JMAC AirRide Capstone Thesis MARCH

CapstoneProjectMasterFile2.12.15.docx

JMACAIRRIDE SEAT KIT

A Capstone ProjectSubmitted to the Faculty of theNational University, School of Engineering and Computingin partial fulfillment of the requirements for the degree ofBachelor of Science in Manufacturing Design Engineering

Prepared By:Miguel GonzalezJosh SoltChristopher BispingAshley Moreno

National UniversityMarch 2015CAPSTONE PROJECT APPROVAL FORM

We certify that we have read the project of Miguel Gonzalez, Josh Solt, Christopher Bisping, and Ashley Moreno entitled JMAC AirRide HPV Seat, and that, in our opinion, it is satisfactory in scope and quality as to the capstone project for the degree of Bachelor of Science in Manufacturing Design Engineering at National University.

Approved:

________________________________________________________________________Prof. Randall Hartman, M.S. P.E.DateFaculty, Department of Applied EngineeringNational University

________________________________________________________________________Prof. Michael Buckley, M.S., M.B.ADateFaculty, Department of Applied EngineeringNational University

________________________________________________________________________Dr. Shekar Viswanathan, Ph.D. P.E., M.B.A. Supervisor and Lead FacultyDateFaculty, Department of Applied EngineeringNational University

ABSTRACTBluevelo, the Canadian based company that designs human powered vehicles, has requested that a new seat assembly and cushion be designed to improve the adjustability and comfort of the Velomobile. The Velomobile is a recumbent bike assembly encased in an aerodynamic and lightweight composite shell. JMACs innovative design incorporates functionality and manufacturability with the intent to satisfy a wider range of desired adjustability for customers. This design integrates Industry standards and best practices as related to Design for Manufacturability and Assembly (DFMA) guidelines, Lean Six Sigma principles, and Total Quality Management (TQM) Requirements. JMAC utilized a design approach that took into consideration existing concepts and products available, and through the employment of manufacturing best practices and the application of risk management techniques, developed an operational and cost effective assembly that meets all of the requirements set forth by Bluevelo.The JMAC AirRide design is manufactured for ease of assembly and installation as a replacement for the pre-existing seat assembly provided by Bluevelo. The design incorporates the composite seat and provides adjustability for riders with heights ranging from 66 to 72. and weights ranging from 150 lbs. to 220 lbs. Furthermore, the JMAC AirRide seat assembly has been designed to provide comfort and ease of adjustability. All of the seat and cushion adjustments, for instance, require only the use of simple pneumatic valves. The design includes front and rear brackets with a pendulum action lever levied with a pneumatic cylinder accompanied by an inflatable seat cushion for additional safety and ergonomic benefits. Because of the lightweight design of the reinforced composite, the seat and all components do not exceed a weight of 10 lbs., with the cost remaining under $1000 USD to keep the product marketable and competitive.

Table of ContentsList of FiguresList of Tables1.SCOPE12.INTRODUCTION AND PROBLEM DEFINITION22.1.HPV Quest Seat Problem Statement22.2.JMACs AirRide Design Delimitations22.3.General Considerations32.3.1.Pneumatic Considerations32.3.2.Frame Considerations42.3.3.Safety Considerations42.3.4.Reliability Considerations52.3.5.Manufacturing Retail Considerations52.4.HPV Seat Industry Design Research53.BACKGROUND AND LITERATURE REVIEW93.1.Variable Analysis of Seat Design93.1.1.HPV Aerodynamic Feature Analysis93.1.2.Structural Frame Design Variables103.1.3.Seat Adjustability Analysis103.1.4.Seat Cushion Variables Analysis113.2.Variable Analysis of Materials for Seat Frame and Cushion Manufacturing113.2.1.Sustainable Materials Variables123.2.2.Seat Cushion Material Variables123.3.Variable Analysis of Manufacturing Strategy143.3.1.Manufacturing Variables143.3.2.Production Variables143.3.3.Ease of Assembly Variables153.4.Variable Analysis of Quality Assurance and Control Strategies153.5.Background Research Variables Summary154.JMAC DESIGN METHODOLOGY174.1.JMAC AirRide Seat Kit Design174.2.JMAC AirRide Seat Position Considerations174.3.JMAC Seat Inflation Design Requirements194.4.JMAC 3-Way Valve Considerations204.5.JMAC Lumbar Support Cushion Considerations204.6.JMACs Air Chamber Cushion Requirements204.7.JMAC Air Cushion Material Considerations214.8.JMAC Vehicle Stability Considerations214.8.1.Directional Stability Considerations224.8.2.Rollover Stability Considerations224.8.3.Table and Graph of Lateral Forces to initiate rollover234.9.JMAC Air Ride Weight Considerations265.JMAC AIRRIDE DETAILED DESIGN AND RISK ASSESSMENT295.1.JMAC AirRide Components and Subassemblies295.1.1.JMAC Front Subassembly Design305.1.2.JMAC Rear Bracket Subassembly Design315.1.3.JMAC Seat Subassembly Design325.1.4.JMAC Air Cushion Design325.1.5.JMAC Air Manifold Subassembly Design335.2.JMAC Bill of Materials355.3.JMAC Cost Analysis365.4.JMAC Weight Analysis395.5.JMAC Risk Mitigation and Considerations405.5.1.FMECA Development415.5.2.Risk Priority Number Development435.5.3.Corrective Action Identification456.CONCLUSION AND RECOMMENDATIONS46REFERENCES AND WORKS CITED49APPENDIX A: ACRONYMS52APPENDIX B: GLOSSARY OF TERMS53APPENDIX C: SUBASSEMBLY MANUFACTURING DATA56

List of FiguresFigure 1: Bluevelo Quest7Figure 2: Windcheetah Sport Compact7Figure 3: Angletech Challenge Seiran SL107Figure 4: Tri-Sled Rotovelo Carbon7Figure 5: Beyss Go-One7Figure 6: Butterfly Gel Cushion8Figure 7: Orthopedic Gel Cushion8Figure 8: Ventisit Seat Pad8Figure 9: Hobie Mirage Seat Pad8Figure 10: Genuine Corflex Medic-Air Seat Cushion8Figure 11: JMAC DESIGN18Figure 12: Center of Gravity Elevation Formula23Figure 13: Tire Side Forces at Rollover23Figure 14: Rollover Lateral Force Chart25Figure 15: Center of Gravity (cg) Elevation Shift25Figure 16: McCraws Weight Study Formula27Figure 17: McCraws Formula for Time Saved or Added27Figure 18: Seconds Per Pound Analysis28Figure 19: Subassembly Detail29Figure 20: Front Bracket Subassembly30Figure 21: Rear Bracket Subassembly31Figure 22: AirRide Cushion Design32Figure 23: Cylinder Assembly with Locking Bar34Figure 24: Bill of Materials35Figure 25: Purchased Parts Cost36Figure 26: Make Parts List37Figure 27: Manufacturing Cost38Figure 28: Buy Parts Weight Summary39Figure 29: Functional Flow Diagram (TOP LEVEL), FUNCTION41Figure 30: Functional Flow Diagram (Second Level)42

List of TablesTable 1: Industry Design HPV Analysis Examples7Table 2: Industry Design Seat Cushion Analysis Examples8Table 3: Comparison of Main Types of Cushions (Karp, 1998)13Table 4: Rollover Lateral Force24Table 5: Risk Priority Analysis44

iv

SCOPEJMAC Engineering Company (JMAC) has been selected to design an ergonomic seat for an existing Human Powered Vehicle design as a result of their innovative yet practical ready to manufacture design reputation. The information presented in this project provides the purpose of the design, an overview of seat concept considerations, analysis of industry techniques and best practices, evaluations of HPV seat standards, an explanation of design methodology, and detailed design characteristics of the ready to manufacture product. The final portion of this project summarizes the design and reaches the conclusion that this design meets Bluevelos expectations along with any additional requirements set forth.

