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Project Readiness Package Rev 11/02/12

INTRODUCTION:Cycling shoes are quite different than running shoes. The primary difference is the stiff sole of cycling shoes designed for efficient power transfer and pressure distribution in contrast to the soft flexible sole of most running shoes. That means triathletes have to stop mid-race and change their shoes when they transition from biking to running. This project will create a shoe and pedal that allow triathletes to wear the same shoe for both sections while not losing the advantages of discipline specific shoes.

ADMINISTRATIVE INFORMATION:

� Project Name: Transforming Triathlon Shoe – Cycling to Running

� Project Number: XXXXXX

� Preferred Start/End Quarter in Senior Design:

� Faculty Consultants:

Name Dept. Email PhoneDr. Kempski* ME [email protected] 585-475-2473Dr. DeBartolo* ME [email protected] 585-475-2152Dr. Gomes ME [email protected] 585-475-2148

*Only available for some consulting, but will not be involved in the design reviews.- Dr. Ghoneim may also be available as a small resource for composites if necessary, but only minimally.

� Potential Team Members:Ryan N Wilson ME 5th YearMadeleine Hoppy Industrial Design 4th YearCody Woods ME 4th Year

� Primary Customer, if known (name, phone, email): Dr. Jeremy Haefner (provost)* Phone: 585-475-6399 E-mail: [email protected]*Organize meetings through his secretary Pamela Spencer <[email protected]>

� Sponsor:

Name/Organization Contact Info. Type & Amount of Support Committed

Mark Smith [email protected] (585) 475-7971 $500.00

� INTEREST IN CONTINUING(Not interested) 0----1----2----3----4----5 (interested)My interest level: 5My dream career is developing performance footwear. I interned for a full year at PUMA Germany doing

that, and this would be a great addition to my experience in that regime. Product design is exciting. Getting the chance to drive the development of an innovative new product with a team of talented engineers fits right in line with my goals.

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Fall/Winter Fall/Spring Winter/Spring

mailto:[email protected]






PROJECT OVERVIEW: Cycling shoes have been made to be quite efficient on the bike over the years. This efficiency has come at the cost of being efficient on the ground though. With the exception of cycling races, pretty much all other uses of the bike require walking or running before and/or after. Walking in cycling shoes is awkward at best, so running is out of the question. Switching out shoes is a nuisance and takes time. In the case of triathlons those few seconds can mean winning or losing. If a triathlete or commuter wants to not have to change shoes, they have two options. Wearing regular shoes or running shoes is good for walking/running and can be biked in, but a lot of power is lost because you can only push the pedals (can't pull up on them) and there is dampening . Also after a long period of time the pressure from the pedals begins to irritate the foot. The other option is to wear shoes designed for multi use, but that really just means they compromised all of the features. The shoes are only a little stiff so they distribute some pressure and make walking only slightly awkward (and running is still not possible). They have dampening, but only a bit. A proper solution to the problem must transform from rigid to soft and flexible when dismounting the bike. The shoe could be built for triathletes, but others could benefit from them as well, just as running shoes are built for runners but see use by many people as casual comfortable shoes.

The objective for this Senior Design Project is to create a system that allows the user to cycle with high performance cycling shoes and then seamlessly transition to running, wearing the same shoes. This involves the development of a new sole unit and most likely a new pedal for it to interface with. The upper of the shoe may be an existing upper taken from another shoe. The user experience must be intuitive and safe with respect to clipping into and out of the pedals, and provide a succinct advantage over current solutions. Some discomfort related to craftsmanship may be acceptable for the first year of the project so long as it is clear that the sole is functional and is not fundamentally the cause of any of the discomfort.

This was a project designed in collaboration with one of the senior Industrial Design students. Madeline Hoppy developed it from the research stage through to a prototype in class. With the addition of a team of engineers it could be redone in a way that more effectively solves the problems she discovered (see Continuation Project Information for more details). DETAILED PROJECT DESCRIPTION:

� Customer Needs and Objectives:

1 Very Important –-- 2 Somewhat Important --- 3 Least Important

No. Importance Need

CN 1 1 Minimal dampening between shoe and pedalCN 2 1 Flexibility during walking/runningCN 3 1 Does not unintentionally bump into the bike frame while pedaling CN 4 1 Allow ankle flexion and extensionCN 5 1 ComfortableCN 6 1 Lets the athlete race fasterCN 7 2 LightweightCN 8 2 Easy effective clip in and clip out of the pedalsCN 9 2 Shoe can twist a little bit on the pedals to relieve torque on the kneesCN 10 2 Shoes can be put on quicklyCN 11 2 Pedals last foreverCN 12 3 Personalization of the shoe position in relation to the pedal

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� Functional Decomposition:

� Specifications (or Engineering/Functional Requirements):

Source Specification (metric) Unit of Measure

Marginal Value

Ideal Value

Comments/Status

S1 CN 1,6 Additional vertical compression between foot and pedal with increased load from 50 kPa to 150kPa at forefoot. mm <=2 <= 1 That is the difference between standing pressure and

pushing pressure.

