ADJUSTABLE UNIVERSAL GOLD MEDAL SAILING SEAT Andrew Sulik

ADJUSTABLE UNIVERSAL GOLD MEDAL SAILING SEAT Andrew Sulik Timothy Slattery Marion Paredes Pages Derek Topper Detailed Design Review 2/8/13, 3: 30 pm

2 Agenda • Meeting Purpose • Overview of Project • Review Customer Needs & Eng. Specifications • Review Decomposition of System • Detailed Design • Test Plan • Review Project Plan • Review Risk Assessment • Conclusions

3 Project Goals • Make system comfortable and adjustable to multiple users • Allow enough room for the use of a jib transfer bench • Increase and/or maintain the functionality already available • Adapt for any C 4 -5 quadriplegic user such as Richard Ramos on a 3 person Sonar keel boat that meets all IFDS regulations

4 Customer Needs Recap Customer Need # CN 1 CN 2 CN 3 CN 4 CN 5 CN 6 CN 7 CN 8 CN 9 CN 10 CN 11 CN 12 CN 13 CN 14 CN 15 CN 16 CN 17 CN 18 CN 19 CN 20 CN 21 CN 22 CN 23 CN 24 Importance Level*1 Description 1 1 1 1 2 2 2 3 3 3 Designed specifically to fit SONAR sailboat Adjustable foot rests Seat Mobility (up/down) Hand crank Adjustability (up/down) Mechanical Advantage Corrosion Resistance Seat Locking mechanism (2 Positions around arc) Cost Allows space for jib transfer bench Safe system to operate for long periods Portable, non-permanent installation Fits on 1 pallet to ship Emergency quick release for rudder control System Controls Rudder Crank Geometry fits multiple users System weight Better Functioning 'Fast Pin' system Crew Safety Enlarge Track Platform Improved harness Interchangeable seats Grab Handle at top of seat Fit to multiple boats Easy to assemble & install Comments/Status 6. 4 x Powder Coat $3, 000 4 years minimum no damage to boats Product for range of users, ie. Yacht club All fast pin locations *1=Most important

5 Engineering Specs Recap Engineering Importance* 1 Specification # Source ES 1 ES 2 ES 3 ES 4 1 1 CN 1, CN 11 CN 2 CN 3 CN 4 ES 5 ES 6 ES 7 ES 8 1 1 CN 5 CN 6 CN 7 CN 8 ES 9 1 ES 10 ES 11 Unit of Measure Specification Marginal Value Ideal Value Secure to Sonar with non-permanent attachments Adjustable Foot Rests Seat Adjustment (up/down) Hand Crank Adjustment Binary in in in % Binary $ 3 rev/ 90° Tiller CN 9 Percentage Amplification of User Force Input Corrosion resistance Seat locks into position anywhere in travel Cost of components manufactured for MSD Entire seating system is moved aft from previous iteration in 0< 3< 1 1 CN 10 CN 13 Minimum FOS of critical elements found via analysis Steps required to release rudder in emergency # # 2≤ 3> 3< 1 ES 12 ES 13 ES 14 ES 15 ES 16 1 1 1 2 2 CN 14 CN 15 CN 22 CN 17 Degree of movement of rudder from centerline of boat Backlash in lines controlling rudder Distance between hand attachment points Grab handle(s) to assist seat movement Time required to attach or detach hands degrees in in Binary s 40< 1> 18± 2 90< 0. 5> 18± 0. 5 Yes 15< ES 17 ES 18 ES 19 ES 20 2 2 2 3 CN 18 CN 19 CN 20 CN 21 System has limited number of sharp corners or edges Pinch points created by track platform Steps required to release from harness System fits multiple seats # # 10> 2> 3> 0 0 1 2< ES 21 2 CN 11, CN 21 Time to fit system in SONAR sailboat minutes 60> 30> ES 22 ES 23 ES 24 2 2 1 CN 11, CN 21 Time to adjust system for new user CN 24 Time to assemble system CN 3 Seat Adjusetmenyt (fore/aft) minutes in 60> 30> 3< 30< Yes 4< 3< 4< 4 rev/ 90° Tiller Yes 3000> Comment/Status Material Selection *1 For importance level 1 is must have, 2 is nice to have, 3 is preference only

6 Functional Decomposition

7 Anthropometry

8 Ergonomics & Adjustability • 95 th Percentile Males – 5 th Percentile Females • Accommodate 90% of the population • Backrest • Proper back support • Minimum 10° rearward tilt ✓ • Handles/Hand Grips • Neutral wrist position • Interchangeable for C 5 gloves and regular grips • 30° angle 30°

9 Adjustability – Detailed Design 30º • Considerations: • Distance from shoulders • Shoulder-forward 3 in • Shoulder-down • Distance from knees 3 in 7 in • Distance between legs • Rotation effects and distance

10 Adjustability – Detail Design • Crank Up/Down • Below shoulder • Accommodate user’s preference

11 Adjustability – Detailed Design • Seat Up/Down • Height • Comfort • Seat Back/Forth • Distance from crank • Foot Rests Up/Down • Leg length • Detachable • Foot Rests Angle • Comfort/Disability

12 Material Selection • Selection criteria • Good corrosion resistance • Good strength • Readily available • Easy to weld • Ideal Material • Aluminum 6061 -T 6 • Yield Strength 40 ksi • Tensile Ultimate 45 ksi • Young’s Modulus 10 ksi

