Pirates of the Caribbean Imagineering

8/12/2019 Pirates of the Caribbean Imagineering

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Pirates of the Caribbean Load WheelDisneyland Resort

Design Team: Vincent RosasRaul ArrietaChris CordinaRafael FolleroJustin Santiago

Faculty Advisor: Nina Robson PhD

Industry Collaborator: Manjit Sagoo- Disney Engineering

California State University FullertonMechanical Engineering

December 5, 2013


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Project Overview

4 load wheels per boat Approx. 22 persons per boat

Ride cycle time 15 minutes

Full boat weight 6400lbs

2 drops at 13 and 8 Bearing life span 6-9 months

Current design used for 40 years


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General Work Breakdown Structure

Pirates Load Wheel Project

Industry Collaborators- Manjit Sagoo- Steven Fremen

Faculty Advisor

- Dr. Nina Robson

Student Team Lead

- Vincent Rosas

Bearing/BushingResearch

Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago

Testing Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago

Solid ModelCreation


MaterialsResearch


Design Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago


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Functional Block Diagram

SEAL

LUBRICATION

SPINDLE BEARINGS

HUB

O-RING

BRACKET

BOAT

RAILS

Comes into Contact with Water


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Design parameters

Design Challenges:o Large PV values for bearings

o High corrosion rate

o Moisture Absorption rateo Wear of materials

Constraints:o

Fit onto current wheel carriero No modification to wheel bore

and spindle dimensions

o Force to push empty boat 50-

60lbf


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Current Bearing Issues

Pressure on seal from load Zero relative translation wheel & bearing

components


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Project goals

Performance (A-Specs)

Must have same or higher load carrying and performance

capacity.

Must not bind, gall or seize on shaft.No modification to the wheel bore is desired.

Higher Corrosion resistance

MaintenanceDecrease frequency of wheel inspections

No need to replace bearings for >1 year

Eliminate lubrication


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Brief Description of the Approach


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Project Status

Design of Load Wheel Analytical performance analysis complete for bushings and bearings Continuing force analysis for bearing seal

Bushing Research Found 3 self lubricating bushings

Igus H370, TriStar Ultraflon 601, TriStar Ultraflon 602e Found 1 stainless steel roller bearing Timken Roller Bearing

Materials Research Hardness affects on mating components Continuing research to decrease corrosion and wear rate Using machinable rubber material for bearing seal

Tivar Ceram, Nylatron Test Plan

6 tests to examine bearing, bushing, and seal performance Procedures and CAD models are complete


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Alternate Approaches: Pugh Chart

Datum 1 2 3 4

Name Weight Current Wheel Self Lubricating Disc Spring Lip Seal Breather

Load Capacity 3 0 1 0 0 0 Durability 2 0 1 1 1 1 Manufacturing

Complexity 2 0 -1 -1 1 -1

Corrosion Resistant 2 0 1 1 1 1

Waterproof 3 0 0 1 1 1

Lubrication 1 0 1 0 0 0 Life Expectancy 3 0 1 1 1 1

Maintenance 2 0 -1 -1 -1 1 Number Better - 0 5 4 4 5 Number Worse - 0 2 2 2 1 Number Same - 8 1 2 2 2

Total 0 3 2 2 4


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Performance Analysis & Margins

Parameters perwheel Requirement

ProjectedPerformance

PredictedMargin

Load Capacity >6400 lbf 8650 lbf 35%

Wheel Velocity >30 ft/s 60 ft/s 50%

Capability of

Seal

< 10% of the hub is

filled with water


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Rationale for Concept Selection

CLIMBING THE INCLINE DESCENDING THE DROP

(6152 lb load) (10,000 lb load)

area P V PV P V PVMax

Speed

Limit

CompressiveStrength

MaxTemperature

Usage(Short term)

Modulus ofElasticity

in^2 psi fpmpsi xfpm

psi fpmpsi xfpm

fpm psi F psi

Timken(Current bearing)

1.542525 498.5332 60.6772 30249.6 810.3596 891.2099 722200.5

igus iglide H370

1.76625 435.3857 60.6772 26417.98 707.3553 891.2099 630402

295 11460 464 16610000

Tristar Tristeel PR 2000 20000 550 160000

Thordon Thorplas 15300 230 350000


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Detailed Design of Complete System

Spring Seal & Tapered Roller Bearing Design

Self Lubricating Bushing DesignSpring Seal

Tapered Roller Bearing


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Tes t Ma t r ixPerformance

MeasurementRequirement

Design Parameters to bevaried

Range of variation Diagnostic

Impact Forces(Tensile Strength)

able to withstand 2500 lbf,only allows less than 10% ofthe hub to be filled withwater

Type and size of bearings andseals

B: Igus, 0.75 to 0.85 inch diameterRoller Bearings, S: Disc Springs,Rubber Spring Seal

Load Frame, Drop Container, SampleWater, Weights

Height of drop 5, 7.5, 10, 12.5 ft Load Frame, Drop Container, SampleWater, Weights

