Sylvain CHARLAT Jean-Christophe FAUROUX IFMA/LaRAMA, Clermont-Ferrand, France
Team Design Process for a 6x6 All-Road Wheelchair Session 5a Studio Based Design Projects
Laboratoire de Recherches et Applications en Mécanique Avancée
KOKOON Project www.kokoon.fr.st
Michel LIMENITAKIS Vitam Artefact EACF, Clermont-Ferrand France
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
1
Introducing the KOKOON Project KOKOON Project : 1999 – 2004 KOKOON Project
Collaboration between two schools (IFMA + EACF) A simple fact :
Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing
Purpose :
Allowing disabled people to ride into nature
A project with 3 aspects :
Conclusion ●
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Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
At this time, no electric wheelchair with real all-road capabilities and more than 2 driving wheels
Design and innovation in MMS Department (Machines Mechanisms and Systems) of IFMA Educational project for about thirty students Technology transfer : towards a product that could be manufactured
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
2
Problem setting : a changing context
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting ●
Changes
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Market
Status changed twice in four years, as in real life sometimes : 1999-2001 : final year student project for a local medical company 2001-2003 : autonomous IFMA+EACF project ● ●
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Specifications
Designing Conclusion
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Studying market Creating an industrial product A product for disabled A multi-purpose electric vehicle
2003-2004 : a mobile research platform for climbing obstacles Noticeable changes in Design Process
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
3
Wheelchair market in 1999 In 1999, there are several types of outside vehicles for disabled people :
Vermeiren
Otto Bock
KOKOON Project Charlat / Fauroux / Limenitakis
Urban electric wheelchairs
Invacare
Not suitable for climbing Introduction Pb setting ●
Changes
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Market
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Specifications
Designing Conclusion
« Moderate » all-road wheelchairs
Permobil
All-road gasoline vehicles Modul'Evasion Oasis LLC Max 6x6
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
4
KOKOON Specifications Existing standards
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction
ISO standards Specifications from CERAH (compulsory for a partial refunding ) CERAH = the French organism in charge of testing wheelchairs
Pb setting ●
Changes
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Market
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Specifications
Designing
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Maximal dimensions : 80x130 cm
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Electrical motors
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Top speed : 10 km/h
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Minimal range : 12 km
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Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
Minimal safety equipments (electromagnetic brake, parking brake, declutching capability, etc.)
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
5
KOKOON Specifications Functional analysis Statistical study with disabled persons and handicap specialists KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting ●
Changes
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Market
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Specifications
Designing Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
6
KOKOON Specifications Final version
KOKOON Project Charlat / Fauroux / Limenitakis
A final version of specifications is obtained ●
Clean and silent electrical motors
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Total weight lower than 350 kg with driver
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To go through vertical obstacles of 15 cm
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Independant suspensions with long travel
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Maximal speed of 10 km/h
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Running on slopes of 36% (20°) at 6 km/h
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More than 4h of autonomy on flat road
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Protection bumper and roll-bar
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Price around 15 k€
Introduction Pb setting ●
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Changes Market Specifications
Designing Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
7
Choosing an architecture for climbing obstacles A qualitative choice between various architectures KOKOON Project
Classical and inefficient for climbing
Track belts : high grip but ripping, wear, low efficiency, difficulties for integrating suspensions
Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing ●
Architecture
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Team design
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Chronology
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Software
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Problems
Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
4x4 : big wheels for climbing but bumping
6x6 : compromise climbing / stability
8x8 : high stability but bad climbing ability
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
8
Choosing an architecture for climbing obstacles Efficiency for climbing sidewalk edges KOKOON Project Charlat / Fauroux / Limenitakis
Introduction
2 front wheels swallow obstacle + tire deformation + rotation of front arm rockers 4 rear wheels for pushing
Pb setting Designing ●
Architecture
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Team design
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Chronology
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Software
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Problems
Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
9
Choosing an architecture for enhancing stability Stability on urban stairs KOKOON Project Charlat / Fauroux / Limenitakis
4 wheels for loading vehicle 2 wheels moving away on obstacle Low pitching compared with the 4x4 solution
Introduction Pb setting Designing ●
Architecture
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Team design
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Chronology
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Software
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Problems
Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
10
Team organization Time unit = semester KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing ●