INTRODUCTION AND PROBLEM DEFINITIONBluevelo, the Canadian based company that designed the Velomobile, has approached JMAC Engineering Company with the request to create a seat design that will improve the mobility and comfort of the user. HPV Quest Seat Problem StatementAlong with the exponential growth rate in technology, the standards of human powered vehicles are having no trouble keeping pace. The development of more lightweight, durable materials has opened up endless possibilities for even the most prehistoric designs. Even without the use of electronics within the vehicle, bicycles are becoming more aerodynamic, comfortable and economically pleasing. As the transition period from fossil fuels to sustainable sources steals the spotlight, the HPVs are stealing the hearts of the daily commuter across the globe with their economical and environmentally friendly benefits. This design includes not only the frame, but the components therein which must be as equally as lightweight and ergonomic to support its mounting host. A required application of the HPV Seat outlines the need to provide ease of adjustment for the mainstream consumer.JMACs AirRide Design DelimitationsThe main limit imposed on this study is working within the design and space restrictions set forth by the Bluevelos model Quest HPV, a composite reinforced structure that houses a recumbent bicycle. The Quest has limited fixed frame mounting points within the structure along with a weak floor that puts the weight bearing responsibility of the operator solely on the seat assembly. Because of the cone like front end design, height restrictions can limit the potential drivers while the distance from the seat to the pedals severely limits the available leg span of the operator. The customer requires the use of air as the main medium to provide the adjustments required in order for the seat to accommodate specified rider characteristics, consisting of a height between 66 and 72, and a weight range of 150 lb. - 220 lb.s. This design must also provide the optimum performance, safety and comfort without the use of any electronic systems. A safety limitation requires that the seat adjustments be accessible at all times while maintaining a line of sight that is both comfortable and non-hazardous to the driver or other vehicles during operation. Because of the lightweight design of the reinforced composite, the seat and all components are not to exceed a weight of 10 lbs. The cost limitations designate a maximum cost of $1000 USD to keep the product marketable and competitive. General ConsiderationsThe purpose of this study is to propose a human powered vehicle seat design ready for manufacturing that meets the specific performance and reliability requirements set forth in this research paper. This paper will detail a cost effective, lightweight and safe design that accommodates a wide range of users while maintaining comfort and accessibility to the driver and conformance to industry best standards for manufacturing. Pneumatic Considerations An important aspect of this design includes using air as the fluid to provide different levels of adjustment to accommodate ergonomic needs and physical characteristics of the user as well provide some utility as a safety device. Due to the weight requirements, using air to generate the pressure needed for the seat cushion and for the seat adjustment will ensure the riders ability to utilize the vehicle to its full potential. The major finding of the research experiment involving the wheelchair cushion study were that the increase in leg volume caused by wheelchair sitting was attenuated by using the dynamic air cushion, but not the static cushion. (Murata, J., Murata, S., Ohyama, M., Kogo, H., & Matsubara, S., 2014) These results suggest that the dynamic air cushion relieved the leg edema induced by wheelchair sitting. Frame ConsiderationsThe seat will have a single fixed frame design that is installable in a pre-existing human powered vehicle and will allow for accordion type adjustments. The solid frame is necessary to assist in achieving the power output and to support the weight of the rider during physical activity. Safety ConsiderationsThe seating angle should recline enough to provide a comfortable ride for the recumbent human powered vehicle while still allowing the driver a full, safe view of the road and surroundings. While bicycles are generally not considered to have blind spots, the Quests recumbent style frame setup combined with the composite casing has the potential to create them should the seat not provide sufficient height. For this seat design, the HPV is analyzed as a road vehicle where blind spots can mean the difference between life and death decisions in maneuvers. There is a trade-off between occupant protection and all-round visibility. Drivers need to make sure that improvements in their safety do not compromise the safety of others. (Millward, 2011)Reliability ConsiderationsThe life cycle of the seat frame will be equivalent to that of the vehicle, with a focus on the shelf life of the inflatable portion of seat based on the material outlined in this document. The seat portion of an HPV will need to be built such that it can withstand daily use, as the target market is the daily commuter. This seat cushion should be water and tear resistant, and the brackets and cylinders have a life span that supports the HPV User throughout the vehicles lifespan.Manufacturing Retail ConsiderationsBecause the HPV design already exists, the best approach is to provide the seat as part of a kit, which will serve as an upgrade to the stock configuration. The Stock Bluevelo Quest comes equipped with a pre-existing seat and adjustability options, but because this design is an upgrade, it will be manufactured as a ready to install kit that the user can easily install in the vehicle. To ensure ease of installation, the design should utilize a quick disconnect mounting option wherever possible. The kit should include all tools and hardware required for installation to existing mounting points to serve as an upgrade to the stock seat. The kit should also include instructions with simple illustrations. HPV Seat Industry Design ResearchAlong with internal research, JMAC has conducted extensive research on commercially available HPV seat design. To allow for a more comprehensive understanding of seat cushions, this research includes seat cushions for wheelchairs. The commercially available Seat designs are identified in Table 1. The commercially available seat cushions are identified in Table 2. This information provides a collaborative view of various characteristics, both aesthetic and ergonomic, used by JMAC in the generation of the most efficient seat design for the Quest HPV Model. In these tables, JMAC has identified several commercially available seat designs, and detailed the notable characteristics and approaches that were utilized in the designs of these seats. Through a complete analysis of the designs identified in Tables 1 and 2, JMAC has identified model features to better evaluate the characteristics that will be utilized in the generation of an optimum HPV Quest Seat Kit Design.

Figure 1: Bluevelo QuestThe Quest Model from Bluevelo comes equipped with a carbon fiber seat bucket and Ventisit Comfort Seat Cushion. Tee mesh Ventisit cushion is the highlight of this seat assembly, however the adjustability of the seat frame leaves something to be desired. Adjusting the seat to fit the desired users height and weight requires a manual adjustment that includes disassembly, adjustment and then reassembly.

Figure 2: Windcheetah Sport CompactAngletech Cycles Windcheetah Sport Compact comes standard with the Ventisit comfort seat, along with its seat that has carbon leaf spring mounts. The main disadvantage of the carbon-reinforced composite leaf springs is that they have been limited to low-volume production models.

Figure 3: Angletech Challenge Seiran SL10The Challenge Seiran SL10, an Angletech Cycle, boasts a Tiefliegersitze, which is considered one of the most comfortable shell seat designs on the market. This model also contains the Ventisit Comfort seat pad.

Figure 4: Tri-Sled Rotovelo CarbonThe Tri-Sled - Rotovelo Carbon design contains a carbon seat bucket with a foam seat pad. This seat model extends the carbon fiber seat upward and behind the riders head. Its just enough to hold your head up but allows some movement if hit any bumps or pedal squares. Tri-Sled covers their super seat (headrest included) with a very thick and comfortable layer of open cell foam.

Figure 5: Beyss Go-OneThe Beyss Go-one standard seat is designed for a certain height, and many use reviews claim the seat had to be replaced with a user designed option in order to utilize the vehicle properly.

Table 1: Industry Design HPV Analysis ExamplesFigure 6: Butterfly Gel CushionThe Butterfly Gel Cushion boasts a high-tech gel. This gel is both nontoxic and recyclable. It has shock absorption and insulation from vibration and rebound, while providing maximum dissipation of pressure points with a relaxed feel. Its channeled/ribbed design maximizes protection of soft tissues, allows ventilated comfort and conforms to the user.

Figure 7: Orthopedic Gel CushionThis high density foam pad conforms to the users contours. Inside the foam pad is a generous layer of soft, supporting liquid gel. This design is intended to banish fatigue and discomfort once and for all. Soft polyester fleece cover removes for washing. Measures 18"W x 13.5"L x 3 1/2"H.

