Wong Chu Bang Heng Cher Guan Daniel Tan Sia Nguan Eugene Ang Ming Hui Louis

Scope of Presentation
1.

Introduction
Problem Description Objective Design Constraints Design Requirements Idea Generation

2. Conceptual Design

Functional Analysis Diagram Morphological Chart Concept Screening (A, B, C) Concept Evaluation

Scope of Presentation
3.

Detailed Design
Working Principle Detailed Calculation

4. Embodiment of design 3 Rules 4 Principles Material Selection

5.

Cost Analysis
Part Explosion Diagram

Introduction
Problem Description

Unable to play basketball due to heavy rain Unable to enjoy a safe game in heavy thunderstorm

Objective

Design an all-weather system to be installed at an existing basketball court

Introduction
Design Constraints
1. 2. 3. 4. 5.

Able to protect user from all weather Able to install to existing basketball courts Safe to operate Must be mounted outside the basketball playing premises Aesthetics

Site Survey

Marine Parade Serangoon

Bukit Batok

Market Survey
100 basketball court users and residents Results:

Design Requirements
1.
2. 3. 4. 5. 6.

7.
8. 9.

Aesthetic Corrosive Resistant (weatherproof) Durable Low Maintenance (modular) Provide Shelter Quickly Strong Structure (able to withstand extreme conditions) Simple Mechanism User Friendly Safety

Exploration of Ideas

Exploration of Ideas

Conceptual Design

Functional Analysis Diagram

Material Energy Signal

Activate Mechanism Cat I Signal

Activate Check whether Mechanism Shelter fullyextended

User Input

Activate Shelter

Move Shelter

Shelter fullyextended

Shelter retract

Shelter Move

Shelter fullyretracted

Activate Check whether Mechanism Shelter fullyretracted

Morphological Chart
Activate Shelter

Move Shelter

Shelter Fully Extended

Patents & Research

Retractable roof - Patent 4204372
Umbrella-type tent apparatus - Patent 6230728 Hand Winch Patent 7793919

Electric Motor/Servo Patent D576941

Hydraulic Motor Patent 6345501 Pneumatic Motor Patent 4407390

Patents & Research

Rack and Pinion Patent 4218933
Linear Guide Patent 7632017 Chain Motor Drive Patent 7080825

Double Pulley Patent 1800664

Limit Switch Patent 7129429 Latch Mechanism Patent 7656663 Proximity Sensor Patent 6798217

Concept Screening

Concept A
Activate Shelter

Move Shelter

Shelter Fully Extended

Concept A: The Seashell

The Seashell
1) Activate : Servo 2) Move: Double Pulley (in Slot Rail) 3) Sense Extension: Proximity Sensor

Concept A : The Seashell

1.

Activate : Servo

Precision required due to Curvy shape Easy to Manipulate Positions Expensive, Difficult to Programme

2.

Move: Double Pulley (in Slot Rail)

Cheap & Easy to Manipulate motion Easy to Manipulate Positions Corrugated tubing required to protect Slot Rail

3.

Sense Extension: Proximity Sensor

Easy to link up with Electrical Systems above Longer Sensing Range Cheap, Consistent detection

Concept B
Activate Shelter

Move Shelter

Shelter Fully Extended

Concept B : The Dome

The Dome
1) Activate : Hand Winch 9 (Mechanical) 2) Move: Rack & Pinion 3) Sense Extension: Catch Mechanism (

Concept B : The Dome

1.

Activate : Hand Winch (Mechanical)

Energy Saving Fixed systematic actuation Prevent Backlash Motion Take long time to fully extend shelter Tiring for User

2.

Move: Rack & Pinion

Simple & Cheap May face functional issues due to obstacles on Rack Fixed systematic actuation

3.

Sense Extension: Catch Mechanism

Energy Saving Prevent Backlash Motion

Concept C
Activate Shelter

Move Shelter

Shelter Fully Extended

Concept C: Flying Wings

Flying Wings
1) Activate : Centrifugal Pump (Hydraulics)
2) Move: Chain Drive 3) Sense Extension: Roller Limit Switch

Concept C : Flying Wings

1.

Activate : Centrifugal Pump (Hydraulics)

Able to Manipulate Heavy Structures Prevent Backlash Motion Expensive, High Maintenance required

2.

Move: Chain Drive

Prevent Backlash Motion Able to Efficiently Move Heavy Loading Possibility of Chain slippage

3.

