Executive Summary - Computer Action Teamweb.cecs.pdx.edu/~far/Past Capstone Projects/Capstone... · Web viewThe results from the FEA analysis of the final Frame and Ladder design

Cabover CamperME 493 Final Report - Year 201605..JUN.2016

Academic Advisor: Dr. Evan ThomasIndustrial Advisor: Zdenek ZmurSubmitted By: P. Chand, T. Croissant, N. Roetemeyer, D. Stasiuk, R. Sutton, J. Wacker

Executive SummaryThe Cabover Camper was proposed by Mr. Zdenek Zmur to allow

him and a companion to comfortably camp in three seasons. The Camper would also allow him to continue to store his sporting equipment in his vehicle while using the built-in rack system of the car in combination with the Camper to sleep. This camper is designed as a one-off, meaning that it is only intended to be used by Mr. Zmur and his party.

The sponsor (Mr. Zmur) currently uses a tent and sleeping bag setup, as is traditional, to camp. This method, however, tends to be cumbersome, time-consuming to set up and, with unpredictable weather, is often uncomfortable to sleep in. The Camper aims to solve all of these problems with a weather proof canopy, fast set-up-and-takedown, and excellent mobility.

Main components of this design are the Ladder, the Frame, the Floor, and the Canopy; all of which come together to form the superstructure. The Ladder and base (Frame) are built with steel in various cross-sectional shapes and sizes, the floor is made of ACP (Aluminum Composite Panel) and the Canopy is constructed with Coroplast.

This specific design is completely new and one of a kind. As a result, it is tailor made to the customer’s exact specifications and requirements. Should it go into mass production a reevaluation of the safety and other features may need to be revisited.

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Table of Contents

Executive Summary ……………………………………………………………………………………………………..1

Introduction.……………...………...………………………………………………………………………………………

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Mission Statement ..……..………………………………………………………………………………………

………3

Summary of Design……………………………………………………………………………

………………3

Main Performance Criteria and Constraints ..……..……………………………………………………3

Top Level Alternatives ...………………………………………………………………………………………

………4

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Final Design………………... ..………………………………………………………………………………………

……4

Product Design Specification Chart ……………………………………………………………………………….7

Conclusion ...………………………………………………………………………………………

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Appendix ………………………………………………………………………………………

………………………….6

Introduction Residents of the Pacific Northwest have a penchant for year-round

outdoor activity--specifically outdoor sleeping or camping--and staying dry, cool and comfortable in unpredictable weather presents an inevitable challenge. Tents are a viable option but can sometimes leave the users wet and uncomfortable and they can be cumbersome and time consuming to erect and take down. Some people may just end up sleeping in their vehicles but this may present issues of where to store their gear, food or other items required for their activity. Consequently, it a sleeping option that would keep users comfortable, allows them to store their gear appropriately, and utilize all of the equipment they have at hand, including their vehicle, is in order.

Mission Statement

Summary of DesignThis team was to design a cabover camper that is aerodynamic and

easily attaches to a 2011 Volkswagen Jetta SportWagen. The cabover was to

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be made of rugged materials to provide durability and maintaining dependability. The target market is outdoorsy folk, in this case Zdenek Zmur, who want to enjoy the perks of camping without extra camping gear. A full scale model was constructed.

Main Performance Criteria and Constraints● Must sit atop a 2011 Volkswagen Jetta SportWagen● Must have minimal impact to fuel efficiency via aerodynamic features● Must sleep two people● Must have sitting clearance of 36 inches ● Must have peripheral door access and minimal rear hatch access● Should be fully rigid● Should be insulated and ventilated

Final DesignThe final design of the Cabover Camper is a collapsible sleeping

compartment that is rigidly mounted to a 2011 Jetta SportWagen with the factory mounted roof rails and an aftermarket 1¼ inch hitch receiver. When collapsed, the camper adds little additional height to the roof line of the vehicle, which keeps the negative impact on fuel economy of the vehicle to a minimum. Once, through a few easy steps ,the structure is deployed on top of the vehicle a dry and warm sleeping area is created with interior space comparable to many two-person backpacking tents.

The project is broken down into two key design components. The first design component is called the Frame and Ladder which form the structural mounting interface for the Canopy structure and the Jetta SportWagen. The second design component is the lightweight, water shedding Canopy.

Frame/LadderThe design of the Frame and Ladder started with deciding on the

mounting mechanisms to the predetermined mounting points of the rails and hitch. The hitch mount was a simple selection of 1¼” square tube steel which is standard for receiver mounts. To mount to the factory rails of the Jetta, a set of Thule 1054 clamps with steel crossbars were selected to build the design around. By selecting manufactured clamps and rails, time and money were saved in redesign, and guaranteed quality. The Thule 1054

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Clamp provided a low profile secure clamping solution to rail mounting design dilemma (Fig 1).