Figure 8: Ventisit Seat PadThe Ventisit is a Netherlands design. The open weave design is loaded with venturi to bring ultimate airflow to the ride. The Ventisit is available in 2 formats/thicknesses, the Classic at 2 cm thick and the Comfort at 3cm thick. Unlike the reticular foam, Ventisit design does not compress permanently over extended use.

Figure 9: Hobie Mirage Seat PadThe Hobie Mirage Seat pad can replace the standard foam seat pad. It can easily adjust the seat to the desired comfort by adding or replacing air pressure. There is an internal valve that allows it to inflate and deflate as needed.

Figure 10: Genuine Corflex Medic-Air Seat CushionThis seat cushion provides stress free sitting with a gentle layer of air. The air assists in eliminating pressure points. This design provides adjustable density by adding or subtracting air. Maximum weight 300 lbs. 15 1/2" x 17 1/2.

Table 2: Industry Design Seat Cushion Analysis ExamplesBACKGROUND AND LITERATURE REVIEWSince the nineteenth century human powered vehicles have played an important role in sports, transportation, and industrial practices. As stated by Rosen in the Encyclopedia of 20th Century Technology, many inventors and industrialists such as Henry Ford and the Wright brothers began their careers as bicycle mechanics. Because of the simplicity in design, bicycles to this day continue to be used in innovative ways to test new materials and industrial processes (Rosen, 2005). This simple design is once again a contender as a daily commuter and with the right design features and characteristics could catapult the HPV into the daily li.ves of citizens across America. Variable Analysis of Seat DesignThe following research material has led the JMAC team to the generation of the latest advancements for the Bluevelos Model Quest HOV Seat. The variables, which are the cornerstones of JMACs AirRide design to support a person between 150 and 220lbs, with a maximum height of 6, and who utilize the vehicle 5 days a week as a daily commuter are noted in the following section. HPV Aerodynamic Feature AnalysisAccording to Lei, Trabia, and Too, the design of human-powered vehicles prior to 1993 was solely focused on aerodynamic characteristics (1993, p. 115). In past endeavors, many innovative designs were tested and proved through competition. In the 1930s, recumbent bicycles were used to break speed and distance records, causing them to be banned in competition to keep other models from being invalidated. It wasnt until the 1970s when recumbent designers and enthusiasts made their own sporting designs for competition that reached speeds up to eighty miles per hour (Rosen, 2005). While Bluevelos Velomobile struggles to reach the speeds of the competition recumbent bikes, it still meets the requirements and expectation of a viable alternative to a gas-powered vehicle. With the right design and features, this recumbent bike could work its way into mainstream commuting. 3.1.2 Structural Frame Design VariablesIn order to better evaluate how the seat frames angles will affect the human operator, the following sections describe the considerations of the Seat adjustability analysis and the seat cushion variable analysis. Careful considerations are given during the development of the JMACs AirRide seat design to ensure the most ergonomic and reliable options are incorporated.3.1.3 Seat Adjustability AnalysisThe research regarding the use of pneumatics as the pressure system to engage the seat adjustments proved useful in overall design consideration. A pressure system must employ an energy source, a transmission path, control, a load device, and possibly one or more indicators in order to function. (Fardo, 2008) The energy source in question would be a variation of the energy transformation from mechanical energy through the handheld pump, the load device, to the energy created in the cylinder. The Transmission path is the hose that connects the load device to the adjustable valves. All of the system aspects are carefully taken into consideration in the adjustability design.3.1.4 Seat Cushion Variables AnalysisThere are a wide variety of cushions available on the market, and research into active cushions versus passive cushions provided valuable insight to the effect of pattern of inflation and deflation. In a study done by Mahender Arjun Mandala at the University of Kansas, two custom active cushions were developed based on the Roho Quadtro passive cushion design. The inflation and deflation pattern of the first cushion was checkerboard (CHK) and the second was column (COL). The study concluded that the active seating system with column based pattern of inflation and deflation (COL) exhibited the best mechanical performance with regards to the parameters calculated. (Mandala, 2011) 3.2 Variable Analysis of Materials for Seat Frame and Cushion ManufacturingThe analysis of the materials used in the manufacturing of the HPV Seat design demands careful consideration due to the wide range of materials that are available today. When utilizing Design for Manufacture and Assembly (DFMA) Principles, the careful selection of materials is detrimental to the optimization of the seat design. The following sections outline the process of material choice and other available options such as material sustainability as it applies to the HPV Air Ride Seat design. According to the research outlined in this project, designs have included space-age materials such as molded thermoplastics, fiber composites, and titanium. The material selection criteria are organized in order of importance: Availability Sustainability Price Sustainable Materials Variables3.2.1 Sustainable Materials VariablesAluminum is one of the most abundant metals available; however it requires significant amounts of energy in order to process the ore into purified and alloyed forms. Aluminum is a versatile metal which may be used for a variety of applications. Recycling allows the recapture of over 1.7 billion pounds of aluminum per year, resulting in major savings in the use of electricity used in the processing of aluminum oxide ore into purified aluminum (Das 2011)Carbon fiber does not benefit from the ease of recycling that aluminum does, and can be as energy intensive to produce as aluminum from its ore, however the inherent durability and versatility of carbon fiber makes it a solid choice when light weight, high strength and unusual molding is required (Mehta 2010). A benefit of recycling carbon fiber is that no solvents or chemicals are required in order to process scraps back into a product suitable for re-use, but rather the scraps are subjected to high pressures and temperatures without any other environmental impact. (Kunz 2013)3.2.2Seat Cushion Material VariablesWhen selecting the material for the seat cushion, consideration needs to be taken to account for the additional localized pressure applied to the seat when the driver is entering and exiting the vehicle and must stand on the seat bottom. Research on a honeycomb type cushion is an essential material design requirement. A good design should utilize abrasion protection for honeycomb cushion while reducing friction against the drivers clothing and allowing ease of ventilation during driving. Table 4 outlines the four basic materials that are used to manufacture seat cushions in the industry. Research on a urethane honeycomb mesh proved efficient air travel and more protection against skin breakdown due to a cooler temperature and minimal moisture level during use. Because there are many individual cells--like a beehive--these cushions are able to distribute weight evenly, but there is no risk of leaking gel or of an air bladder being punctured. (Karp, 1998). Cushion typeAdvantagesDisadvantages

FoamInexpensive.Very lightweight.Comes in range of densities.Holds shape (memory).Provides even support.Can be cut to relieve sores.Nothing to leakWears out faster.Loses its shape.Old, compressed foam could lead to a sore.

GelExcellent pressure distribution.Very comfortable.May have supplemental inserts to stabilize legs.Heavy.Chance of leakage.Less able to absorb impact.Some designs allow gel to push out to sides.

Air floatationLightweight.Even pressure distribution.Will not bottom out if properly inflated.Can be modified to relieve pressure sores.Some models inflate to user's specific needs.Waterproof.Less stable.Chance of puncture/leakage.High maintenance: need to check pressure frequently.

Urethane honeycombVery lightweight.Low profile in appearance.Distributes weight evenly.Good support.Absorbs shock.Keeps skin cooler.No risk of leakage.Machine washable/dryable.Relatively new, so not much of a track record yet.

