Small-scale prototype repairs needed + general update

Here are some updates that Kenny and I have put together for the Small-Scale Track / Podcar.

Small Scale   Note: Bogie bearings are the "metal wheels" that touch the track

1) Bar codes posed an issue when podcar moved too fast / slow, and the ambient light may have affected a proper reading from the light sensor.

i) A method using a corrugated piece of sheet metal in unison with a hall effect sensor and neodymium magnet could be used as a podcar tracking solution. The magnet would be positioned at a particular fixed distance from the hall effect sensor and both would be placed on the podcar. The corrugated piece of sheet metal would be fixed to the guideway, and as the podcar drove past the valleys and peaks of the sheet metal, the hall effect sensor would be able to detect the change in magnetic field due to the magnet and the sheet metal. This could be used to create a signal that would allow for tracking the podcar.

2) Multiple problems with the podcar switching mechanism:

i) When the top bearing of the switching mechanism doesn't have a good connection with the top rail, the vehicle will fall off the guideway.

ii) The screws on the top rail of the curves could be loosened to allow the middle of the curve to be lower. This will help prevent a loss of connection between the bearing and the top rail.

iii) If the bottom wheels of the bogie are only on one rail then the vehicle will pivot. When the vehicle pivots, it lengthens the distance between the top rail and the top bearing of the switching mechanism. To mitigate this increase of distance, we have added spacers where necessary between the connector and the top rail. In some places we've added 4-5 nylon washers. This could be prevented by having a thicker top rail.

3) If the switching mechanism comes up against the bottom face of the top rail, the vehicle will get stuck along certain stretches of the guideway.

i) One reason could be that it switches too late, or from not reading the bar codes effectively

4) Bogie getting stuck along curved sections of the guideway.

i) The new bogie design is slightly different from the old design. On one bogie, Kenny has filed down the edges where it was binding.

ii) Another contributing factor is that the bearings on the bottom portion of the switching mechanism are slightly too large in diameter. Through the curve, the bearings on the inside and outside of the bottom rail experience such little clearance that it will bind.

4) The entry and exit of the station rails need to be parallel with each other.

i) One difficult fix would be to bend them (or have them re-manufactured)

ii) An easier fix that could work would be to add more connectors. I believe it would be best to have a connector on the station rail at both, the beginning and ends of the parallel portion.

5) Need wayside power for small-scale guideway that can be connected to the solar panel arrays

6) The switching arm attached to the Servo-motor needs to be more robust to improve mobility and strength

i) It currently contains piano wire that can become deformed after many uses

7) Bottom guideway rail may interfere with the bottom switching arm bogie bearing
i) The bottom bearings were interfering with the bottom rail in some instances of switching.

ii) Filing the bottom rail in places we noticed this was occurring was decent remedy. (needs better fix)

iii) This is most likely due to the slightly larger bearing wheels used. You may be able to order some from Boca Bearings. The screw attaching the bearing also needs to be analyzed.

8) Solar frame needs to be upgraded to metal to improve strength and aesthetics
i) You may want to start playing with the idea of using the 80/20 stock that we have or look into something new

9) Solar angular mounts could be upgraded to linear actuators for full automation

Small-scale Team:

The small-scale team has just formed this week with two M.E's and two E.E's. The M.E's are working on redesigning portions of the Podcar as last semesters posed some issues as seen above. The E.E's are working on understanding the electronics and coding that went into last semesters Podcars. They are going to use GPS to have the computer communicate with the Podcar. More updates soon on this team.

The civil team meeting with Prof. McMullan 6/30/16 @ 1:00 pm / PROF. McMullan cannot attend next Thursday for a meeting as he will be out of town.

• Ed needs to start adding dimensions to his drawings
• Kelvin needs to put his drawings in to templates like Ed does
• Generally with AutoCad drawings, change line weights, add dimensions, and make drawings clear on 36'' x 24'' sheet size.

In this meeting a lot of ideas were discussed.