13 Fastener Material Selection • Fastener Material • 316 Stainless Steel • Limited Galvanic Corrosion • Cheap and readily available • Yield Strength 34 ksi • Tensile Ultimate 79 ksi • Galvanic Corrosion • Reduced by material selection • Reduced by Delrin washers at all bolts

14 Seat & Footrest Adjustability

15 Hand Crank Adjustability

16 States of Loading • Worst Case (P 12031) • 170 lb applied horizontally to hand crank • 150 lb applied downward on collection barrel • 1349 lb impact force applied to end of track

17 Detailed Design-Track Platform • Similar to original design – ½” thick marine fir • Aluminum L-beam (underneath) adds support to track platform • Added 2 detachable pieces in the front • Secured using dovetail tabs • Drilled holes in plates on allow for the adjustment of handle locks • Rubber plugs are used to eliminate sharp edges and corners on the handle locks

18 Track Platform Analysis Track deflection with load Max deflection = 0. 2960 in Max deflection = 0. 1224 in

19 Track Platform Analysis • Stress on bolts during impact of 1349 lb (worst case. From P 12031. ) • Shear strength = 30000 psi • ¼”-20 aluminum bolts – Stainless Steel bolts to be used • •

20 Detailed Design-Pedestal Base • Clamping fixture same as P 12031 • Platform extended aft 3 in to accommodate Jib Transfer Bench • Support Ribs contoured to boat deck

21 Detailed Design-Pedestal • Swivel plate provides rotation and deceleration • Pedestal will interface with swivel via welded plate or bolt pattern • Maximum loading parameters determined by manufacturer

22 Pedestal Forces • MA=MB=2804. 88 lb*in • RB=260 lb • Specified at 750 lb compression (Trendler) • Specified moment of 9000 lb*in (Trendler) 13 in

23 Detailed Design-User Support • Seat support frame from P 12031 • Main support arm fixed to top of swivel plate

24 Main Support Arm • δy. A = 0. 29 in • M = 2804. 88 (in*lbs) • σ = 7250. 0 psi • σy for 6061 -T 6 Aluminum is 45, 000 psi. • FOS = 6. 2

25 Detailed Design-Hand Crank • Centered pulley system allows individual barrels • Telescoping tube allows vertical adjustment • Center pivot allows space for user entry • Adjustable tensioner allows for easy set up

26 Detailed Design-Crank Support Arms • Case 1 (worst case) • Fa=170 lb • Mb=838. 68 lbin/arm • σ=11981. 14 psi/arm • σy=45 ksi (6061 -T 6) • FOS=3. 76

27 Detailed Design-Crank Support Arms • Case 2 (normal conditions) • Fa=20 lb • Mb=98. 76 lbin/arm • σ=1409. 57 psi/arm • σy=45 ksi (6061 -T 6) • FOS=31. 9

28 Detailed Design-Rotation Pin • Since bearing cannot apply moment, need pin to lock crank arm into place • These calculations still need to be completed

29 Detailed Design-Hand Crank • Lower pulley axle • Aluminum 6061 -T 6 • Yield strength: 45000 psi

30 Detailed Design-Hand Crank • Upper pulley axle • Same properties as before

31 Hand Crank Fatigue • From quadsailor. com, we found evidence of 3 hour trips • Assuming a 5 month season, 1 tack every 5 minutes, and 4 cranks per tack we get 8460 rev/season • Based on a life of 8 years you get a lifetime use of 69, 120 revolutions • Due to this low number, fatigue analysis on these axles is unnecessary

32 Hand Crank Gearing • Goal: 4 cranks for 90 degree tiller movement • Want to keep 4” load pulley • Based on current system, where 3 cranks give 90 degree tiller movement, we have a 1. 25 pulley ratio • To get 4 cranks, need pulley ratio of 0. 9375 • Requires 3. 75” drive pulley – Not Readily Available • Using 1 pulley ratio need 3. 75 cranks for 90 degree tiller movement

33 Hand Crank Gearing • Options for gearing 1. Keep current gear ratio with 3 cranks per 90 degree tiller rotation 2. Use decreased gear ratio with 3. 75 cranks per 90 degree tiller rotation • Options to be given to Richard Ramos

34 Detailed Design-Hand Crank Grips • System designed to mimic C 5 grips • Detent pin to keep hands in place • Detent pin axial pull out force needs to be acquired

35 Bearing Specifications • Sealed bearings to last in Max Dynamic Load 2110 Lb Max Static Load 966 Lb Max Axial Load 966 Lb elements • Able to withstand larger loads than applied • Cheap to replace if needed

36 Tiller Strut • Same structure as P 12031 • Hasp fitting connection removed • Replaced with clamp • Clamp geometry has not been determined

37 Emergency Tiller Release • Cam cleat concept has not been fully developed • Requires testing of cam cleats (on Skip’s boat)

38 Preliminary Test Plan • MSDII Test Plan • See Excel Spread Sheet

39 Project Plan • MSDI final Project Plan • See. pdf Files • https: //edge. rit. edu/edge/P 13032/public/Working. Documents/Project%20 Information/General%20 Information/Project %20 Plan%20/Project%20 Plan%20 MDSI%201_4. pdf

40 Risk Assessment • Overall assessment of risks • See Excel Spreadsheet

41 Questions?