Table 3: Comparison of Main Types of Cushions (Karp, 1998)

3.3 Variable Analysis of Manufacturing StrategyThe details in the following paragraphs provide a high level overview of the manufacturing strategies utilized based on literature available. These will be incorporated into the design of the JMAC AirRides Seat design Kit. 3.3.1 Manufacturing VariablesThe planning and execution of the manufacturing process will be largely controlled by the following variables: selection of material types, material forms, tolerances, design and shape. Material types and forms will be chosen based on ease of machining and forming as well as minimizing the amount of waste. Processes which yield a reduction in the amount of time required to achieve the final geometry required are also a major consideration. The design should allow for a generous degree of tolerance without compromising performance and function in order to reduce machining setup time and maintain first pass yield. Implementation of DFMA from initial design to end product will result in reduced number of parts and manufacturing cycles in order to minimize material cost and production cost.3.3.2 Production VariablesWhen developing the production plans for the assembly kit, the focus will pertain to part handling, designing for inserting and fastening, and defining which components will be provided pre-assembled and which components will require the consumer to install into the vehicle itself. Packaging is another main component of getting the product kit ready for retail, along with shipment options for the consumer.3.3.3 Ease of Assembly VariablesNot only should the design incorporate ease of manufacturing at the factory, but for the consumer it should provide easy assembly at home as well. To better serve the consumer, this design will be provided in a kit with simple instructions detailing the installation required. Because of the kit approach JMAC is taking, Design for Assembly (DFA) Principles were carefully considered when designing this product for ease of Assembly. DFA is also a vehicle for questioning the relationship between the parts in a design and for attempting to simplify the structure through combinations of parts or features, through alternative choices of securing methods, or through spatial relationship changes. (Design for Assembly, 2004)3.4 Variable Analysis of Quality Assurance and Control StrategiesIndustry Standard Practice Manufacturing Strategies all adhere to stringent quality engineering principles such as Six Sigma and Total Quality Management (TQM) methodologies to ensure manufacturing success and product optimization. These systems allow the design and manufacturing companies to remain competitive in the consumer market by providing the most efficient product at the best possible price. The culture requires quality in all aspects of the companys operations, with processes being done right the first time and defects and waste eradicated from operations. (Hashimi, 2014)3.5 Background Research Variables SummaryUtilizing a combination of existing technology and new designs, this study will demonstrate an improved design for providing seating to the operator of a Human Powered Vehicle which enhances the comfort, safety and individual customization to the drivers physical characteristics and preferences, all while conforming to the requirements, specifications and limitations provided. The study has analyzed the amassed knowledge relevant to the subject matter and delineated the methods, design features and manufacturing technologies that will be utilized to bring this product to market.

JMAC DESIGN METHODOLOGYJMAC strives toward creating an efficient design that incorporates best practices into functionality and material selection to guarantee customer requirements are met and ensure all manufacturing needs are addressed. 4.1 JMAC AirRide Seat Kit DesignJMAC has utilized the Five Principles of Design to better evaluate and meet the outlined requirements. The five principles of design taken into consideration are form, function, quality, sustainability, and low price. The AirRide Seat kit is provided complete with all manufactured and purchased parts, along with a simple installation manual. 4.2 JMAC AirRide Seat Position ConsiderationsTraditional designs of HPVs have typically focused on aerodynamics as the most important characteristic to consider when determining proper seat position. The seat position is adjusted to meet size and shape of the HPV as opposed to optimizing power output. While aerodynamics is very important of the overall performance of the HPV, sacrificing performance to meet the aerodynamic shape could become counterproductive to achieving maximum efficiency. With efficiency in mind, the focus shifts to identifying and setting the HPV seat to the proper position, allowing the rider to maximize power output while exerting minimum energy. Many factors have to be considered when determining the best seat position and different riding styles require a different seat position. Seat position is generally defined and represented through a series of measurement including seat angle (Figure 1, Reference A), the distance from the back of the seat to the pedals (Leg length), (Figure 1, Reference B), and the minimum height required to maintain proper line of sight to the road (torso height), (Figure 1, Reference C).

Figure 11: JMAC Design

Reference A - Seat angle is obtained by measuring the angle created at the base of the seat in relation to the top of the seat and the center of the pedal crankshaft. Proper seat angle can range from 110-150 degrees and usually is adjusted based on the specific application intended for each HPV (Reiser II, Peterson, Broker, 2011). Riders looking for a better position for climbing a hill may choose a greater seat angle than a flat surface rider. The seat position can affect the power output both directly and indirectly. It can affect the power directly through the optimized use of leg power, whereas it can indirectly affect the power by providing a comfortable, relaxed seating position that allows for proper alignment of the body to maximize air intake while the rider breathes. Reference B - The leg length is measure from the base of the HPV seat to the center of the pedal crank and is most important in determining the rider height range, which the HPV can accommodate. Proper adjustment of leg length is also an important factor in maximizing power output.Reference C - The torso height is measure from the base of the seat to the minimum point in which the rider can maintain an unobstructed view of the road and surrounding area. This measurement in combination with the leg length is used to determine the rider height range.The JMAC AirRide takes into account the option of changing riders and allows for proper seat adjustment for riders ranging from 52 to 62. This adjustment is made through the use of an air-operated cylinder and JMACs original pendulum seat mounts. The pendulum mounts allows for two directions of travel simultaneously allowing shorter rider to move both, closer to the pedals and higher in the cockpit to maintain a proper view of the road. 4.3 JMAC Seat Inflation Design RequirementsThe JMAC AirRide will feature an inflatable seat design which will provide the vehicle operator with the ability to customize support points, seat height, and distance to the vehicle controls which accommodate different body types within the height and weight range specified by the customer. Inflation will be accomplished utilizing a hand-operated pump, which will supply air to a set of strategically positioned chambers. Each chamber will be adjustable through the use of a smart valve system. This smart valve system will regulate adjustability, and also prevent over pressurization. Seat inflation is accomplished utilizing an ambidextrous hand-operated pump located on the JMAC Air Manifold subassembly and designed to allow two-handed operation, allowing the driver to produce the most amount of mechanical energy with the least amount of physical exertion. The pump is connected to an air supply system that feeds into a 3-way valve that can be switched between two positions. 4.4 JMAC 3-Way Valve ConsiderationsThe first position supplies air to a pneumatic cylinder mounted to the vertical support post connected to the seat frame. This pneumatic cylinder provides back and forth movement to the seat by pushing the seat forward, and also provides vertical movement to the seat by pushing upward.The second position supplies air to a manifold with 6 outlets, each of which connects to a check valve. The check valve controls the pressure at each of the 6 chambers throughout the inflatable seat. Each check valve can be adjusted by the driver to the desired pressure in order to control both the firmness of the seat and also to provide additional control to the height of the seat for the purpose of providing a clear line of sight for the driver. The chambers include the following in order to provide support to key areas: backrest, lumbar, seat height 1, seat height 2, seat height 3, and seat surface.4.5 JMAC Lumbar Support Cushion ConsiderationsBackrest and lumbar chamber inflation allow the driver to adjust optimized support to the back and shoulder area independently from the chamber providing lumbar support. This is to allow customization to the unique physical characteristics of the driver.4.6 JMACs Air Chamber Cushion RequirementsThe JMAC Air Chamber Cushion will consist of 17 connected tubes which have been separated into chambers, Upper-Back, Lumbar and Waterfall. Each of the 3 chambers will be individually controlled through a regulator allowing the rider to set each of the chambers to their preferred setting. Control of the air cushion will be accomplished through a manifold assembly containing air regulators. The mini air regulators attached at the manifolds are calibrated to inflate within 1 psi of the desired pressure setting. Excess air supplied to various chambers will be expelled by the relief valve, which prevents over pressurization and resulting damage to the seat. The air pump has a high pressure low volume stage and a low pressure high volume stage. Changing between stages is accomplished with a simple twist of the handle. 4.7 JMAC Air Cushion Material ConsiderationsSeat materials were selected to account for the additional localized pressure applied to the seat when the driver is entering and exiting. The honeycomb cushion will be protected by a Ventisit comfort cushion screen mesh cover providing abrasion protection to the honeycomb cushion while reducing friction against the drivers clothing and allowing ease of ventilation during driving. The Ventisit is the cushion provided with the Bluevelos Velomobile stock assembly.4.8 JMAC Vehicle Stability ConsiderationsThe stability of a vehicle is largely determined by center of gravity and the response of tires to applied forces, specifically the relationship between lateral acceleration, longitudinal acceleration, and control characteristics. Driver input in the form of braking and cornering, and the resulting forces resulting from both actions as they occur simultaneously affect center of gravity of the vehicle, and its stability. Generally speaking, when lateral forces from the center of gravity are equal or greater than the forces of the vehicle mass at the center of gravity, rollover can occur. As the center of gravity elevates, the vehicle requires a greater amount of downward force at the center of gravity in order to retain stability, or a greater lateral distance between the center of gravity and the center of the tires. (HS, 807 956)4.8.1 Directional Stability ConsiderationsDirectional stability, also called Yaw or Heading, depends on horizontal planar moments applied against opposing tire forces. When driver input in the form of braking and cornering are applied, the load of the vehicle is transferred from the inside of the tires to the outside of the tires. When those forces exceed the opposing forces of the tires, lateral acceleration will occur and the risk of vehicle rollover increases. (HS, 807 956)4.8.2 Rollover Stability ConsiderationsWhen the Center of Gravity (cg) is elevated over one of the wheels, rollover can occur. Figure 11 illustrates the change in elevation Delta h as the center of gravity cg shifts from the center of the wheel axel to be directly over the center of the tire in a lateral motion. The height and lateral position of the center of gravity relative to the ground and wheel center respectively determine how much of a change in cg elevation is required for this to occur. The side forces exerted on the tires do not have a high enough coefficient of friction to initiate a rollover unless there are outside forces such as changes in the road surface or physical obstructions on the road such as speed bumps, contact with a curb or foreign objects which can change the height of the side forces and cause a tripping event which leads to rollover.

