ProgressReport

MaseehCollegeofEngineering&ComputerScience Winter2016

Kart 2

DesignTeam
AtomFalcone
AustinGreene
JesseMajoros FacultyAdvisor
NickVanklompenberg Dr.Yi
JakeWaterman Sponsor
JeffreyWilliamson Dr.Turcic

 ExecutiveSummary

A kart stand enables kart racers the ability to safely unload, transport, repair, and load

their kart at a racing event. Most weekend racers travelalonetoandfromthetrack.Thisraises

the issue of how does one person safely move an awkward shaped 200 pound uneven load?
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The objective of the PSU Kart Capstone Team is to design a reliable standforkartracersthat

can raise/lower and transport the kart around any racing complex. The stand must attach to a

standard trailer hitch receiver for safe & secure device transportation while the cart resides

inside thetransport vehicle.Thedesignandprototypeforthekartstandwillbedeliverable toDr.

TurcicinJuneof2016.

To date, the team has identified product design specifications (PDS), completed

external/internal searches of existing products, and conducted group brainstorming sessionsto

develop and evaluate various concepts. After reviewing the design requirements for the

deliverable project and meeting with the sponsor, the team scaled back from completing a

finished stand to refining a set of plans and designs with a scaled prototype whichcanthenbe

used by Dr. Turcic and the karting community. The team is currently in thedetaildesignphase

ofproductdevelopment.

The key PDS defining points of the stand are its reliability and single person operation.

Through our external search it was identified that there are existing solutions to the design

requirements. The important search parameters includedpoweredlifting,collapsibility,andsafe

singlepersonoperation.

The team developed five concepts and evaluated them based on the PDS criteria. The

chosen concept incorporates reliability through detailed engineering analysis, safety, battery

poweredwinch,onepersonoperable,andtheabilitytobetransportedviaatrailerreceiver.

CONTENTS


ExecutiveSummary..1

Introduction.....3

MissionStatement....3

ProjectPlan........4

ProductDesignSpecifications.....5

ExternalSearch.....6

InternalSearch....7

DesignEvaluation/ConceptSelection.....8

DetailDesignProgress......9

Conclusion....9

References.........XX

Appendices....XX

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 Introduction

Kart racingis a variant ofopenwheel motorsport with small, open,fourwheeled

vehicles called karts. They are raced on scaleddown demanding pavement circuits.

The karts themselves weigh 200lbs andmust be transported totherace complex by a

transportationvehicle. Amechanismisneeded tofacilitatethemovingofthekarttoand

from the transport vehicle and the raceway as seen below in Figure 1. For solo

operations,thisismadeimpossiblebytheawkwardsizeandweightofakart.

Currentstandwithkartshownontypicalterrain.
Figure1:


Current off the shelf solutions are either expensive and or unstable. The client

currentlyusesasolidstandwithwheelswhichrequiresaminimumoftwopeopletoload

and unload the kart from the stand. The current stand also does not facilitate easeof

karttransportation becauseitrequirestwopeopletoplacethekartontothestand.Thus,

there exists a needforareliableandstablestandwhichcanassistthesolokartracerin

transportationandstorageofthekart.

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 MissionStatement

2
The objective of the Portland State University (PSU) Kart capstone team is to

design a reliablesingle operator stand forkart racersthatcanraise/lowerand transport

the kart around any racing complex. The stand must attach to a standardtrailerhitch

receiver for safe & secure device transportation while the cart resides inside the

transportvehicle.

4
 ProjectPlan

Table1:
Projectplanmajordatesanddeadlines.

Ganttchartofmilestones.
Figure2:

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 ProductDesignSpecificationSummary