Test Track: 10 meter radius okay since 30 meter radius is too much for space allowed. Potential Easement problem (to be determined). Must think about potential utilities that may need to be removed / relocated (trees, powerlines, gas lines, etc). Podcar is approx 6 - 7 ft wide ~ 2 meters (upper limit). Test track height can be potentially 13.5 ft because there is no worry for vehicles being struck as testing will occur with operator on site. (not operated all the time). Redraw in AutoCad test track as far from property line as possible to avoid potential easement and in accordance with building owners. Prepare Plan View, Section View, and Elevated View of test track for city inspection to obtain building permits. Supply Chain: Get track length and number of columns to get a total steel tonnage to obtain approximate price. (Start researching steel manufacturers) 

Additional notes: Need street blue prints for better AutoCad Drawings through South Campus and routes to SJSU, instead of using Google Earth. Podcar needs sensors for object avoidance (Potential trucks. Using ramps for stations are an issue as ramps require a lot of horizontal distance to gain vertical distance per city regulations. Having a raise platform station would decrease the distance required for landing / take off. 

Future goals: Next phases of routes through San Jose, Santa Clara Valley, San Jose Airport, Los Banos, San Francisco, major businesses, malls, under-served neighborhoods, Cal-Train stations, and networks in between. Potential high speed podcar from SJ to SF. 

Update 7/1/16: Civil team met with BSB (Berry Swenson Builders) to discuss test track plan. Meeting went well. BSB discussed potential new location for test track, but must wait approximately 60 days to hear back if property can be purchased from city. 

Solar Team: 

Solar team has been working on developing models in SolidWorks that display how the solar panel arrays will look, and will be placed on the guideway. There has also been development in using a maximizer to quickly connect the solar arrays to each other without the need for an electrician to be present when the solar arrays are installed. SolidWorks models of the rails / guides for the solar arrays have also been worked on this week.

Solar team is current on a tour at Britmore facilities learning how their robots work in autonomously installing solar panel arrays. 

Bogie Team:

The Bogie team has been working on redesigning their first design of the bogie with the retractable frame for ease of maintenance. The initial design posed some mobility issues and issues with the strength of the retractable design. The bogie team has been developing a SolidWorks model of how the hub motor will be installed along with a linear actuator that will provide a normal force against the roof of the guideway along sloped paths. This will increase the friction force on the hub motor so it will not slip if the roof of the guideway is slippery due to ice or rain. There has been work done in programming the hub motor and understanding the circuity used by the senior class last semester. The braking system SSolidWorks model is underway as well, and will use a recently purchased disc brake as the means for the braking caliper to brake the system. The disc brake was ordered without a calipher or master cylinder due to Honda not disclosing the thickness of the disc brake. Once this data is recorded, the proper caliper and master cylinder will be ordered. A fail safe braking system is also be developed, so if the power to the podcar is lost, the podcar will stop. This could be potentially achieved using a powered solenoid that releases when current is removed from the system. The bogie team is planning on using the same steering design that the seniors used last year. Suspension has yet to be worked on.

David, a recent senior from last year, has offered his time to help the bogie team learn how to use the laser cutter at SJSU engineering building. This will be very helpful for when the bogie team has a final design to cut out of MDF wood and assemble their design.

Modeling Team:

The modeling team has been working hard on modeling the streets through which the podcar will travel, along with the guideways and everything else that goes into the construction of the Spartan Superway. This team is very important so that a visual representation of the Spartan Superway can be created and viewed. 

ISE Team:

The ISE team has been split so that some members are on the 5S team and others are micro-managing the other teams. The 5S team has still been organizing the shop, and a recent pegboard tool wall has been built. (almost completed) The 5S team will design a safety plan for the machine tools that are functional in the SSDC (IE, how to properly and safely use machines), as well as signage that will indicate proper tool usage and replacement. (IE, importance of putting tools back when done, etc)

The sub-team micro-managers have been keeping up with their teams in order to keep their team blogs updated, and files kept in an orderly and standardized fashion. (in the Spartan Archive) The team charters from Monday need to be place on the team blogs as well in PDF format. Gantt charts for next week need to be developed as well so team scheduling and deadlines are met. Supply chain and financial members need to develop standardized forms for their work, so when a sub-team needs material goods, these forms can be followed. Supply chain should be working will all teams to see what materials are needed and keep digital copy. Documentation from all teams should be on team blogs and updated to Spartan Superway Archive with proper naming convention.