Architecture
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Team design
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Chronology
A concurrent design strategy with 3 teams ●
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Software
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Problems
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Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
Mechanical design structure and platform (including suspension, transmission and motors) J.C. Fauroux Electrical power transmission design choosing electrical motors, designing control board and power supply S. Charlat External aesthetic design of product Ergonomics for disabled people M. Limenitakis
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
11
Chronology : 1999 - 2000 Mechanical Design
Electrical Design
External Design
(Manager J.C. Fauroux, IFMA)
(Manager S. Charlat, IFMA)
(Manager M. Limenitakis, EACF)
Sept 99
1.1
1.3 Caption
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction
Semester 1
Crossed briefing 2nd year project 3rd year project Final year project Exhibition Media coverage Fundings
Pb setting
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Architecture
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Team design
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Chronology
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Software
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Problems
First specifications
No project
Jan 00
2.1
2.3
Semester 2
Designing
First mechanical design research
Conclusion
Digital mockup First chassis
No project
First aesthetical design research
Sept 00
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
12
Chronology : 2000 - 2001 Sept 00
Mechanical Design
Electrical Design
External Design
(Manager J.C. Fauroux, IFMA)
(Manager S. Charlat, IFMA)
(Manager M. Limenitakis, EACF)
3.1 3.1
3.3
3.2 Power module
Drive 1
Charlat / Fauroux / Limenitakis
Introduction
Semester 3
KOKOON Project
Battery
Add components Improving transmission Upgrading mockup
Pb setting
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Architecture
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Team design
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Chronology
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Software
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Problems
Light module
Principles of control Analysing old card
First aesthetical design research
Jan 01
4.1
Semester 4
Designing
Drive 2 Joystick
Cournon
4.3
4.2
1 Paper 2 TVs 2 Radios
Conclusion
Articulated roll bar
First model of control card
First attempts of roll bar and body
Sept 01
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
13
Chronology : 2001 - 2002 Mechanical Design
Electrical Design
External Design
(Manager J.C. Fauroux, IFMA)
(Manager S. Charlat, IFMA)
(Manager M. Limenitakis, EACF)
Sept 01
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting
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Architecture
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Team design
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Chronology
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Software
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Problems
Thinking about body Translatable seat
5.3
Making the card Debugging
Round look
Jan 02
6.1
6.3
Paris
Caption Crossed briefing
Semester 6
Designing
5.2
Semester 5
5.1
2nd year project 3rd year project Final year project Exhibition Media coverage Fundings
Conclusion Sept 02
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
Making the body Integration
No project
Multi-part body Light & sporty look
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
14
Chronology : 2002 - 2003 Mechanical Design
Electrical Design
External Design
(Manager J.C. Fauroux, IFMA)
(Manager S. Charlat, IFMA)
(Manager M. Limenitakis, EACF)
Sept 02 3.1
7.2 Caption
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction
Semester 7
Crossed briefing 2nd year project 3rd year project Final year project Exhibition Media coverage Fundings
Pb setting Designing
No project
No project
Jan 03
8.1 ●
Improving reliability of control card
Paper
Lyon
Aix-en-Provence
Architecture
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Team design
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Chronology
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Software
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Problems
Semester 8
Clermont-Ferrand
Conclusion
Integration Testing phase
No project
Sept 03
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
15
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
16
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
17
Using software in design process Choosing software Basic 3D CAD software for initial sketches KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing
Middle-end CAD software ● ● ● ●
Parametric / variational modelling Assembly Easy to use Educational licence
Pushing assembly to the limits More than 600 parts : high latency
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Architecture
Collision detection / vehicle center of mass
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Team design
Part naming conventions (3.1 for cleaning mock up)
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Chronology
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Software
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Problems
Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
Inter-team data exchange CAD (*.prt) vs. Rendering (*.3ds) via DXF PDM : problems of price and network 2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
18
Problems and mistakes in design process At the student level Insufficient planning
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Introduction
Design stage is before manufacturing stage in product life If manufacturing actors feel concerned : ✔ ✔
Pb setting Designing ●
Architecture
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Team design
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Chronology
✔
At the manager level Systematic briefing / debriefing Parallel treatment and prediction branching ●
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Software
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Problems
Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
active attitude make suggestions benefit of their manufacturing experience
External Design
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Electrical Design
Charlat / Fauroux / Limenitakis
Involving people who manufacture Mechanical Design
KOKOON Project
Underestimating provider delays
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Predicting task duration for synchronicity Keeping customer in mind : where is the real need ?