Figure 1: Thule 1054 clamp used in combination with the Inno 50 inch cross bar provides a secure clamping solution for the Camper.

The Frame and Ladder are designed to be welded rectangular-tube structural steel components. Being the mounting interface and providing the structural support for the sleeping area, the frame and ladder are designed to balance structural rigidity with weight savings. This balance was obtained through multiple FEA iterations where the final structural steel cross sections and the structural arrangement was determined. The results from the FEA analysis of the final Frame and Ladder design is located in Appendix D. Under the designated loading condition of Mr. & Mrs. Zmur’s combined weight in the sleeping quarter, the observed maximum deflection of the structure is 0.17” which is well within Mr. Zmur’s definition of acceptable deflection.

The Frame and Ladder incorporate key design features to aid the performance of the overall Camper. The Frame and Ladder are two separate components that are attached by ¼” cotter pins (Fig 2). This allows for easy removal and attachment of the Ladder for storage when not in use.

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Figure 2: CAD Detail view of the mounting location between the Frame and Ladder that allows of separation for ease of attachment and storage.

The next design feature incorporated is the the profile of the Ladder (Fig 3). The Ladder is designed with the intention of allowing partial access to the rear gate of the Jetta. By adding this feature, an increase in usable bed space is created atop the vehicle, and the front of the camper is shifted back from the windshield.

Figure 3: CAD detail of the Ladder Profile that allows partial access to the Jetta’s rear liftgate.

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To help the mitigate drag caused by the Cabover during its closed state, and when the vehicle is driving, provisions were made for mounting locations on the front of the Frame (Fig 4) to attach a fairing similar to the one shown in Figure 5 to direct airflow as it comes of the windshield.

Figure 4: CAD detail of a fairing mount provision on Frame. Figure 5: Example of wind Fairing to direct airflow

CanopyThe design of the Canopy began by selecting a corrugated plastic

material called Coroplast. It was selected because it is lightweight, cheap and easy to fold. The Canopy needed to be waterproof when deployed and collapsed. Scaled mockups were created to help plan out the how the canopy would fold. It was decided to make the Canopy a tapered design as seen in Figure 6. Essentially the Canopy consists of three walls and a roof that acts as both a wall and the actual roof. The structure was secured with velcro in a number of places to add stiffness to the structure. The velcro ensures that the Canopy would not collapse with a gust of wind as well as keep the mated edges secure so as not to allow the elements in.

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Figure 6: Deployed camper Canopy

To collapse for travel, the velcro is undone, the side walls folded in, followed by the rear wall (with the door) and the roof is layered on top of it all. When fully collapsed (Fig 7) the camper has a profile of only an inch or two. This, coupled with the Frame’s slim dimensions, equates to a slim structure that will lower the impact on fuel economy.

Figure 7: Collapsed camper Canopy

Product Design SpecificationsPerformance Outlined in Mission Statement and further

defined in AppendixEnvironment AppendixMaintenance Appendix

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Quantity Outlined in Mission Statement and further defined in Appendix

Size and Shape AppendixWeight Appendix

Materials AppendixLaws, Codes &

StandardsAppendix

Ergonomics AppendixTesting Appendix

Time Scales Outlined in Mission Statement and further defined in Appendix

Safety AppendixDocumentation Appendix

Installation Outlined in Mission Statement and further defined in Appendix

**Certain elements of the PDS have been deliberately left out as there is no applicability at this stage of the product development.

ConclusionThe team was able to create a one-of-a-kind Cabover Camper to fit

Zdenek’s Jetta while meeting the criteria outlined in the design specifications. The project, as of the current bids received, does not meet the budgetary constraints outlined but that may change based on further bids from fabrication shops. All in all the camper will sit atop the 2011 VW Jetta SportWagen, have minimal impact to fuel efficiency via the collapsible feature of the canopy, it will sleep two people with a sitting clearance of more than three feet, it will also allow for peripheral door and rear hatch access and be fully rigid while still being insulated and ventilated appropriately.