A detailed list ofdesignrequirementsandspecificationswascreatedbasedoncustomer

and group input as found in the PDS document in appendix A. Each design specification was
prioritized and quantified as noted in the spreadsheet. To summarize the PDS document, the
toplevelspecificationsarelistedandexplainedbelow:
Cost: The total cost of a full scale working product should be less than what is readily
available on the market. External research and customer input hasdeterminedthatthe
price of materials and fabrication should not exceed approximately $1000. The budget
forourscalemodelistobelessthan$600.
Weight: The weight of the stand is important for mobility, ease of operation, and
transportation. To meet all of thesecriteria,atargetweightoflessthan100lb.has been
set.
Ability to stow: With limited spaceinsidethecustomer'svehicle,thefinaldesignwillbe
capableofattachingtoastandardtrailerhitch.
Stability: The stability of the cart stand is crucial during all modes of operation.
Calculationswillbemadetoensurestabilityduringliftingandloweringofthecart,aswell
asstaticandimpactloads.
Reliability: The final design is intended to be 100% reliable throughout the life of its
service, whilealsorequiringminimalmaintenance.Reliabilityofthestandisanimportant
factor in the overall performance of the kart racer. If the stand fails at any timeduringa
raceday,theusersraceperformancewillbeputinjeopardy.
Safety: Precautions will be made to ensure the safety of the end user throughout the
design process. Areas of concern include pinch points, electric shock, stability, and
sharp edges. The lifting mechanism will also include an emergency stop/start button to
mitigateanyaccidentsduringthelifting/loweringactionofthestand.
One person operation: One of the main criteria defined by the customer is that the
product should be able to be operated by a single person with ease. The customer
currently uses a dependable stand, but requires more thanone persontolift,lower,and
unloadthecart.
Powered lift: In order to maximize the ease and safety of use of this stand, the
customerrequirestheliftingmechanismtobefullypowered. Thestandwillbeabletolift
the kart from the transportation vehicle orgroundlevel tothefullyuprightposition bythe
pressofabutton.

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 ExternalSearch
ThePSUKartcapstoneteamreviewedexistingkartliftingdevicesaswellassomeother
compactliftingdevicestodevelopaproductthatmeetsthePDSrequirements.

JEGSPerformanceProductsJEGSMultiPurposeLift
JEGSmultipurposelift,showninfigure3,isaliftusedtypicallyformotorcycles,ATVandgolf
carts.Thelifthasaliftheightof4.5to16.5.Duetothesizeofthewheelstheliftwouldhave
troublenavigatingdiverseterrains.Duetothegroundclearanceoftheagokarttheliftcouldnot
fitunderneathtoliftthekart.

Figure3:
JEGSMultiPurposeliftisandofftheshelfautomotivelift.[1]

KartLiftBigfoot
KartLiftsBigfoottraditionalstand,showninfigure4,featureslargepneumatictiresforeasy
maneuverability.Thestandfoldsforeasystorageandtransport.Howeverthisstanddoesnot
assistinliftingofthestandandwouldrequiretwopeopletoliftthecartontothestand.

Figure4:
KartLiftBigfootstandshowninunfoldedposition.[2]

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KartLiftWinchLift
KartLiftsWinchLiftonepersonstand,showninfigure5,usesaelectricwinchtoliftthekart
usinghooksthatattachtothebackbumper.Thestandcostsupwardsof$700andcannotbe
foldedtostowmoreeasily.

KartLiftWinchLiftStandshowninloadedpositionwithoutakart.Usesanelectricwinchtoliftthekart.[3]
Figure5:

HepfnerRacingProductsStreeterSuperLift
HepfnerRacingProductsstreeterlift,showninfigure6,usesanelectricwinchtoliftthekart
similartoKartliftsWinchLiftstand.Thestandisconstructedfrom1.25steeltubingandusesa
trusssystemmakingthestandweighupwardsof150lbs.

Figure6
:HepfnerRacingProductsSuperLiftstand.Liftskartusinganelectricwinchandframeconsistof1.25steel
tubingforaheavyweightstand.

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 InternalSearch
After surveying the commercially available solutions,our teamwentthroughtheprocess

of brainstorming to generate ideas and concepts which would successfully fulfill the PDS

requirements set forth by thecustomer. ThemainPDScriteriathatledthebrainstormingphase

wasreliability,operabilityandstorability
.

In order to accomplish the Top Level Design criteria, we determined that the main

differences in our concepts was the way in whichtheliftwasaccomplished.Poweredliftingcan

be accomplished by pivotlift, forklift or scissor lift. Preliminary static and dynamic analysis of

operationwasexaminedforeachdesign.

Reliability wasdeterminedin relationtomovingpartsandsingleuserinterfaceaswellas

complexity of lifting mechanism. Operability by a single person guided the designs decision

regarding ergonomics and interface. Storability is a matterofmodifyingastandtointerfacewith

areceivehitch,mattersofsizeandweightdominatedthesedecisions.

