MSD II Logbook Capture

P13031 - Zeb Koch, Charles Kowalyshyn, Michael P Walshinator, Nick Davis

This document is intended to capture the process followed in MSD II. The intent is to make every facet of MSD II accessible on EDGE so that the next poor saps that try to do our project can follow our workflow. The things described in this list include, but are not limited to:

Project execution (maximum of week by week resolution) All design ideas created in MSD II Any necessary analysis on MSD II design ideas Testing and results Photos

Going into MSD II, the remaining undersigned components include:

The exact execution of the Purchase System The Handholds The Lazy Susan design and method of mounting the seat to the seat bracket Side Platforms

Captioning the photos is unnecessary and repetitive, so each image goes with the description above (not below) it.

Week 1 - 3/4 – 3/10Purchasing & Procurement of Materials

Monday Meeting to revisit and finalize Bill of Materials. BOM is linked and updated on

EDGE.

Tuesday Purchasing requisitions started. Nick is the go-to purchasing guy, buy

everyone filled out PR forms and he submitted them Some quotes acquired, linked on EDGE Most purchase requisitions and quotes are linked on EDGE.

Wednesday, Thursday Nick continued with purchasingFriday Started working on machining in the machining shop Received some parts

Week 2 – 3/11 – 3/17Monday

E-mailed Final DDR presentation to the customers for feedback Basic machining started More purchasing done

Wednesday

Nick picked up metal stock in BuffaloThursday Water jet cutting the side L-bracketsFriday Mike & Zeb went to Klein Steel Direct and SMC

Week 3 – 3/18-3/24Machining

Purchasing continued Machining continued Acquire material from vendors Cut stock metal to length (box tube, etc.) Milled the components for the cup assembly Started milling holes in blocks Machined linear track guide holes

No significant design changes this week

Week 4 – 3/25 – 3/31Machining.

This week consisted of significant machining and assembling of some components. The Side L-Bracket, Box tube, Linear Guide Rail, and Back Bar came together this week

Woodwork

Nick did a great job at getting started on the baseplates

Week 5 – 4/1 – 4/7Machining

Continuation of woodwork

Woodwork

Baseplate painting and fit ups began

Thursday

Zeb bends breaks seat bracket The design called for 440C steel seat bracket to support the user’s chair.

Zeb had a connection at an old co-op with a metal bending machine. Unfortunately, it snapped in half in the machine, and Zeb was angry for well over a week. It was pretty upsetting but also pretty funny.

Began preliminary designs for handholds The handholds need to be modular and adjustable for different models of

Sonars. The intent of the design must include a strong way to take some of the moment from the person’s weight, while also being adjustable for different system positions (forward or backward).

The approach in the design shown below is to use two pivot points that can slide linearly forward and backward on an 80/20 rail. Then, a hand-shaped

metal component is attached using a turnbuckle so that it may be inserted into the handhold cups.

The metal component that is inserted into the cup should also have some adjustability, as seen in this sketch:

Week 6 – 4/8 – 4/14Handholds:

Found material for handholds. We used two pieces of metal that were leftover from the water-cutting of the Side L-Brackets from Week 2. There were also 2 almost identically shaped scrape pieces that we were allowed to have from the ME Machine Shop. This is why one set is a rectangle and the other has two corners shaved off.

Built two sets of these handholds but milling out slots in the metal plate, allowing for the modular adjustability. The design allows the user to slide the handhold assembly into place, lock its location and angle, slide the plate into the handhold cup, and then tighten the connection with the turnbuckle. The drawings below illustrates the plate that slides into the handhold cups.

The final design shows the handhold subassembly mounted on the 80/20 Rail that will attach to the box tube and Side L-Bracket for support.

Snapped Seat Bracket Design gusset to fix the seat bracket problem

This gusset was suggested by the Machine Shop instructors, and is detailed in the drawing below. Stainless Steel Hexstock was donated by the ME Machine Shop for us to use. The details were hashed out and are available online.

Week 7 – 4/15 – 4/21 Cut 80/20 rails, drilled holes Small L-brackets designed to give additional security to side L-Bracket/ 2x4 box

tube connection. Shown in drawing below:

Assembled handhold things and tested: Test: Handholds and if they work and are awesome

Test Results: Handholds are very adjustable and secure. They are awesome.