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Appendix A:

Product Design Specification Priority Matrix

High Priority Medium Priority Low Priority

Performance

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis

Verification

Aerodynamic to minimize MPG

impact

Zdenek Zmur

< 10 MPG Reduction

MPG < 10 MPG Reduction

Defined by Customer

Testing

Must sleep two people

ZdenekZmur

Product width and length, 50 in wide at shoulders

Inches 50 in wide at the head

Defined by Customer

Testing

Must be able to sit up at head

ZdenekZmur

Product Height, 36 in sit up height

Inches 36 in height at

head

Defined by Customer

Testing

Must sit atop 2011 Jetta SportWagen

ZdenekZmur

Product Length/Car

Length

Inches Will sit on roof with support

from hitch

Defined by Customer

Testing

Environment


Metrics & Targets


Verification

Three Season Capable (Fall,

Winter, Spring)

ZdenekZmur

“Warm” sleeping quarters/ Insulated

TBD TBD Defined by Customer

Testing

Fully waterproof Zdenek Zmur

Nonporous outer shell

Plastic, metal or

Waterproof

Defined by Customer

Testing and Material

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composite Selection

Maintenance


Metrics & Targets


Verification

Car washable/Power

washable/Spray off

ZdenekZmur

Nonporous outer shell

Plastic, metal or

composite

Waterproof/No

Canvas

Defined by Customer

Testing

Minimal Moving Parts

Zdenek Zmur

Collapsible design

with 3-4 fold out panels

Hinged walls

Easy fold open

design

Defined by Customer

Manufacture/Modeling

Quantity


Metrics & Targets


Verification

One-off initially Zdenek Zmur

Count N/A One Defined by Customer

Constructed Prototype

Size and Shape


Metrics & Targets


Verification

Defined by Jetta dimensions

Zdenek Zmur

H-36 in @ head

L-5 ft 8 inW-50 in @

head

Inches H-36 in @ head

L-5 ft 8 inW-50 in @

head

Defined by Customer

Measuring

Weight


Metrics & Targets


Verification

<300 lb on the side rails

Zdenek Zmur

<300 lb Pounds <300 lb Defined by Vehicle

Specification

Weighing

Minimization of overall mass

Zdenek Zmur

Secondary to 300 lb

max

Pounds Reduction through

modeling,

Function of 300 lb max requiremen

Modeling/Testing

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requirement

etcetera t

Aesthetics


Metrics & Targets


Verification

Streamlined shape Cabover Camper Team

CFD Analysis

for minimal

MPG impact

CFD Decrease MPG

impact as much as possible

Defined by Customer,

Jetta dimension

s and Camper

dimensions

Testing/ Modeling

Painted and styled Cabover Camper Team

N/A N/A Painted and styled to match the target

vehicle

Defined by Cabover Camper

Team and Customer

A painted prototype

Materials


Metrics & Targets


Verification

Steel frame structure

Zdenek Zmur

Jetta Dimensions

Inches Match Jetta

dimensions

Defined by Vehicle

and Customer

Prototype/ Modeling

Plastic Inner/Outer Covering

Zdenek Zmur

Camper Dimension

Inches Match Camper

Dimension

Defined by Camper

and Customer

Prototype/ Modeling

Laws, Codes and Standards


Metrics & Targets


Verification

Meet all applicable DOT laws regarding license plate and tail light visibility

Zdenek Zmur and Cabover Camper Team

DOT Regulations

: FORM 734-2359

(6-15) STK#

DOT Regulations, will not cover tail lights, or protrude

Meet all standards at time of testing. Will not

cover tail

Defined by laws and

regulations of DOT:

FORM 734-2359 (6-

Pre-test inspection

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320853 more than 4ft in the rear. See

FORM 734-2359 (6-15) STK#

320853 for details

lights or protrude

more than 4ft in the rear. See

FORM 734-2359 (6-15) STK#

320853 for details

15) STK# 320853

Ergonomics


Metrics & Targets


Verification

Interior length Zdenek Zmur

86 in (Fig 1)

inches 78 in Defined by customer

Measuring

Interior width Zdenek Zmur

50 in @ shoulders and head

inches 48 in @ shoulders and head

Defined by customer

Measuring

Interior height Zdenek Zmur

42 in(Fig 1)

inches 36 in Defined by customer

Measuring

Figure 1. Spatial capacity of the interior of the cabover with a 90in footprint, and 42in of head space