Sense Extension: Roller Limit Switch

Easy to link up with Electrical Systems above More accurate that Level Limit Switch

Concept Evaluation
Criteria
Aesthetics Durability Low Maintenance Provide Shelter Quickly Strong Structure Simplicity of Mechanism User Friendly Safety

Weight Factor
0.22 0.07 0.11 0.12 0.08 0.05

Concept A
Values
4 4 3 4 3 3

Concept B
W.V
0.88 0.28 0.33 0.48 0.24 0.15

Concept C
W.V
0.66 0.28 0.55 0.36 0.32 0.25

Values
3 4 5 3 4 5

Values
5 3 2 4 4 2

W.V
1.1 0.21 0.22 0.48 0.32 0.1

0.15
0.2

4
4

0.6
0.8

3
4

0.45
0.8

3
3

0.45
0.6

Sum of Weighted Value

3.76

3.67

3.48

Modifications to Selected Design

1.

Activate : Brushless DC Motor

Precision required due to Curvy shape Easy to Manipulate Positions Regenerative Function, Easy to Programme Expensive

2.

Move: Double Pulley (in Slot Rail)

Cheap & Easy to Manipulate motion Easy to Manipulate Positions Corrugated tubing required to protect Slot Rail

Addition of Fans & Lights

3.

Sense Extension: Proximity Sensor

Easy to link up with Electrical Systems above Longer Sensing Range Cheap, Consistent detection

Final Design Closed

Closed Views

Final Design Deployed

Deployed Views

Detailed Design

Working Principle (1/3)

Working Principle (2/3)

Working Principle (3/3)

Detailed Calculations
1.

Main Structure

Stress Deflection

2.

Brushless DC Motor

Speed Power Consumption

3.

Fan

Rate of Cooling, Speed, Flow rate Length of Fan Blades

4.

Lightings

Luminance

Main Structure (1/5)

Since the Main Structure would be piled into ground, Assume X-Directional Forces to be Zero

Side View of Main Structure

W = 100N/m RAY RAX
7m

RAX RAY
7m

RX RY
21.5m

RBX RBY

Main Structure (2/5)

Removed y subscript & Assume W = 100 N/m
W = 100N/m

Centroid
X = 9.13 m Y = 2.97 m RA
7m X 21.5m Y

W = 100N/m = 2150N

RA

RB

RB

Main Structure (3/5)

W = 100N/m = 2150N

RA
X Y

RB

Main Structure (4/5)

W = 2150N

Free Body Diagram

1237N

913N

1237N

Shear Force Diagram

5.25 m -913N 6494 Nm 7.94 m

913N

Bending Moment Diagram

-7249 Nm

Main Structure (5/5)

Bending Moment Equation

Cross Section Area of Beam Assume mass = 1 kg of material

Select Material with

Singapores Record Wind Speed

On April 1984, a small-scale event which produced very high gust speed of 40.1 m/s at Tengah
Note: 40.1m/s = 144.36km/hr

Beaufort Wind Speed Scale

Forces of Wind
Note: 40.1m/s = 144.36km/hr = 89.7 mph

For 90 mph

Brushless DC Motor (1/3)

Brushless DC Motor (2/3)

Brushless DC Motor (3/3)

Aluminium Alloy 6061: Supporting Poles Density: 2700kg/m Diameter: 0.0254m Weight= r2 l = 205.2kg Polyester Canopy 300g/m2 Total Area: 577m2 Weight = 173.1 kg
Total weight of canopy and supporting poles: 378.3kg
(Note: Weight used for Motor Selection) 3 x Supporting Poles

Fan Selection

There would be 124190.5 ft3 of static air within the Basketball Court
In the scenario that the air is turned over 1 times in 1 hour Basketball Court will require 124190.5 ft3 of air

Hence, 2 fans of 1000 CFM or 4 fans of 500 CFM will be required

Lighting Calculation (1/4)

Lighting Requirement for Basketball Court = 50 footcandles ( fc)

Lighting Calculation (2/4)

Lighting Requirement for Basketball Court = 50 footcandles ( fc)

Assume: Lamp Lumen Depreciation (compact fluorescent) = 0.85 Ballast Factor = 0.95 Luminaire Dirt Depreciation = 0.85

Lighting Calculation (3/4)

To Find Coefficient of Utilisation, Room Cavity Ratio must be found (Assume Room is a Cuboid)

Coefficient of Utilisation Table Assume that the surface reflectances: Pfc, floor = 20% PCC, ceiling = 10% Pw, wall = 10% RCR = 3 (round down) Coefficient of Utilisation = 0.48

Lighting Calculation (4/4)

Lighting Requirement for Basketball Court = 50 footcandles ( fc) Average Maintained Illumination = 50 fc Coefficient of Utilisation = 0.48 Light Loss Factor = 0.686 Area of of Shelter = 363 m2 = 3907 ft2