4.8.3 Lateral Forces Rollover AnalysisThe forces required to initiate a rollover are dependent on the location of the center of gravity, and the downward forces being applied by the weight of the vehicle. Figure 11 and 12 reference the center of gravity elevation formula and the side forces at rollover.

Figure 12: Center of Gravity Elevation Formula

Figure 13: Tire Side Forces at RolloverTable 4 and Figures 13 and 14 represent the effect of the shift of center of gravity as the seat position is moved upwards. Zero position represents the lowest seat position, and this position shifts upward as the seat is elevated. Different weights of the rider are then applied against this shifting center of gravity. As the rider weight increases, so does the amount of lateral force required for the vehicle to roll over.Zero + 5Zero + 4Zero + 3Zero + 2Zero + 1Zero

cg Elevation4.4014.0413.7273.4533.2123

Lateral Forces (ma) required for Roll-over

Zero + 5Zero + 4Zero + 3Zero + 2Zero + 1Zero

150118.402122.264125.839129.141132.188135

155122.349126.340130.034133.446136.595139.5

160126.296130.415134.229137.751141.001144

165130.243134.491138.423142.055145.407148.5

170134.189138.566142.618146.360149.813153

175138.136142.642146.813150.665154.220157.5

180142.083146.717151.007154.970158.626162

185146.030150.793155.202159.274163.032166.5

190149.976154.868159.397163.579167.439171

195153.923158.944163.591167.884171.845175.5

200157.870163.019167.786172.189176.251180

205161.817167.095171.981176.493180.657184.5

210165.763171.170176.175180.798185.0642189

215169.710175.246180.370185.103189.470193.5

220173.657179.321184.565189.407193.876198

Table 4: Rollover Lateral Force

Weight of Rider (lbs)Lateral Force Required to Roll Vehicle(lbs)Figure 14: Rollover Lateral Force Chart

Seat Height SettingVertical Shift of Center of Gravity (in)

Figure 15: Center of Gravity (cg) Elevation Shift

4.9 JMAC Air Ride Weight ConsiderationsLightweight and HPV are almost interchangeable when it comes to developmental and competitive designs. The following sections define the weight aspect as it pertains to the rider and the overall vehicle weight in terms of both the operators performance and the vehicles performance. Understanding the weight relationship between each of these aspects will better determine the performance output of the JMAC Air Ride seat kit design.When it comes to HPV and their aerodynamic attributes, it is no surprise that weight will affect overall performance. During the Tour de France, Lance Armstrong switched his wheels, frame and components to a more efficient and lightweight alternative during the mountain legs of the race. This provided Armstrong with a lighter bike that provides less rolling resistance, improved acceleration, and requires less power while in an incline (Burke, 2014). According to Burke, it takes more power to achieve the same speed of a lighter bike. Adding weight increases the bikes inertia, thereby slowing down acceleration rate, and increasing rotating friction on the wheels (2014).McCraw discusses how the speed in an incline is influenced by the energy the rider puts out versus the work that is required to overcome inertia. Therefore the speed lost by adding the additional weight from the improved seat design may be calculated using the following formula (McCraw 2012).

Figure 16: McCraws Weight Study Formula

For this study, in McCraws formula the kilogram unit of measurement was converted to pounds and the unit of speed was kept as miles per hour. Thereby, using a rider that is 190 lbs., the original bike weight at 77.16 lbs. for Bike 1, the new bike weight of 87.16 lbs. for Bike 2, and using 12 mph as Bike 1s speed, Bike 2s speed can be calculated as 11.57 mph. Therefore the new design is 0.43 mph slower than the original design. Taking into account of the speed lost with the improved design, the time added to a 10 mile commute can be calculated using McCraws formula for time saved or added in Figure 12.

Figure 17: McCraws Formula for Time Saved or Added

For this study, 10 miles was be used as the Distance for the commute, and Speed 1 and 2 was utilized from the previous formula. Therefore the time added to the commute by using the heavier design is 111.49 seconds, almost 2 minutes more of a commute than the original design (McCraw 2012). Figure 13 illustrates the time added to a ten-mile commute for every pound added to the HPV. As each pound is added, 38.88 seconds is added to the commute.

Figure 18: Seconds Per Pound Analysis5 JMAC AIRRIDE DETAILED DESIGN AND RISK ASSESSMENTJMAC has taken an innovative design approach to provide a more versatile option for Velomobile riders. With the use of lean manufacturing principles, risk management techniques and careful material selection JMAC has been able to produce a design that meets the all of the customer requirements and cost goals in a competitive market. 5.1 JMAC AirRide Components and SubassembliesThe JMAC AirRide System is made up of five subassemblies. The front and rear bracket subassemblies provide for the mounting and pivot points for JMACs original pendulum driven seat positioning system. The seat subassembly contains all the necessary brackets to convert the original HPV seat bucket for use with the AirRide system. The last subassembly is the Air manifold subassembly providing all the controls to set the perfect seat position. Figure 18 provides an overall view of the subassemblies within the final assembly.

Rear Bracket(3) Seat Brackets(4) Seat Cushion( 1) Front Bracket(5) Air Manifold (Not shown in this View)Figure 19: Subassembly Detail5.1.1 JMAC Front Subassembly DesignThe front bracket assembly consists of a mounting bracket which mounts directly to the existing mounting holes for the current forward seat brackets and JMACs unique pendulum drop arm. The drop arm connects to pivot pins on both the mounting bracket and the front corners of the seat subassembly. Figure 19 shows one of the two front bracket subassemblies required.

Figure 20: Front Bracket Subassembly

5.1.2 JMAC Rear Bracket Subassembly DesignFigure 21 conveys the rear-mounting bracket that bolts directly to the existing rear mounting holes and provides mounting points for the rear pendulum drop arms and the air cylinder. The rear pendulum drop arms connect to a pivot pin at the top of the rear mounting bracket and to the back of the existing HPV seat via the provided mounting bracket. A second pin connects the air cylinder to the bottom of the rear-mounting bracket.