Testing


Metrics & Targets


Verification

Test drive with mock up of clamshell

Zdenek Zmur

< 10 mpg reduction

MPG < 10 mpg reduction

Defined by customer

Testing

Time Scales

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Metrics & Targets


Verification

Working Prototype by June, 2016

Zdenek Zmur

N/A N/A Working Prototype by June,

2016

Defined by Customer and ME

Sequence

N/A

Safety


Metrics & Targets


Verification

Setup is safe and easy

ZdenekZmur and Cabover Camper Team

User Defined, Fold-up design

User Defined

Fold-up design


Team and Customer

N/A

Appropriate lighting addition

Cabover Camper Team

TBD TBD Light inside of Camper

Defined by Cabover Camper Team

N/A

Appropriate ventilation

Cabover Camper Team

Not included in prototype

TBD Ventilation for

condensation and

fresh air

Defined by customer

and Cabover Camper Team

Testing/ Modeling

Documentation


Metrics & Targets


Verification

Documentation of dimensions

Zdenek Zmur

Sketches, meeting notes,

documentation

N/A Full product

documentation and drawings

Defined by Cabover Camper Team

Implicit

Material List Zdenek Zmur

Full material

list in progress

N/A Material manufactu

ring list


Team and Customer

Implicit

Installation

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Metrics & Targets


Verification

Ease of InstallationZdenek Zmur

TBD User defined

Fully built structure

with anchor

points on the vehicle

Defined by vehicle, Cabover Camper,

Team

Testing

Camper functionality for

one-time installation

Zdenek Zmur

Camper allows

access to all

peripheral doors and

limited rear hatch

without removal of

camper

N/A Camper allows

access to all

peripheral doors and rear hatch

without removal of

camper

Defined by vehicle

dimensions and

layout, Customer

and Cabover Camper Team

Testing

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Appendix B.1:

External Research SummaryMost of the external research resulted in designs for pick-ups and

SUVs. Some examples we found are seen here.

External research for sedans resulted in designs that included 5th wheels, a trailer, or a canvas tent. The customer is against using any canvas in the design. Ease of maintenance and fully weatherproof is a high priority.

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Appendix B.2:

Internal Research SummaryDuring the internal research, it was decided that the cabover be made

of a rugged and stiff plastic rather than sheet metal. Due to the 300 pound weight restriction, and desired ease of installation, sheet metal was too heavy for both applications. After some alternative materials research and customer approval, coroplast was chosen. Coroplast is rugged, waterproof and has excellent insulation. The foldable nature of the coroplast gave way to a better collapsable design.

An origami fold seemed most attractive until it proved to change shape and to be too bulky in its collapsed form. See examples below from cardboarigami shelters.

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Appendix C:

Finite Element Analysis In order to house two bodies in the structure and maintain appropriate

clearance to the roof and rack system of the car, the deflection needed to be minimized to less than one-half inch in the z-direction. Also,this would validate material selection made for the base of the superstructure. This

was done using Abaqus FEA modeling software and results are in (Fig D.1).

Figure D.1: Finite element model of the base and ladder of the superstructure done in Abaqus FEM software. The design requirements of the structure limited the deflection in the z-direction was not to exceed one-half an inch. Material selection was also validated by meeting this requirement.

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Appendix D:

Mass AnalysisIn order to house two bodies in the structure and satisfy loading

conditions on the suspension and structure of the car, the total weight of the camper could not exceed 300 lbs . This was validated using Siemens NX 10 modeling software and results are in (Fig E.1) and (Fig E.2)

Figure E.1: Mass analysis of the base of the superstructure using Siemens NX 10 software. The combined weight of the structure is not to exceed 30lbs static weight.

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Figure E.2: Mass analysis of the base of the superstructure using Siemens NX 10 software. The combined weight of the structure is not to exceed 30lbs static weight.

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Appendix E:

Fabrication Drawings

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Appendix G:

Bill of Material

Bill of Material

Part Description Manufacturer

Part Numbe

r

Quantity

1 Orafol Pressure Sensitive Tape Orafol N/A 32 5ft. x 12ft. Plastic Sheets Coroplast N/A 33 50in. Cross Bars Inno IN-B127 24 415 Railing Foot Thule TH-100415 4

5 1.00in x 0.500in x 92.00in Tube Steel (0.065in wall thickness) N/A N/A 2








13 Angle, 1.00in x 1.00in x 1.50in (0.125in wall thickness) N/A N/A 34

14 Plate, 1.00in x 4.00in (0.065in wall thickness) N/A N/A 2


16 Tube, 1.25in x 1.25in x 6.00in (0.188in wall thickness) N/A N/A 1



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24 Rivets, Domed Aluminum with Steel Mandrl McMaster-Carr

97524A108 3

25 4ft x 8 ft Sheet of ACP - 3mm Multicraft PF2 White 1

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Documents

Executive Summary - Computer Action Teamweb.cecs.pdx.edu/~far/Past Capstone Projects/Capstone... · Web viewThe results from the FEA analysis of the final Frame and Ladder design