time
Finding funds Media coverage for sponsoring 2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
19
Experimental validation Lateral climbing Frontside climbing KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing Conclusion
Vidéo
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
20
Conclusion Design process of a complete electro-mechanical product knowledge inheritance different types of software Concurrent engineering exchange problems digital mock-up management 3 teams, 30 students on 4 years team synchronization Real life constraints financial management ✔ ✔ ✔
KOKOON Project Charlat / Fauroux / Limenitakis
✔ ✔ ✔ ✔ ✔
media communication marketing prospection
Introduction Pb setting Designing Conclusion
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
21
In the future...
KOKOON Project
Usable by hospitals / associations Riding into nature, at least ! Towards an industrial product Also a research platform
Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing
Acknowledgements ANVAR Auvergne (French National Agency for Development of Research)
Conclusion
Federation of Disabled People of Aubière Medical Childhood Center Romagnat 63
And many others on www.kokoon.fr.st
Functional Reeducation Center Clémentel 63 Handi Sup ClermontFerrand
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
22
Designing motors Dimensioning at constant speed climbing The energy injected in the system by motors is directly converted into potential energy of gravity (apart from energy loss due to transmission efficiency)
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing
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g = 9.81ms-2
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VG = 6 km/h
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α = 20°
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ηT = 0.7
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P = 2800W
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Conclusion
m = 350 kg (100 kg driver included)
VG
G
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Capacity 160 Ah
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2x12V serial
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Waterproof
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2 motors of 1400W
Two tractions batteries
Gas recombination 2x67kg = 134 kg
Bonus
m.g
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
23
Designing Transmission
KOKOON Project
Transmission via belts (slipping = fuse) Compatible with suspension displacements Good efficiency Clutching capability
Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing Conclusion Bonus
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
24
Designing frame Frame length 1700 mm > 1300 mm of CERAH ● ● ●
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction
Starts above rear wheel Compatible with 3 wheels of 40 cm + functional clearance A real outside vehicle
Loads 150 kg of batteries + 100kg of driver Center of gravity centered on polygon of support Aluminum modular structure FEM calculations
Pb setting Designing Conclusion Bonus
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
25
Designing whole frame Maquette numérique : 600 pièces KOKOON Project Charlat / Fauroux / Limenitakis
Introduction
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Problèmes d'encombrement et de répartition des masses Détection des interférences / collisions
Pb setting Designing Conclusion Bonus
Vidéo
Réalisation du prototype du châssis Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
26
External Design Collaboration
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing Conclusion Bonus
Un fauteuil 6 roues Un arceau protecteur Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
27
External Design
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction
+ Garde-boue enveloppant + Rangements + Repose-pieds - Accès à bord - Monocoque fragile
Pb setting Designing Conclusion Bonus
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
+ Garde-boue dupliqués + Pare-choc avant robuste - Arceau ouvert fragile 2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
28
Rool-Bar Design Arceau double courbure + résistance 500 daN
KOKOON Project Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing Conclusion Bonus
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
Arceau ouvrant
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
29
The Transfer Problem
KOKOON Project
Contrainte forte envisagée un peu tard L'arceau ouvrant : compliqué et pas idéal Solution retenue après sondage : translation assise
Charlat / Fauroux / Limenitakis
Introduction Pb setting Designing Conclusion Bonus
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
30
Electrical Design
Introduction Pb setting
Moteur D
Charlat / Fauroux / Limenitakis
Moteur G
KOKOON Project
Forte motorisation Très forte intensité nominale 67 A Aucun produit du marché ne convient Conception d'un variateur
Designing Conclusion Bonus
Module de puissance
Batteries Joystick
Jean-Christophe FAUROUX IFMA, Clermont-Ferrand
2nd International Engineering and Product Design Education Conference TU Delft, The Netherlands, 2-3 September 2004
31