Test: Old Lazy Susan model, This test yielded results that the Lazy Susan we purchased could not

withstand any kind of dynamic load. Nick sat in the bucket seat on top of the Lazy Susan on some plywood, and almost immediately broke the plywood and the Lazy Susan. Maybe if he would just lay off the donuts, we would have been fine. But noooooo.

Test Results: Needed new Lazy Susan

Week 8 – 4/22 – 4/28New lazy susan arrived

Test: New Lazy Susan

This test yielded much better results, with the more durable LS withstanding all sorts of pressure. Nick literally stood on something mounted off the side of it, and it held up and spun. This is much more durable, and we realize we should have gone with this from the start. The other LS was not designed for such an excessive moment.

Test Results: New LS is great

Baseplates done with legs welded to footplates

Side Platforms

We determined that we need short side platforms for Cindy’s system in parallel with Gold Medal Captain Chair. The photo below shows the shorter platform (used for Cindy w/ Captain’s Chair in tandem) and the medium sized platform (Cindy w/o Captain’s Chair).

Zak and Gary’s Chair mounted on Lazy Susan and riveted and five point harness footrests

Friday 4/26 – The Great CAD Loss

Zeb, the resident CAD monkey, experienced a huge setback when his late 90’s model laptop inexplicably jumped off the table, sending our fully developed (backed up to a month ago) CAD model back to whence it came: our minds and the drawing board. Zeb then powered up into Super CAD mode, and cranked out the last month’s additions in a few days. Here, we take a moment of silence to reflect on the man-hours lost as well as Zeb’s laptop.

Thank you.

Week 9 – 4/29 – 5/5 Rigged up Cindy’s chair – this process was largely jerry rigging – there were

few full initial sketches. One basic compilation of the components is provided below. This includes the mounting of the Lazy Susan to the Seat Bracket through the existing bolt patterns. Then, the stool that was purchased long ago had to be fit to the Lazy Susan. This was done by attaching a series of metal spacer tubes and plates for mounting.Adapter Plate: Lazy Susan Hole Pattern:

Plate Spacer:Adapter Spacer:

Drilled and tapped holes in Side L - Brackets

Friday

Installed purchase system for a 2-1 mechanical advantage. Late-night testing and setup in boat occurred, trying to make sure everything

works for Imagine. Everything worked well except for the purchase system, which locked up and

had no mounting in the front. However, we could still pull ourselves across the boat to demo it.

Saturday – Imagine RIT

Set up boat in the morning, demonstrated at our station in the sailboat all day. Disassembled. Success. Here is a stud explaining boats to folks.

This image shows a point-of view image of the system when installed during Imagine RIT.

The next photo shows the only documentation of the two systems mounted in the boat with each other:Test: System fits with other MSD Project?

Test Results: Both systems fit into the Sonar, so Cindy can sail with Richard!

Week 10 -5/6 – 5/12Tuesday Comfort Testing – Poll of 25 people for Zak and Gary’s seat, found out that it

was actually a dumb specification. The test required a perfect 5, so test can be lessened.

Purchase System was functional for Imagine RIT, but had to be redesigned for functionality. Dozens of pulley configurations were tried, so documenting would have been near impossible and time-consuming. Final sketches and the system pictures are shown:

Initial Sketching

Final System Sketching:

Cheek Block mounting 45° block:Used to re-route line to the front of the Jib Trimmer Bench

Back of seat bracket w/ purchase system mounted:

Charley Installing things in the boat:

Purchase System in Action:

Wednesday Continued machining on second system. Lots to catch up on for second

system.

Thursday

Found out boat was leaving Friday morning and that all testing needed to be completed

Rushed to finish testing Finished final presentation Finished technical paper

Friday

Z supports designed Z supports needed to keep the side platforms from moving now that the

Purchase system has been redirected to the side platforms rather than the baseplate platform. The drawing below shows the contour of the side of the boat and the basic z support to be made out of leftover box tube.

Early morning testing Built Z supports to realign the purchase system Ran purchase system, got final configuration

Final Presentation

Saturday

MFA work – uploaded to EDGE

Week 11 – 5/3 – 5/19Finished building parts for second system

Worked on getting EDGE updated and videos into this file

Cleaned up cubicle

Worked on preparations for delivery to customer.

Final Project Review with Kate and Dr. DeBartolo