Figure 21: Rear Bracket Subassembly5.1.3 JMAC Seat Subassembly DesignThe JMAC AirRide Seat uses the existing carbon fiber seat bucket. As part of the installation kit, templates are provided to drill and mount the AirRide brackets. The Seat subassembly has a total of four brackets providing pivot/mounting points for the pendulum drop arms and the air cylinder.5.1.4 JMAC Air Cushion DesignThe JMAC air cushion is comprised of three separate chambers: Upper-Back, Lumbar and Waterfall. Each chamber can be inflated to a specific pressure, allowing for fine tuning of seating position. Figure 21 demonstrates the 17 different sections of the cushion as it fits on the existing carbon fiber seat. The JMAC AirRide logo is also included as part of the cushion design.

Figure 22: AirRide Cushion Design

5.1.5 JMAC Air Manifold Subassembly DesignThe Air Manifold subassembly houses all the pressure controls for operation of both the air cushion and cylinder. The subassembly is made up of two air manifolds, a three-way valve, mini air regulators and a hand pump. The components of the subassembly are attached to the mounting bracket that is bolted directly to the carbon lip formed by the two halves of the HPV body. The three-way valve directs air to one of the two air manifolds, each containing mini pressure regulators for fine-tuning the seat position and a small needle valve for easy deflation. The air pump has a high-pressure low volume stage and a low pressure high volume stage, changing between stages is accomplished with a simple twist of the handle. The operation starts with a three-way valve that directs flow from the air pump to either the air cushion or the air cylinder. Stage one of setting proper seat position is accomplished by setting the three-way valve to the downward position, directing airflow to the air cylinder. Using the air pump, air is utilized until proper seat height is obtained. Stage two is accomplished by moving the three-way valve to the forward position, directing airflow to the air cushion manifold. Figure 22 references an image of the cylinder assembly and the locking bar.

Figure 23: Cylinder Assembly with Locking Bar

The air cushion manifold provides airflow to the three chambers of the JMAC air cushion. The air cushion manifold contains a combination mini Air regulator and relief valves for each chamber. Pressure can be set and adjusted for each chamber by setting the relief valve to a set pressure to allow for maximum comfort. Individual riders can also record their preferred pressure setting for each chamber for a faster set-up during subsequent rides. Deflation is accomplished by slowly opening the two needle valves until seat has returned to original position.

5.2 JMAC Bill of MaterialsA comprehensive parts list has been generated in Figure 23 that outlines all of the materials needed to manufacture and assemble the JMAC AirRide Seat.

Figure 24: Bill of Materials5.3 JMAC Cost AnalysisFigure 25 is a detailed Bill of Material with Cost information for the purchased parts of the JMAC Air Assembly.

Figure 25: Purchased Parts CostFigure 26 is a detailed Bill of Material for all of the Make Parts in the JMAC Air Assembly.

Figure 26: Manufactured Parts List

Manufacturing processes costs were a subject of consideration based on the suitability of the process for the part geometry and the resulting cost of manufacturing. Cost analysis is based on processes utilized by machine shops in estimating costs for performing cutting services, bending, machining and welding. The estimated costs for the various manufacturing services and processes are detailed in Figure 26. This cost was arrived at by considering several factors such as cut inches for cutting services and the number of bends for bending operations. Given a bulk order of 1000 assemblies, the estimated price for all custom manufactured parts is $342.22.

Figure 27: Manufacturing Cost

5.4 JMAC Weight AnalysisJMAC AirRide weight considerations were calculated using the Solid Works Files material properties and weight calculation features, coupled with a summary of Buy Parts Weights as outlined in Figure 28. The total weight output from the Assembly is 4.96 lbs. The Total weight of the Buy parts is 4.79. This creates a total Assembly kit weight of 9.75 lbs.

Figure 28: Buy Parts Weight Summary

5.5 Risk Mitigation and ConsiderationsRisk Mitigation strategies and considerations must take into account a variety of factors when analyzing potential sources of failure and difficulties in the product design and manufacturing process. An evaluation of product and process technologies which are going to be utilized in the system must be undertaken. Technologies which are new and untested are especially in need of special consideration when performing a risk assessment. The allocation of development team resources and the supply chain are also important points which may affect the successful development and manufacture of the product. (Montgomery 2011)Mitigating these risks for each of the systems and subsystems is a critical step during the product design phase. Development of a Failure Mode, Effects and Criticality Analysis (FMECA) is instrumental in this regard. (Blanchard 2011)

5.5.1 FMECA DevelopmentThe Failure Mode, Effects and Criticality Analysis will evaluate the design and function of AirRide. Figure 29 is a top level functional flow diagram. Figure 30 is the second level functional flow.

Figure 29: Functional Flow Diagram (TOP LEVEL), FUNCTION

Figure 30: Functional Flow Diagrams (Second Level)

5.5.2 Risk Priority Number DevelopmentRisk priority factors are derived as outputs based on these functional diagrams. These risk priority factors are evaluated utilizing three criteria: severity, occurrence, and detection. Each component is assigned a score from 1 to 10, from lowest to highest level of priority. A Risk Priority Number (RPN) will be determined by multiplying the scores for each component, yielding the order by which corrective actions may be taken to mitigate those risks. (Blanchard 2011) Table 5 details a comprehensive Risk Priority Number Analysis.

Table 5: Risk Priority Analysis

5.5.3 Corrective Action IdentificationThe most commonly observed potential sources for failure were related to the use of air as the medium for seat adjustment and seat comfort. The inherent relative weakness of air filled cushions combined with the need to manually provide air to the system via a hand actuated pump create risks which can be mitigated but not completely eliminated through the use of mechanical support to the air system. The stop bar assembly which provides additional structural support to the air cylinder was implemented due to this observed and measured risk, and is meant to provide an additional layer of safety and reliability which cannot be as readily obtained through the use of the pneumatic system and air cushions alone.

6 CONCLUSION AND RECOMMENDATIONSJMACs innovative design successfully incorporates functionality and manufacturability with the intent to satisfy a wider range of desired ease of adjustability for customers. While the original design offered the customer to specify his/her desired configuration when the vehicle was first purchased, it was not easy for him to make adjustments later as the process was cumbersome and require the use of hand tools. JMAC utilized a design approach that took into consideration existing concepts and industry products available, and through the employment of manufacturing best practices and the application of risk management techniques, developed an operational and cost effective assembly that meets all of the requirements set forth by Bluevelo. The JMAC AirRide seat assembly has been designed to provide comfort and ease of adjustability, with all of the adjustments made using simple pneumatic valves on both the seat and cushion adjustments. The design includes front and rear brackets with a pendulum action lever levied with a pneumatic cylinder accompanied with an inflatable seat cushion for additional safety and ergonomic benefits. JMAC intends to sell the new seat system as an upgrade kit, utilizing the existing seat panel and mounting points.Based on the research and analysis performed by JMAC in creating a design that meets customer specifications, the following recommendations are provided to increase assembly performance and reduce cost. JMAC recommends the use of an electric pump instead of a manual hand pump. A small battery operated electric pump would decrease seat adjustment and cushion inflation time considerably, reduce rider fatigue without adding a significant increase in either weight or cost. Another suggestion is the use of a small sealed hydraulic system. One of the main concerns when using a pneumatic system is the compressibility of air which is less efficient when using a liquid medium to actuate the cylinder. This would only have a marginal effect on the overall weight but could be provided as an option if the consumer chooses the upgrade. Although comfortable and efficient, the neoprene material can be costly. JMAC suggests retaining the existing mesh seat cover in lieu of the inflatable air cushion. The JMAC AirRide Seat Kit allows for sufficient adjustability, making the neoprene cushions focus mostly about comfort. Additional cost and weight savings could be accomplished by retaining the use of the original mesh cover that comes stock with the vehicle, since air would no longer be necessary for providing the user full adjustability. The mesh would also enhance user comfort as it naturally provides superior ventilation and breathability as opposed to the inflatable neoprene bladders used in the seat cushion assembly. The weight that was introduced into the final design by the inclusion of the air control system would be eliminated, thereby offsetting the marginal increase in weight from the use of a hydraulic cylinder.The JMAC AirRide design allows the use of air as a medium for providing adjustability both vertically and longitudinally, while at the same time reducing the amount of effort required by the rider to make the necessary adjustments.