Angle of decent 25, 45, 60 degreesLoad Frame, Drop Container, SampleWater, Weights

Amount of additional weights100 lbs, 250 lbs, 500 lbs (dependenton the height of drop)

Load Frame, Drop Container, SampleWater, Weights,

Corrosion rate of

materials

Sample Material weight lossof less than 5% (dependingon the size of the materialused)

Sample Materials,Materials: Stainless Steel, Igus Bearing,Original Carbon steel roller bearing,

Undetermined Spring Seal Material

Individual Containers, Small Samplesof each material, a waterproof heatsource, scale to measure thedifference in weight, thermometer

Temperature of the water 70, 80, 90, 95 degrees F

Individual Containers, Small Samplesof each material, a waterproof heatsource, scale to measure thedifference in weight, thermometer

Rolling under loadWhile going up and downthe ramp, the wheel mustnot seize

Bearings, SealsB: Igus, Roller Bearings, S: DiscSprings, Rubber Spring Seal

Load Frame with roller attachments,Weights, Ramp,

Water tight seal testExpectable amount of waterwould be less than 10% inthe hub

Type and size seals S: Disc Springs, Rubber Spring Seal Container, Sample water, graduatedcylinder,

Preload forceOptimizing the bearing inorder to hold the 2500lbf

Diameter of the bearing 0.75 to 0.85 inches in diameter Calipers, strain gages,

Preload Force Less than a 1000 lbs of torque Calipers, strain gages,

Strain test for pressurewithin hub withlubrication

Releases 5% of thelubrication through the sealwhile in motion

different amounts and typesof lubrication, each of thedesigned seals

TBDContainer, Sample water, aircompressor (simulate thelubrication), lubrication, strain gage


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Testing Models

Impact Test Apparatus

Load Frame

Guild Cylindersinto Guild Rails

Container


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Testing Models

MTS Insight Tension Machine

Load Frame

Wheel attachedfrom the Spindle

Wheel Durability

DC Motor

Roller Frame


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Budget

No. Description Part Number QTY Status Cost (ind) Cost

(Final)

1 O-RingRetainer

PRMC-101 2 No Action $20.00 $40.00

2 Spindle PRMC-102 1 No Action $10.00 $10.00

3 Hub PRMC-103 1 No Action $100.00 $100.004 Lock Nut PRMC-104 2 No Action $10.00 $20.005 Test Fixtures PRMC-105 1 No Action $300 $300.00

6 Load Frame:Side Bracket PRMC-106 2 No Action $86 $172.98

7 Load Frame:Middle Bracket PRMC-107 1 No Action $20 $20.00

8 Load Wheel:Spring Seal PRMC-108 2 No Action RFQ RFQ

9 Container: DropTest PRMC-109 1 No Action Donation Donation

Total $662.98

No. Description Part Number QTY Status Cost (ind) Cost (Final)

1 Wheel MEPC-001 1 No Action $35.00 $35.00

2 Carbon SteelBearing MEPC-002

2 No Action $50.00 $100.00

3

Bearing Cone

MEPC-003

2

No Action

$10.00 $20.004 Bearing Cup MEPC-004 2 No Action $10.00 $20.005 Bearing Seal MEPC-005 2 No Action $10.00 $20.006 Rubber O-ring MEPC-006 1 No Action $5.00 $5.007 Spacers MEPC-007 5 No Action $8.79 $43.95

8 Load Frame: Bolts MEPC-008 2 No Action $7.00 $14.00

9 Load Frame: Nuts MEPC-009 2 No Action $8.00 $16.00

10 Load Wheel: RollerBearing MEPC-010 2 No Action $92.10 $184.20

11 Load Wheel:Lubrication MEPC-011 Varies No Action Donation Donation

12 WheelDurability:Spring MEPC-012 1 No Action $35.00 $35.00

Total $493.15

Purchased Parts: Manufactured Parts:


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Schedule for Testing & Manufacturing

Description Date

Corrosion Rate of Materials January 7, 2013- January 21,2013

Manufacturing January 21,2014 -February 8, 2014

Testing the Preload Forces February 9, 2014- February 15, 2014

Pressure Strain Test February 16, 2014- February 22, 2014

Water Tight Seal Test February 16, 2014- February 22, 2014

Impact Test February 23, 2014- March 8,2014

Rolling Under Load Test February 23, 2014- March 8,2014

Wheel Durability Test March 2,2014- March 15, 2014


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High level Schedule


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Conclusion & Innovation

Reduce Cost Eliminate bearing lubrication and maintenance

Increase corrosion resistance of components

Decrease number of components

Multiple design paths Increase the probability of meeting the design goals

Use bushings in new application Similar applications


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References

SAE Handbook. Vol. 3. Texas: SAE International, 2005. 41.121. Print.

Tuthil, Arthur H. Nickel Institute. FNACE, n.d. Web. 29 Oct. 2013..

Documents

Pirates of the Caribbean Imagineering