DUSTIN BRAUN
ORIGINAL SKETCH
SUMMARY
The design was inspired by the performance shifters of today. Manufactured from aluminum, the frame is stronger and more durable then anything on the market today. The assembly design allows for the customer to install the shifter with ease and comfort. With assembly design also comes the ability to change out shifters and adjust shifters at a drop of a hat.
THE DESIGN
RENDER
APPROACH
The proposed solution for the build is to create a three part frame so that it can be assembled in the car. This will allow very easy access for all nuts and bolts as well as lots of space for the pieces of the frame to slide through the hole in the floor boards. The housing will be made up of two parts that will separate in the middle to allow the shifter mechanism to slide between. They will then get bolted down along with the rest of the frame in the car. This three part system will allow for quicker install and uninstall speeds.
LINKS
REPORT
BUDGET
SCHEDULE
JHA
REQUIREMENTS
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Be able to mount to stock mounting points
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Be able to install without removing drive shaft.
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The design will require hand assembly only.
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Move ball joint 1-3in into cab of the car.
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The Safety Factor of the frame must be the same or better than stock
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Frame precision tolerance allows a tenth of an inch of movement(Under a load of 50lbs) in each direction.
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Device must be protected from the elements (maintain strength after a week in salt water)
ANALYSIS
The analysis for this project was mainly static and stress calculations. Since the frame is in a static position solving for its reactionary forces were critical. Using the yield strength of the stock shifter the team was able to work backwards and create a shifter frame that could withstand more force then then the original shifter. The green sheets below demonstrate the calculations done on the Long-arm part of the assembly and how it easily withstands the max forces being applied. For more green sheets and original calculations, please click on the report link above.
Max Moment in Long-Arm
Max Stress and Shear in Long-Arm
CONSTRUCTION
Hand Assembly
This build was conceived and is being built at the facilities of Central Washington University. This gave many options for building and designing that most people would not have, but is still limiting in some areas. The University as such tools as CNC lathes and mills and a fully equipped machine shop which allowed for easy manufacturing of the aluminum parts of the project. The housing and long-arm parts could all be CNC milled easily from aluminum in house. The short-arm however, because it was made out of 1020 steel plate, had to be sent out to be plasma cut. This ended up costing a little more($20) but was worth it in the end. The plasma cutter used could hold a better tolerance(+-0.003”, top to bottom) then the one out of commotion at CWU(+-0.008)”. This led to a better part and a better build all around. For any more details on the build or construction of the project, please click the report link above.
METHOD
1ST OPERATION(LONG-ARM)
TESTING
The testing for the ASTS Frame consisted of three main tests: the install/install speed test, the strength test, and the corrosion test
The Install/Install speed Test
The goal of this test was to test the frames ability to mount to the stock mounting points of the car, as well as record the speed at which it could does this. This was accomplished by jacking up the car, removing the old shifter, and then installing the ASTS Frame. this was done a total of 4 times, 3 of which were timed.
The Strength Test
The goal of this test was to show that the frame could withstand the forces that it would experience in the car(50lbs). This was accomplished by building a jig that simulated the cars mounting points, and then applying the 50lbs to the frame and inspecting the frame for stress.
The Corrosion Test
The goal of this test was to show that this frame would last a life cycle underneath the car. This was accomplished by using salt water(2Tbls salt per 300ml water) and a containment systems(Plastic bag). The frame was kept in the bag for 1 week and then examined and strength re-tested.
Install
Strength Set-up
Corrosion Set-up
Testing Issues
One of the main issues of the testing process came from the building of the jig for the strength test. The original plan was to use the CWU's resources to build one out of steel, but, due to COVID-19 the university was closed. To get around this, the jig was constructed out of wood. It was not as rigid as one made out of steel, but it held up to the 50lbs+ that was put on it and allowed the testing of the frame to continue.
RESULTS
Success, Problems, & Results
Success
Problems
There were two big successes in testing. The first was that the frame installed perfectly to the stock mounting points of the car. This was huge as the rest of the testing hinged on this test being passed. The second, was the install speed of the ASTS frame. As you can see from the graph above, the install speed crushed the standard baseline by 60%, recording average install speeds of 10:19. These recorded times are +-5sec for human error. They were recorded on a stopwatch, and was difficult to get the exact(closer then +-5sec) start and end times.
One of the main problems of the testing came in the strength portion of the testing. Because the jig could not be made out of steel, wood had to be used, which in turn led to some inconclusive numbers. Though the frame moved 1/8"(goal was 1/10"), it was hard to tell if it was the frame deflecting or if it was the wood. The other area of concern with the testing was the corrosion weight test. The results show that the frame's weight only went up by 0.5oz. This was recorded with an analog food scale, who's precision is +-0.5oz. So even though the frame passed the corrosion test, the results are a little bit questionable. The frame was weighed multiple times, getting the same results, but the precision of the scale still lingers.
Results
The frame on a whole was a success. It held the fully adjustable shifter mechanism firmly in place, and allowed it to move freely and shift into all gears. The strength test proved that it could withstand daily use, and the corrosion test showed that it could last a life cycle underneath the car well maintaining its strength.
BUDGET & SCHEDULE
BUDGET
The estimated cost of building this project was estimated at $250.02. This included all stock materials, and the labour of the CNC operator(market value). Some of the things that kept the cost down was the availability of the stock material. Central Washington University had several of the stock pieces already in stock, which allowed for the purchase of shorter stock material(14" instead of 24" for the long-am, and 3.5" instead of 6" for the housing). The increase of cost came from time of machining and some custom shop work. Time taken to run the CNC, for both the Long-arm and the Housing, each took a hour longer due to added operations. Due to some unforeseen circumstances the schools plasma cutter could not be used, which lead to the Short-arm being sent out to a custom shop to be cut out. This added $20 to the total cost of this part. The testing of the ASTS frame was all done in house. This means that all material was either scrap or borrowed. No extra cost was added to complete the testing. For any more details on the budget, please click the budget link above.
SCHEDULE
The goal was to have this project completely done by the end of May 31st. To do this there was a few milestones that would need to be hit. The first was getting the Proposal and Analysis done by January 1st. The second, was to have the frame completely manufactured by March 1st. And the last was to have all testing and device evaluation done by May 1st. The Proposal and Analysis got completed right on schedule and was completed on December 15th. The construction of the frame got completed two weeks early due to overtime and putting in extra work on the weekends. Due to COVID-19, the testing of the ASTS frame started a week later then what had be originally planned. Even with this delay, the testing went smooth and get completed in a reasonable time frame. The testing started on April 17th and ended on May 11th. For any more details on the schedule, please click the link above.
DESIGN PHILOSOPHY & WEBSITE WALK THROUGH
DESIGN PHILOSOPHY & WEBSITE WALK THROUGH
MET489c Presentation Video 720
