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Pirates of the Caribbean Load WheelDisneyland Resort
Design Team: Vincent RosasRaul ArrietaChris CordinaRafael FolleroJustin Santiago
Faculty Advisor: Nina Robson PhD
Industry Collaborator: Manjit Sagoo- Disney Engineering
California State University FullertonMechanical Engineering
December 5, 2013
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Project Overview
4 load wheels per boat Approx. 22 persons per boat
Ride cycle time 15 minutes
Full boat weight 6400lbs
2 drops at 13 and 8 Bearing life span 6-9 months
Current design used for 40 years
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General Work Breakdown Structure
Pirates Load Wheel Project
Industry Collaborators- Manjit Sagoo- Steven Fremen
Faculty Advisor
- Dr. Nina Robson
Student Team Lead
- Vincent Rosas
Bearing/BushingResearch
Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago
Testing Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago
Solid ModelCreation
Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago
MaterialsResearch
Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago
Design Raul Arrieta Chris Cordina Rafael Follero Vincent Rosas Justin Santiago
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Functional Block Diagram
SEAL
LUBRICATION
SPINDLE BEARINGS
HUB
O-RING
BRACKET
BOAT
RAILS
Comes into Contact with Water
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Design parameters
Design Challenges:o Large PV values for bearings
o High corrosion rate
o Moisture Absorption rateo Wear of materials
Constraints:o
Fit onto current wheel carriero No modification to wheel bore
and spindle dimensions
o Force to push empty boat 50-
60lbf
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Current Bearing Issues
Pressure on seal from load Zero relative translation wheel & bearing
components
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Project goals
Performance (A-Specs)
Must have same or higher load carrying and performance
capacity.
Must not bind, gall or seize on shaft.No modification to the wheel bore is desired.
Higher Corrosion resistance
MaintenanceDecrease frequency of wheel inspections
No need to replace bearings for >1 year
Eliminate lubrication
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Brief Description of the Approach
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Project Status
Design of Load Wheel Analytical performance analysis complete for bushings and bearings Continuing force analysis for bearing seal
Bushing Research Found 3 self lubricating bushings
Igus H370, TriStar Ultraflon 601, TriStar Ultraflon 602e Found 1 stainless steel roller bearing Timken Roller Bearing
Materials Research Hardness affects on mating components Continuing research to decrease corrosion and wear rate Using machinable rubber material for bearing seal
Tivar Ceram, Nylatron Test Plan
6 tests to examine bearing, bushing, and seal performance Procedures and CAD models are complete
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Alternate Approaches: Pugh Chart
Datum 1 2 3 4
Name Weight Current Wheel Self Lubricating Disc Spring Lip Seal Breather
Load Capacity 3 0 1 0 0 0 Durability 2 0 1 1 1 1 Manufacturing
Complexity 2 0 -1 -1 1 -1
Corrosion Resistant 2 0 1 1 1 1
Waterproof 3 0 0 1 1 1
Lubrication 1 0 1 0 0 0 Life Expectancy 3 0 1 1 1 1
Maintenance 2 0 -1 -1 -1 1 Number Better - 0 5 4 4 5 Number Worse - 0 2 2 2 1 Number Same - 8 1 2 2 2
Total 0 3 2 2 4
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Performance Analysis & Margins
Parameters perwheel Requirement
ProjectedPerformance
PredictedMargin
Load Capacity >6400 lbf 8650 lbf 35%
Wheel Velocity >30 ft/s 60 ft/s 50%
Capability of
Seal
< 10% of the hub is
filled with water
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Rationale for Concept Selection
CLIMBING THE INCLINE DESCENDING THE DROP
(6152 lb load) (10,000 lb load)
area P V PV P V PVMax
Speed
Limit
CompressiveStrength
MaxTemperature
Usage(Short term)
Modulus ofElasticity
in^2 psi fpmpsi xfpm
psi fpmpsi xfpm
fpm psi F psi
Timken(Current bearing)
1.542525 498.5332 60.6772 30249.6 810.3596 891.2099 722200.5
igus iglide H370
1.76625 435.3857 60.6772 26417.98 707.3553 891.2099 630402
295 11460 464 16610000
Tristar Tristeel PR 2000 20000 550 160000
Thordon Thorplas 15300 230 350000
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Detailed Design of Complete System
Spring Seal & Tapered Roller Bearing Design
Self Lubricating Bushing DesignSpring Seal
Tapered Roller Bearing
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Tes t Ma t r ixPerformance
MeasurementRequirement
Design Parameters to bevaried
Range of variation Diagnostic
Impact Forces(Tensile Strength)
able to withstand 2500 lbf,only allows less than 10% ofthe hub to be filled withwater
