4 5 5 Weighted Score

0.4

1 1 (Reference) Battery Pack

Rating 2 2 3 Weighted Score

0.2

0.4

0.6

4 5 4

3.9

2 No 0.8

1 0.4

4 5 3

4.5

1 Yes 0.8

1 0.3

2 2 3

2.3

3 No 0.4

0.4

0.3

Dual Fixed Mid-mounted Propellers 4 "AA" Serial Battery Holders

Team Strider’s Gantt Chart

Hovercraft Concept Design By Team Strider

Gantt Chart

TASKS: Team Contract Prospectus Introduction, Benchmarking, and Specification Concept Generation and Selection Presentation I Preliminary Design Design Report Final Presentation and Report Research/ Specification Stage Concept Generation and Selection Stage Drawing/ Design Stage Build (Subsystems) Stage Integration Stage Prototype Testing Stage Redesign Stage WEEK 1 (Jan 30 Feb 03) WEEK 2 (Feb 6 10)

Key

Assignment Already done Presentation Project Stages: Should be done by Buffer Deadline Break WEEK 3 (Feb 13 17) WEEK 4 (Feb20 24) WEEK 5 (Feb 27 Mar 3) WEEK 6 (Mar 6 10) WEEK 7 (Mar 13 17) WEEK 8 (Mar 20 26) TASKS: Team Contract Prospectus Introduction, Benchmarking, and Specification Concept Generation and Selection Presentation I Preliminary Design Design Report Final Presentation and Report Research/ Specification Stage Concept Generation and Selection Stage Drawing/ Design Stage Build (Subsystems) Stage Integration Stage Prototype Testing Stage Redesign Stage WEEK 9 (Mar 27 31) WEEK 10 (Apr 3-7) WEEK 11(Apr 10 14) WEEK 12 (Apr17-21) WEEK 13 (Apr 24-28) WEEK 14 (May1-5) WEEK 15 (May8 11) WEEK 16 EXAMS

Conclusion

References

Reference 1: RC Hovercraft Models. (9 February, 2005). Reference 2: US. Patent Bureau www.uspto.gov

(1 March, 2006) Reference 3: Hobby Lobby www.hobby-lobby.com

(1 March, 2006) Reference 4: Thomas Distributing www.thomas-distributing.com

(5 March, 2006) RC Hovercraft Models. (9 February, 2005).

References (continued)

Reference 5: Strikalite Batteries www.strikalite.co.uk

(5 March, 2006) Reference 6: Only Batteries www.onlybatteries.com

(6 March, 2006) Reference 7: Silicon Solar Inc www.siliconsolar.com

(3 March, 2006)