Original project intent was to result in a full scale operable unit. After meeting with the

sponsor and clarifying deliverables and goals, we revised thePDStoestablishreflectthegoals

ofafulltheoreticalmodelwithanalysisandinstructionswiththepossibilityofascaleprototype.

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 DesignEvaluationandConceptSelection
The three concepts developed in our internal search weredistinguishedprimarilybythe
mechanisms in which the kart is lifted: scissor lift, winch lift and forklift, see appendix B. Our
three concepts were compared alongwiththeunfinishedSOKSstandfromapreviouscapstone
team and the unpowered stand that is currently in use. The SOKS stand makes use of a lead
screw as the drive system. Thecriteriausedintheevaluationwere:cost,weight,abilitytostow,
stability, reliability, safety, the ability to be operated by a single person, and the inclusion of a
powered lifting mechanism all of which were deemed essential criteria in the PDS report. The
clearchoicebasedonthedesignmatrix,table2wasthewinchstandconcept.
The strength of the winch stand design is the compactandsimpleliftingmechanism.Of
the lifting mechanisms considered the winch has the lowest cost and the lightest weight, and
since the winch is compact and transmits its power via a flexible belt rather than through rigid
members, the winch stand concept also has the greatest potentialfor foldingintoa smallerand
morestowableform.
Table2
:Designmatrixwhichincludesthethreeconceptsdevelopedintheinternalsearch,theunfinishedSOKS
standfromapreviouscapstoneteam,andtheunpoweredstandthatiscurrentlybeingusedbythecustomer.Based
ona04scalewhere4isthemostdesirableand0istheleastdesirable.

Criteria Unpowered LeadScrew ScissorLift WinchStand ForkLift

Cart (SOKS)

Cost 4 2 1 3 0

Weight 4 3 1 2 0

Abilityto
Stow 1 3 1 4 0

Stability 1 3 4 3 4

Reliability 4 1 0 4 2

Safety 0 1 1 3 3

One
Person
Operation 0 4 4 4 4

Powered
Lift 0 4 4 4 4

Sum 14 21 16 27 17

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 Conclusion

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The Kart team has concluded the PDS and finalized design decisions after having

conducted both internal and external searches. After an evaluation of different concepts, a

design was agreed upon that uses a similar frame to the SOKS kart and a powered winch as

the drive system for lifting andloweringthekart.Thusfartheteamisonscheduleasdefined by

theprojectplan,withthedetaileddesignstobecompleteearlyspringandreadyforrevisions.

Having decided on the design, the next stage involves creating the detailed design

plans, choosing specific parts/materials, 3D CAD drawing, finite element analysis, prototyping

for a scale model, and performing analysis to verify the design specifications and customer
2
requests have been met. TheKartteamfeelsconfidentinthedesignoftheframe,beingthatit

is the least complicated and there are many examples currently in the market to guide design

choices. Themainchallenge movingforwardwillbethedetaileddesignofthedrivesystem.The

key needs for a functioning drive system are safety and reliability. A large amount of analysis

willgointoconfirmingthechoiceforthedrivesystemandinsuringitsreliability.

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References:
1. "JEGSPerformanceProductsW41035,JEGSMultiPurposeLift|JEGSPerformanceProducts."
JEGSHighPerformanceProducts .Web.21Feb.2016.
<http://www.jegs.com/i/JEGSPerformanceProducts/555/W41035/10002/1?parentProductId=3170
513>.
2. KartLift
"BigFootStand." .Web.21Feb.2016.
<http://www.kartlift.com/store/index.php?route=product%2Fproduct&path=11&product_id=57
>
KartLift
3. "WinchLiftHD." .Web.21Feb.2016.
<http://www.kartlift.com/store/index.php?route=product%2Fproduct&path=10&product_id=52
>.
4. "StreeterSuperLiftBlack."HepfnerRacingProducts.Web.28Feb.2016.
<http://www.hrpracing.com/streetersuperliftblack>.

Appendices:
AppendixA:FullProductDesignSpecification(PDS)
AppendixB:ConceptDrawings

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 AppendixA

:Projectdesignspecification(PDS)
Figure7

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 AppendixB

:Forkliftconcept
Figure8



14


Figure9
:Scissorliftconcept

Figure10
:Winchliftconcept

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