S2 CN 2,5 Flex angle of forefoot with 30N of force compressing the shoe toe to heel. degrees >=40 >= 45 This means the toes flex up when pushed on. This

applies only when shoe is in running mode.S3 CN 3 Shoe touches typical bike frame while pedaling Y/N NO Use a typical road bike.

S4 CN4,5 Degrees of plantar flexion (extension) of foot from 90 degrees while wearing shoe degrees >=40 >=50

S5 CN 4,5 Degrees of dorsal flexion of foot from 90 degrees while wearing shoe degrees >=15 >= 20

S6 CN 4,5,12 90% of tested triathletes would be willing to repeat wearing them for a 20km bike ride followed by a 5km run. Y/N Yes (for 75%

of triathletes) Yes

That is the distance for a sprint triathlon. This metric would be relevant only for training, because in a race, they would be concerned with other factors so it wouldn't be a good metric for comfort.

S7 CN 6 Transition from cycling mode to running mode is faster than changing shoes from cycling shoes to running shoes Y/N Yes (critical) Yes

You could have a set time, but it would be different for everyone. Just need to verify that time is being saved.

S8 CN 6,7 Weight grams <=450 <=350This is the weight of the shoes, which is critical for running. The weight of the pedals is not particularly important.

S9 CN 8 95% of athletes can clip into and out of the pedals by the 3rd attempt, without falling Y/N Yes (for 75%

of triathletes) Yes

S10 CN 5,6,9 Range of rotation around the vertical axis degrees >=2 This is motion occurs while biking, it is not a pre-adjusted position

S11 CN 6,10 Time to put on shoes <= the time to put on cycling shoes for 95% of triathletes. Y/N Yes (for 75%

of triathletes) Yes Assume the athletes put their shoes on on the ground and don't have them already clipped to the bike.

S12 CN 11 Factor of safety for pedals reaching infinite life under alternating load from 2000N down to 1000N up N/A >=3 >=5

S13 CN 5,12 Range of adjustment of the pedal to shoe contact in anterior/posterior directions mm >=0 >=10 Nice to have, not critical

S14 CN 5,12 Range of adjustment of the pedal to shoe contact in medial/lateral directions mm >=0 >=5 Nice to have, not critical

S15 CN 1,6 Maximum pedal deflection (at 2000 N of downward force) mm <=4 <=1


� Constraints: *Budget limit to $500*Need a functional prototype in 20 weeks*Shoe should be as light as possible (comparable to current cycling shoes).*Pedals should fail at infinite life.*Shoe clear the bike frame while pedaling

� Project Deliverables: *1 final pair of functional prototype triathlon shoes (not yet optimized for manufacturing)

� If the team thinks it appropriate, and budget allows, then multiple concepts may be prototyped to see which product meets the specifications most effectively.

*1 set of pedals that can be attached to a standard bike*Verification that they have met specifications and that customer is satisfied*A Poster*A Presentation

� Budget Estimate: Total: $230 minimum – more would allow making more shoes for a second solution. Yellow line items are very likely to be needed.

Other items are optional and very solution path specific.

MATERIAL COMMENTS COST

SHOE Looking for a donation or discount price from local retailer, but can afford to buy if necessary.

$70.00

Steel block (pedals)

Speedymetals.com $30.00

Outsole Store.acore.com $30.00

EVA (midsole) Minimum quantity so needs to be purchased from local cobbler or my uncle's company, De La Torre Orthotics and Prosthetics

$20.00

Barge Cement Hanksclothing.com $35.00

Shapelock Plastic Shapelock.com – easily molded plastic for internal structure. $30.00

Pedal Bearings Bikeparts.com $12.00

Composites Depends on solution directions varying

1mm steel cable Only needed with some solutions

Stiffness actuator Only needed with some solutions

� Intellectual Property (IP) considerations: There is patent potential but I am not interested in pursuing it at this point. I explored that option and it doesn't seem worth it.