REFERENCES AND WORKS CITED

Blanchard, S. & Fabrycky, W. (2011). Systems Engineering and Analysis. Upper Saddle River, NJ: Prentice Hall

Burke, E.R. (2014). The Effect of Weight on Speed. Retrieved from http://www.active.com/cycling/articles/the-effect-of-weight-on-speed.

Design for assembly. (2004). Manufacturing engineering handbook. Retrieved from http://ezproxy.nu.edu/login?url=http://literati.credoreference.com.ezproxy.nu.edu/content/entry/mhmeh/design_for_assembly/0

Fardo, Stephen W., and Patrick, Dale R.. Industrial Process Control Systems (2nd Edition). Lilburn, GA, USA: The Fairmont Press, Inc., 2009. ProQuest ebrary. Web. 10 February 2015.

Hashmi, K. (2014). Introduction and implementation of total quality management (TQM). iSixSigma. Retrieved from http://www.isixsigma.com/methodology/total-quality-management-tqm/introduction-and-implementation-total-quality-management-tqm/

Karp, G. (1998). Choosing a wheelchair: A guide for optimal independence. Retrieved from http://www.oreilly.com/medical/wheels/news/chair_cushions.html

Leil, Y., Trabial, M.B., & Too, D. (1993). Optimization of the seating position in a human-powered vehicle. 11 International Symposium on Biomechanics in Sports (1993), pp. 115-119. Retrieved from https://ojs.ub.uni-konstanz.de/cpa/article/view/1691/1593.Mandala, M. A. (2011). Evaluating the effect of pattern of inflation and deflation and cycle time on the pressure relieving characteristic of a dynamic seat cushion using seat interface pressure measurements (Order No. 1496880). Available from ProQuest Dissertations & Theses Full Text; ProQuest Dissertations & Theses Global. (884580382). http://ezproxy.nu.edu/login?url=http://search.proquest.com/docview/884580382?accountid=25320

McCraw, D. (2012, June 19). Bike weight and performance. Retrieved from http://mccraw.co.uk/bike-weight-performance/#comments.

Millward, David. (2011). Blind spot crashes increase. The Telegraph. Retrieved from http://www.telegraph.co.uk/motoring/news/8779153/Blind-spot-crashes-increase.html

Montgomery, D., Jennings, C., & Pfund, M. (2011). Managing, controlling, and improving quality. Hoboken, NJ: John Wiley & Sons.

Murata, J., Murata, S., Ohyama, M., Kogo, H., & Matsubara, S. (2014). Effect of a dynamic air cushion on the development of leg edema during wheelchair sitting. Journal of Physical Therapy Science, 26(6), 911913. doi:10.1589/jpts.26.911 Retrieved from http://www.ncbi.nlp.m.nih.gov/pmc/articles/PMC4085220/

Raoul F. Reiser II, Micheal L. Peterson, Jeffrey P. Broker: Anaerobic Cycling Power Output With Variations in Recumbent Body Configuration, Journal of Applied Biomechanics, Vol 17, No. 3, 2001.

Rosen, P. (2005). Transport, human power. Encyclopedia of 20th Century Technology. Retrieved from the Literati by CREDO Database. Retrieved from http://literati.credoreference.com.ezproxy.nu.edu/content/entry/routt/transport_human_power/0?searchId=d32f4209-7d76-11e4-a634-0aea1e24c1ac&result=0.

APPENDIX A: ACRONYMS

DFA: Design for AssemblyDFMA: Design for Manufacture and AssemblyHPV: Human Powered VehicleMPPU: Machining Price Per UnitPPA: Price Per AssemblyPPB: Price Per BendPPI: Price Per InchPPM: Price Per MinutePPP: Price Per PiercePPU: Price Per UnitPPW: Price Per WeldPSI: Pounds per Square InchTPPU: Total Price Per UnitTQM: Total Quality Management

APPENDIX B: GLOSSARY OF TERMS For the purposes of this study, the following terms will be utilized with the given definitions below. (Defined terms to be inserted into this section as needed during subsequent research)

Chamber: Each of the individually inflatable pockets within the seat, which when grouped as a single entity form the entirety of the inflatable component of the seat.

Cylinder A device that converts fluid power into linear mechanical force and motion; consists of a movable piston, connecting rod, and plunger operating in a cylindrical cavity.

Edema: An abnormal accumulation of fluid in the interstitium, located beneath the skin and in the cavities of the body.

Honeycomb Cushion: The surface upon which the drivers bottom will be resting. The honeycomb cushion is composed of a matrix of inflated pockets maximized to provide the most surface contact with the occupant possible.

HPV: A Human Powered Vehicle with a recumbent seat design

Leg Length: the measure from the base of the HPV seat to the center of the pedal crank and is most important in determining the rider height range which the HPV can accommodate.

Main Manifold: The distribution junction for air produced utilizing the hand operated pump. Each manifold outlet will be directed towards a chamber and will allow adjustability of air pressure through use of an adjustable check valve.Smart Valve: Adjustable valve which will allow the user to set the pressure within a given chamber, thus controlling the height and longitudinal position of the user under a given inflation setting.

Seat Angle: the angle created at the base of the seat in relation to the top of the seat and the center of the pedal crank shaft. Proper seat angle can range from 110-150 degrees and usually is adjusted based on the specific application intended for each HPV.

Torso Height: the measure from the base of the seat to the minimum point in which the rider can maintain an unobstructed view of the road and surrounding area. This measurement in combination with the leg length is used to determine the rider height range.

Valve A device that controls fluid flow, direction, pressure, and flow.

Vertical Support Post: the vertical aluminum post integrated into the Quest HPV which provides a resting point for the upper seat support bracket when the seat is in the full back position. The Post features a bracket with three columns of holes which function as mounting points for fasteners.

APPENDIX C: SUBASSEMBLY MANUFACTURING DATAThis appendix is a detailed outline of the JMAC AirRide Seat Design, as represented by detailed manufacturing drawings. Defined in this section is a complete list of the subassembly Bill of Materials to indicate which materials and components were utilized in each one of the JMAC AirRide Subassemblies.

1.000 .500

.563

Spacer, Teflon

01DO NOT SCALE DRAWING

20-0010SHEET 1 OF 1

2/15/15CJB

UNLESS OTHERWISE SPECIFIED:

SCALE: 2:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

Roundstock, 1ODx0.5IDx0.5625

FINISH

MATERIAL

INTERPRET GEOMETRICTOLERANCING PER:

DIMENSIONS ARE IN INCHESTOLERANCES:FRACTIONAL 0.005ONE PLACE DECIMAL 0.05TWO PLACE DECIMAL 0.005THREE PLACE DECIMAL 0.0015

APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THISDRAWING IS THE SOLE PROPERTY OFJMAC. ANY REPRODUCTION IN PART OR AS A WHOLEWITHOUT THE WRITTEN PERMISSION OFJMAC IS PROHIBITED.