Type and size of bearings andseals
B: Igus, 0.75 to 0.85 inch diameterRoller Bearings, S: Disc Springs,Rubber Spring Seal
Load Frame, Drop Container, SampleWater, Weights
Height of drop 5, 7.5, 10, 12.5 ft Load Frame, Drop Container, SampleWater, Weights
Angle of decent 25, 45, 60 degreesLoad Frame, Drop Container, SampleWater, Weights
Amount of additional weights100 lbs, 250 lbs, 500 lbs (dependenton the height of drop)
Load Frame, Drop Container, SampleWater, Weights,
Corrosion rate of
materials
Sample Material weight lossof less than 5% (dependingon the size of the materialused)
Sample Materials,Materials: Stainless Steel, Igus Bearing,Original Carbon steel roller bearing,
Undetermined Spring Seal Material
Individual Containers, Small Samplesof each material, a waterproof heatsource, scale to measure thedifference in weight, thermometer
Temperature of the water 70, 80, 90, 95 degrees F
Individual Containers, Small Samplesof each material, a waterproof heatsource, scale to measure thedifference in weight, thermometer
Rolling under loadWhile going up and downthe ramp, the wheel mustnot seize
Bearings, SealsB: Igus, Roller Bearings, S: DiscSprings, Rubber Spring Seal
Load Frame with roller attachments,Weights, Ramp,
Water tight seal testExpectable amount of waterwould be less than 10% inthe hub
Type and size seals S: Disc Springs, Rubber Spring Seal Container, Sample water, graduatedcylinder,
Preload forceOptimizing the bearing inorder to hold the 2500lbf
Diameter of the bearing 0.75 to 0.85 inches in diameter Calipers, strain gages,
Preload Force Less than a 1000 lbs of torque Calipers, strain gages,
Strain test for pressurewithin hub withlubrication
Releases 5% of thelubrication through the sealwhile in motion
different amounts and typesof lubrication, each of thedesigned seals
TBDContainer, Sample water, aircompressor (simulate thelubrication), lubrication, strain gage
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Testing Models
Impact Test Apparatus
Load Frame
Guild Cylindersinto Guild Rails
Container
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Testing Models
MTS Insight Tension Machine
Load Frame
Wheel attachedfrom the Spindle
Wheel Durability
DC Motor
Roller Frame
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Budget
No. Description Part Number QTY Status Cost (ind) Cost
(Final)
1 O-RingRetainer
PRMC-101 2 No Action $20.00 $40.00
2 Spindle PRMC-102 1 No Action $10.00 $10.00
3 Hub PRMC-103 1 No Action $100.00 $100.004 Lock Nut PRMC-104 2 No Action $10.00 $20.005 Test Fixtures PRMC-105 1 No Action $300 $300.00
6 Load Frame:Side Bracket PRMC-106 2 No Action $86 $172.98
7 Load Frame:Middle Bracket PRMC-107 1 No Action $20 $20.00
8 Load Wheel:Spring Seal PRMC-108 2 No Action RFQ RFQ
9 Container: DropTest PRMC-109 1 No Action Donation Donation
Total $662.98
No. Description Part Number QTY Status Cost (ind) Cost (Final)
1 Wheel MEPC-001 1 No Action $35.00 $35.00
2 Carbon SteelBearing MEPC-002
2 No Action $50.00 $100.00
3
Bearing Cone
MEPC-003
2
No Action
$10.00 $20.004 Bearing Cup MEPC-004 2 No Action $10.00 $20.005 Bearing Seal MEPC-005 2 No Action $10.00 $20.006 Rubber O-ring MEPC-006 1 No Action $5.00 $5.007 Spacers MEPC-007 5 No Action $8.79 $43.95
8 Load Frame: Bolts MEPC-008 2 No Action $7.00 $14.00
9 Load Frame: Nuts MEPC-009 2 No Action $8.00 $16.00
10 Load Wheel: RollerBearing MEPC-010 2 No Action $92.10 $184.20
11 Load Wheel:Lubrication MEPC-011 Varies No Action Donation Donation
12 WheelDurability:Spring MEPC-012 1 No Action $35.00 $35.00
Total $493.15
Purchased Parts: Manufactured Parts:
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Schedule for Testing & Manufacturing
Description Date
Corrosion Rate of Materials January 7, 2013- January 21,2013
Manufacturing January 21,2014 -February 8, 2014
Testing the Preload Forces February 9, 2014- February 15, 2014
Pressure Strain Test February 16, 2014- February 22, 2014
Water Tight Seal Test February 16, 2014- February 22, 2014
Impact Test February 23, 2014- March 8,2014
Rolling Under Load Test February 23, 2014- March 8,2014
Wheel Durability Test March 2,2014- March 15, 2014
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High level Schedule
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Conclusion & Innovation
Reduce Cost Eliminate bearing lubrication and maintenance
Increase corrosion resistance of components
Decrease number of components
Multiple design paths Increase the probability of meeting the design goals
Use bushings in new application Similar applications
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References
SAE Handbook. Vol. 3. Texas: SAE International, 2005. 41.121. Print.
Tuthil, Arthur H. Nickel Institute. FNACE, n.d. Web. 29 Oct. 2013..