Hence, 10 light blubs of 60000 lumens or 20 light blubs of 30000 lumens

Embodiment of Design

3 Rules

Clarity Simplicity Safety

4 Principles

Force Transmission Division of Tasks Self-Help Stability/Instability

3 Rules
1.

Clarity

Any ambiguity in the design must be eliminated No unintended functions Simple words to indicate clearly the function of buttons on

the controller for activation of shelter

Arrows to indicate direction of motion shelter

2. Simplicity
Design as simple as possible Unnecessary complicated steps are eliminated

3 Rules
3. Safety
Adequate strength, reliability and accident prevention

measures are to be ensured

Signs to warn users of the danger zone when shelter is

operating
When shelter mechanism fails, warning signals and alarm

will be activated
Proximity sensor to detect obstacle at the track

4 Principles
1.

Force Transmission Reducing of stress concentration at sharp corners

Curvature of the main supporting structures No sharp turning points on the track

2. Division of Tasks Dissimilar functions are to be performed by different parts

In the case of two or more parts performing the same function,

work should be separated equally to each part

4 Aluminium Alloy poles are used to support the canopy Improves clarity as tasks do not interfere with one another

4 Principles
3. Self-Help

Symmetrical shelter from both sides balance each other.

4. Stability/Instability As canvas is spread over entire basketball court, Al Alloy Poles are used to support the canvas sheet to prevent drooping of canvas

Cost Estimation

Cost Estimation
To fully estimate the cost of a product, the following steps are needed: 1. Have a set of detailed drawings of all components; 2. Create a Part Explosion Diagram (PED) and list out the items; 3. Come up with a sketch routine for self-manufactured items; (will be done in later part of project)

4. Obtain the prices of raw materials and commercial items, then the overall selling price of design

Material Selection
Material A
Galvanised Steel Track

Material B
Steel Track

Material C
Steel Track

Properties
Corrosion resistance, high durability, light weight, good heat insulation, good surface finish

1. Steel Track

2. Stainless Steel Wire

SS Wire Rope 304 6x19 Class

Bright Wire Rope EIPS FC - 6x19 Class

Galvanized Wire Rope EIPS IWRC -6x37 Class

High corrosion resistance , flexibility and resistance to wear-and-tear, high strength to weight ratio

7. Canvas Sheet

100% Polyester

100% Polyester

100% Acrylic

Waterproof, Tear-Resistant with excellent tensile strength, Flame Retardant and lightweight good mechanical properties, good weldability, suitable for general purpose use

8. Canopy Supporting Pole

FibreGlass Rods

Al Alloy Rods

4130 Alloy Structural Steel Bar

11. Steel Frame Structure

4130 Alloy Structural Steel Bar

Structural Steel Bar

4340 alloy structural steel

high strength, high toughness, high temperature strength with good workability, good weldability

Part Explosion Diagram

Steel Frame structure 11 2 P Steel Track 1 6 P Steel Track Rollers 2 6 P Canopy Supporting Pole 8 6 P Canvas sheet 7 4 P Ventilation Fan Stainless Steel Wire 3 4 P Electrical Wire Drum 4 4 P 9 2 P Shelter Assembly

Main structure 10 1 M

12
1 M

Lightings
14 10 P

Cable Assembly
6 1 M

Drive System 13 1 M

Steel Wire clip 5

12 P

List of Make/Purchase parts for Shelter system

Item nunber 1 2 Description Steel Track Steel Track Rollers Make or Purchase P P

3
4 5 6 7 8 9 10 11 12 13 14

Stainless Steel Wire

Electric Wire Drum Steel Wire Clip Cable Assembly Canvas Sheet Canopy Supporting Pole Ventilation Fan Main Structure Steel Frame Structure Shelter Assembly Drive System Lightings

P
P P M P P P M P M M P

Cost Centre
Item nunber Description Unit Cost ($/unit) 1.30 2.50 0.2 1,500 10.77 Quantity Per Assembly (units) 2.60 6 7874.02 4 12 Cost Per Assembly ($/order) 338 15 1,574.8 6,000 129.24 338 15 1,574.8 6,000 129.24 Order Cost ($) 1 2 3 4 5 Steel Track Steel Track Rollers Stainless Steel Wire

(6x19, 7/16)per inch

Electric Wire Drum Steel Wire Clip

7
8 9 11 14

Canvas Sheet (m2 )

Canopy Supporting Pole(feet) Ventilation Fan Steel Frame Structure (ton) Lightings Metal Halide M47 Light Bulb

1.97
5.18 290 2000 44.95

1218
88 2 98.95 10

2,399.46
455.84 580 197,902 444.95

2,399.46
455.84 580 197,902 444.95 209, 839

Total (based on order of 1 unit)

66