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� Continuation Project Information, if appropriate: As mentioned before, this is a continuation of an Industrial Design project that was done by RIT student, Maddi Hoppy. She conducted a brief survey looking at the needs of bikers and concluded that a shoe was needed the people could cycle in efficiently, but then get off and walk in. She created a simple prototype pictured below. It was an interesting solution to the problem. The concept could definitely be used in some form in MSD but it doesn't address the need of being clipped into the pedals, and her prototype was not functional enough to handle the high forces of actual biking. It is simply a rigid sole with flex grooves letting it flex up but not down. Also, making this a triathlon shoe, it needs to function well as a running shoe, not just be something that people can walk around in. This project has enough history to add value, but there is still a lot of room to work.

STUDENT STAFFING:� Skills Checklist:

1 Required – 2 Preferred – 3 Valuable - “Blank” Not Needed

MECHANICAL ENGINEERING1 3D CAD Aerodynamics

MATLAB programming CFD1 Machining (basic) Biomaterials1 Stress analysis (2D) Vibrations1 Statics/dynamic analysis(2D) Combustion engines

Thermodynamics GD&T (geometic dimensioning & tolerancing)

Fluid dynamics (CV) Linear controlsLabView (data acquisition, etc.) 3 Composites

3 Statistics DFMRobotics (motion control)

1 FEA CompositesHeat transfer Other:Modeling of electromechanical & fluid systems

Other:

1 Fatigue & static failure criteria (DME) Other:2 Specifying machine elements

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Maddi's prototype. It is a passive solution. The grooves cut into the rigid outsole keep the toes from bending down but allows the to bend up. They are good for walking and cycling casually, but lack a clip to the pedals, cushioning, and the level of rigidity required for this project.


INDUSTRIAL AND SYSTEMS ENGINEERING3 Statistical analysis of data – regression Shop floor IE – methods, time study

Materials science Programming (C++)2 Materials processing – machining lab

Facilities planning – layout, material handling 1 DOEProduction systems design – lean, process improvement

Systems design – product/process design

1 Ergonomics – interface of people & equipment (procedures, training, maintenance)

Data analysis, data mining

Math modeling – linear programming), simulation

Manufacturing engr.

Project management DFx -- Manuf., environment, sustainability

Engineering economy – ROI Other:Quality tools – SPC Other:Production control – scheduling Other:

� Anticipated Staffing Levels by Discipline:

Discipline How Many? Anticipated Skills Needed (concise descriptions)

EE 0 N/A

ME 3

ME 1: Design a pedal, CAD drawings for pedal, Machine the pedal, perform fatigue failure analysis on the pedal, gather the necessary data for simulating the forces a pedal deals with. FEA of Pedal.ME 2: Lead design of first triathlon shoe (simple mechanical solution). CAD drawings of shoe soles. FEA analysis of pressure distribution, material selection, stress analysis, shoe construction.ME 3: Lead design of second triathlon shoe (composite based solution). CAD drawings of shoe soles. FEA analysis of pressure distribution, material selection, stress analysis, shoe construction.

CE 0 N/A

ISE 1 ISE 1: Ergonomics, Biomechanics, DOE, Statistical Analysis of test results

Other (Industrial Design)

1

ID 1: Final Product Renderings, Aesthetic Design of what the product could look like if this product were going to market, Provide knowledge from her first round prototype and work experience in footwear. Drive presentation and poster creation.

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OTHER RESOURCES ANTICIPATED:

Category Description Resource Available?

Faculty ME consultant

Environment Senior Design Center

Track or Road to Run and bike on

ME Machine shop

ME computers with CAD software and FEA software

Equipment Standard Road bike

Materials Cycling or Running shoe (to retrofit)

Steel for pedal

Sheets of cushioning

Shapelock

Other Testers (cyclists and runners or both) – 10 people per category

Rig to hold shoe while under construction (a custom shoe last perhaps)

Alternate Electrical Engineering Version:This project is ME heavy, but if we needed an EE heavy version we could pursue an electromagnetic solution. The magnet could hold the shoe rigid and/or clipped to the pedals. It would be on when on the bike and off when on the ground. I would not put the power source on the shoe due to bulk, but it could be built into the pedal arms. Their motion could provide the power. The major pitfall is that then that power is coming from the cyclist's legs and will slow him down. In this version of the project, 2 ME would handle a simplified version of the work done by the 3MEs in the other variation. They would also have to do the work integrating the electrical system into the bike and the shoes. The ISE position would be the same. Then we would have 2 EEs to work together finding a creative solution for power generation, and how to get that power into the shoe to do the job it needs. I am skeptical of this approach. I tend to think the simplest solutions are the best. Attempts by adidas to integrate electrical components into footwear (the adidas 1) made a stir, but in the end was not really received by the public.

Prepared by: Ryan Nathan Wilson Date: 11/09/12

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