5 4 3 2 1

Sheet1Drawing View1Drawing View2Drawing View3

7.500 1.000

1.000

1.000 R.500

.500

4x R.247

12.000 .250

Bar, Locking


20-0011SHEET 1 OF 1

2/15/15CJB


SCALE: 1:4 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

Flat Bar, 1x12.50x0.25

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


R.250

.200

.250

Ball, LockRelease Arm


20-0012SHEET 1 OF 1

2/15/15CJB


SCALE: 4:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

AluminumFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1

Sheet1Drawing View1Drawing View2

.500

R.250

R.625 R.500

1.000

5.000

1.750

1.250

.222

2x .100

1.813

.250

Pivot Arm


20-0013SHEET 1 OF 1

2/15/15CJB


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

Flat Bar 1.25x6.125x0.25

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


1.682

.460

4x R.105 1.250

1.472

.100 1.4

Spring, Pivot Arm


20-0014SHEET 1 OF 1

2/15/15CJB


SCALE: 2:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

Roundstock 0.10dia

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


2.500

.500

Pin, Locking Arm


20-0015SHEET 1 OF 1

2/15/15CJB


SCALE: 2:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

Roundstock, 0.5dia

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


R.250

.250

.200

Ball, LockRelease


20-0016SHEET 1 OF 1

2/15/15CJB


SCALE: 4:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

Aluminum

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1

Sheet1Drawing View1Drawing View2

JMAC AirRide Adjustable Seat Kit


Final Assem. 1SHEET 1 OF 2

2/22/15CJB


SCALE: 1:12 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

N/A

N/AFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION Default/QTY.

1 10-0001 Rear Bracket Assembly Rear Bracket Assembly 1

2 10-0002 Front bracket assembly Front bracket assembly 2

3 10-0003 Seat Assembly Seat Assembly 1

4 10-0004 Locking Bar Assembly Locking Bar Assembly 1

5 10-0005 Pivot Arm Assembly Pivot Arm Assembly 4

6 35-0001-1 Cylinder, Air 1

7 35-0001-2 Piston, Cylinder, Air 1

8 20-0002 Pin, Rear Bracket Locking Bar Assembly 1

9 90302A482 90302A482 MCMASTER CARR 1

10 20-0009 Neoprene, Cushion Neoprene, 0.15in thk 1

11 20-0010 Spacer, Teflon Roundstock, 1ODx0.5IDx0.5625 2

12 33-0003 Washer, Teflon Washer, Teflon, 1ODx0.50IDx0.125 2

13 20-0015 Pin, Locking Arm Roundstock, 0.5dia 1

14 CR-RHMS 0.25-20x0.5x0.5-N Round Head, Screw 1/4-20x0.5 2

01Final Assem. 2SHEET 2 OF 2SCALE: 1:12 WEIGHT:

REVDWG. NO.

ASIZE

5 4 3 2 1

Sheet1Drawing View1Drawing View2Drawing View3Drawing View4

Sheet3Drawing View5

4 1 2

56

7

3

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 Preferred Narrow FW 0.25 2


3 33-0002 Washer, AluminumAluminum Washer,

0.68ODx0.25IDx0.125 2

4 CR-RHMS 0.25-20x0.5x0.5-N 4

5 20-0001 Bracket, Rear Bracket, Rear 1

6 20-0002 Pin, Rear Bracket Locking Bar Assembly 1

7 20-0003 Pin, Rear Bracket, Cylinder Pin, Rear Bracket, Cylinder 1

Rear BracketAssembly


10-0001SHEET 1 OF 1

2/22/15CJB


SCALE: 1:4 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

N/A

N/AFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


53

4

2

1


1 20-0004 Bracket, Front Mounting Flat, Bar, 1x5x0.1875 1

2 20-0005 Pin, Front Bracket Round Stock, 0.5Diax0.6875 1

3 Preferred Narrow FW 0.25 1


5 CR-RHMS 0.25-20x0.5x0.5-N 1

Front BracketAssembly


10-0002SHEET 1 OF 1

2/22/15CJB


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


3 2

5

8

47

6


1 CR-RHMS 0.25-20x0.5x0.5-N 4

2 CR-RHMS 0.25-20x0.25x0.25-N 8

3 Seat 1

4 Seat2 1

5 20-0006 Bracket, Upper Seat 1

6 10-0006-1 Bracket, Front Right, Seat 1

7 10-0006-2 Bracket, Front Left, Seat 1

8 20-0008 Bracket, Cylinder to Seat 1

Seat Assembly


10-0003SHEET 1 OF 1

2/15/15CJB


SCALE: 1:12 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1



1 20-0011 Bar, Locking Flat Bar, 1x12.50x0.25 2

2 20-0012 Lock Release Arm Bar Stock 0.20dia 1

3 20-0016 Ball, Lock Release Arm 1

Locking BarAssembly


10-0004SHEET 1 OF 1

2/15/15CJB


SCALE: 1:4 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1



1 20-0013 Pivot Arm Flat Bar 1.25x6.125x0.25 1

2 20-0014 Spring, Pivot Arm Roundstock 0.10dia 1

Pivot ArmAssembly


10-0005SHEET 1 OF 1

2/15/15CJB


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


Bracket, FrontRight, Seat


10-0006-1SHEET 1 OF 1

2/15/15CJB


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1

Sheet1Drawing View1Drawing View2Drawing View3Drawing View4Drawing View5

5 4 3

2

1


1 20-0007 Bracket, Seat Front Flat Bar, 1x3x0.1875 1

2 20-0005 Pin, Front Bracket Round Stock, 0.5Diax0.6875 1


4 33-0002 Washer, AluminumAluminum Washer,

0.68ODx0.25IDx0.125 1

5 CR-RHMS 0.25-20x0.5x0.5-N 1

Bracket, FrontLeft, Seat


10-0006-2SHEET 1 OF 1

2/15/15CJB


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1

Sheet1Drawing View1Drawing View2Drawing View3Drawing View4Drawing View5

4.000

.500

2x1/4-20 Tapped Hole 0.50"

Pin, RearBracket


20-0002SHEET 1 OF 1

2/15/15CJB


SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

ALUMINUMFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


3.000

2x1/4-20 Tapped Hole 0.50" .500

Pin, RearBracket, Cylinder


20-0003SHEET 1 OF 1

2/15/15CJB


SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

AluminumFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


5.000

.500 .250 .250 .500 2.500

4.250

.500 1.000

.188

Bracket,Front Mounting


20-0004SHEET 1 OF 1

2/15/15CJB


SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONEFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1

Aluminum, Flat, Bar, 1x5x0.1875


.500

.688 .500

1/4-20 Tapped Hole

Pin, FrontBracket


20-0005SHEET 1 OF 1

2/15/15CJB


SCALE: 2:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

Round Stock, 0.5Diax0.6875

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


4.250

R.500 .250 THRO. ALL

1.875

3.000

1.000

1/4-20 Tapped Hole

Bracket, UpperSeat


20-0006SHEET 1 OF 1

2/15/15CJB


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

None

AluminumFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


3.000

.500 THRU. ALL

.333 .500

.500 1.500

2.500

2x 1/4-20 Tapped HoleTHRU. ALL

.188

Bracket, SeatFront


20-0007SHEET 1 OF 1

2/15/15CJB


SCALE: 1:1 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

N/A

Flat Bar, 1x3x0.1875

FINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


3.250

1.000

.750

2.750

R.500

1.125

1.000

2x .250

.750

4x 1/4-20 Tapped Hole

Bracket, Cylinderto Seat


20-0008SHEET 1 OF 1

2/15/15CJB


SCALE: 1:2 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

NONE

AluminumFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


Neoprene,Cushion


20-0009SHEET 1 OF 1

2/15/15CJB


SCALE: 1:12 WEIGHT:

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

N/A

NeopreneFINISH

MATERIAL



APPLICATION

USED ONNEXT ASSY



5 4 3 2 1


JMAC AirRide Capstone Thesis MARCH

Documents

Transcript of JMAC AirRide Capstone Thesis MARCH