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Cabover CamperME 493 Final Report - Year 201605..JUN.2016Academic Advisor: Dr. Evan ThomasIndustrial Advisor: Zdenek ZmurSubmitted By: P. Chand, T. Croissant, N. Roetemeyer, D. Stasiuk, R. Sutton, J. WackerExecutive SummaryThe Cabover Camper was proposed by Mr. Zdenek Zmur to allow him and a companion to comfortably camp in three seasons. The Camper would also allow him to continue to store his sporting equipment in his vehicle while using the built-in rack system of the car in combination with the Camper to sleep. This camper is designed as a one-off, meaning that it is only intended to be used by Mr. Zmur and his party. The sponsor (Mr. Zmur) currently uses a tent and sleeping bag setup, as is traditional, to camp. This method, however, tends to be cumbersome, time-consuming to set up and, with unpredictable weather, is often uncomfortable to sleep in. The Camper aims to solve all of these problems with a weather proof canopy, fast set-up-and-takedown, and excellent mobility. Main components of this design are the Ladder, the Frame, the Floor, and the Canopy; all of which come together to form the superstructure. The Ladder and base (Frame) are built with steel in various cross-sectional shapes and sizes, the floor is made of ACP (Aluminum Composite Panel) and the Canopy is constructed with Coroplast. This specific design is completely new and one of a kind. As a result, it is tailor made to the customer’s exact specifications and requirements. Should it go into mass production a reevaluation of the safety and other features may need to be revisited. Table of ContentsExecutive Summary ……………………………………………………………………………………………………..1Introduction.……………...………...………………………………………………………………………………………3Mission Statement ..……..………………………………………………………………………………………………3Summary of Design……………………………………………………………………………………………3Main Performance Criteria and Constraints ..……..……………………………………………………3Top Level Alternatives ...………………………………………………………………………………………………4Final Design………………... ..……………………………………………………………………………………………4Product Design Specification Chart ……………………………………………………………………………….7Conclusion ...……………………………………………………………………………………………………………….7Appendix ………………………………………………………………………………………………………………….6Introduction Residents of the Pacific Northwest have a penchant for year-round outdoor activity--specifically outdoor sleeping or camping--and staying dry, cool and comfortable in unpredictable weather presents an inevitable challenge. Tents are a viable option but can sometimes leave the users wet and uncomfortable and they can be cumbersome and time consuming to erect and take down. Some people may just end up sleeping in their vehicles but this may present issues of where to store their gear, food or other items required for their activity. Consequently, it a sleeping option that would keep users comfortable, allows them to store their gear appropriately, and utilize all of the equipment they have at hand, including their vehicle, is in order. Mission StatementSummary of DesignThis team was to design a cabover camper that is aerodynamic and easily attaches to a 2011 Volkswagen Jetta SportWagen. The cabover was to be made of rugged materials to provide durability and maintaining dependability. The target market is outdoorsy folk, in this case Zdenek Zmur, who want to enjoy the perks of camping without extra camping gear. A full scale model was constructed. Main Performance Criteria and ConstraintsMust sit atop a 2011 Volkswagen Jetta SportWagenMust have minimal impact to fuel efficiency via aerodynamic featuresMust sleep two peopleMust have sitting clearance of 36 inches Must have peripheral door access and minimal rear hatch accessShould be fully rigidShould be insulated and ventilatedFinal DesignThe final design of the Cabover Camper is a collapsible sleeping compartment that is rigidly mounted to a 2011 Jetta SportWagen with the factory mounted roof rails and an aftermarket 1? inch hitch receiver. When collapsed, the camper adds little additional height to the roof line of the vehicle, which keeps the negative impact on fuel economy of the vehicle to a minimum. Once, through a few easy steps ,the structure is deployed on top of the vehicle a dry and warm sleeping area is created with interior space comparable to many two-person backpacking tents. The project is broken down into two key design components. The first design component is called the Frame and Ladder which form the structural mounting interface for the Canopy structure and the Jetta SportWagen. The second design component is the lightweight, water shedding Canopy.Frame/LadderThe design of the Frame and Ladder started with deciding on the mounting mechanisms to the predetermined mounting points of the rails and hitch. The hitch mount was a simple selection of 1?” square tube steel which is standard for receiver mounts. To mount to the factory rails of the Jetta, a set of Thule 1054 clamps with steel crossbars were selected to build the design around. By selecting manufactured clamps and rails, time and money were saved in redesign, and guaranteed quality. The Thule 1054 Clamp provided a low profile secure clamping solution to rail mounting design dilemma (Fig 1). Figure 1: Thule 1054 clamp used in combination with the Inno 50 inch cross bar provides a secure clamping solution for the Camper.The Frame and Ladder are designed to be welded rectangular-tube structural steel components. Being the mounting interface and providing the structural support for the sleeping area, the frame and ladder are designed to balance structural rigidity with weight savings. This balance was obtained through multiple FEA iterations where the final structural steel cross sections and the structural arrangement was determined. The results from the FEA analysis of the final Frame and Ladder design is located in Appendix D. Under the designated loading condition of Mr. & Mrs. Zmur’s combined weight in the sleeping quarter, the observed maximum deflection of the structure is 0.17” which is well within Mr. Zmur’s definition of acceptable deflection.The Frame and Ladder incorporate key design features to aid the performance of the overall Camper. The Frame and Ladder are two separate components that are attached by ?” cotter pins (Fig 2). This allows for easy removal and attachment of the Ladder for storage when not in use. Figure 2: CAD Detail view of the mounting location between the Frame and Ladder that allows of separation for ease of attachment and storage.The next design feature incorporated is the the profile of the Ladder (Fig 3). The Ladder is designed with the intention of allowing partial access to the rear gate of the Jetta. By adding this feature, an increase in usable bed space is created atop the vehicle, and the front of the camper is shifted back from the windshield. Figure 3: CAD detail of the Ladder Profile that allows partial access to the Jetta’s rear liftgate. To help the mitigate drag caused by the Cabover during its closed state, and when the vehicle is driving, provisions were made for mounting locations on the front of the Frame (Fig 4) to attach a fairing similar to the one shown in Figure 5 to direct airflow as it comes of the windshield. Figure 4: CAD detail of a fairing mount provision on Frame. Figure 5: Example of wind Fairing to direct airflow CanopyThe design of the Canopy began by selecting a corrugated plastic material called Coroplast. It was selected because it is lightweight, cheap and easy to fold. The Canopy needed to be waterproof when deployed and collapsed. Scaled mockups were created to help plan out the how the canopy would fold. It was decided to make the Canopy a tapered design as seen in Figure 6. Essentially the Canopy consists of three walls and a roof that acts as both a wall and the actual roof. The structure was secured with velcro in a number of places to add stiffness to the structure. The velcro ensures that the Canopy would not collapse with a gust of wind as well as keep the mated edges secure so as not to allow the elements in. Figure 6: Deployed camper Canopy To collapse for travel, the velcro is undone, the side walls folded in, followed by the rear wall (with the door) and the roof is layered on top of it all. When fully collapsed (Fig 7) the camper has a profile of only an inch or two. This, coupled with the Frame’s slim dimensions, equates to a slim structure that will lower the impact on fuel economy.Figure 7: Collapsed camper CanopyProduct Design SpecificationsPerformanceOutlined in Mission Statement and further defined in AppendixEnvironmentAppendixMaintenanceAppendixQuantityOutlined in Mission Statement and further defined in AppendixSize and ShapeAppendixWeightAppendixMaterialsAppendixLaws, Codes & StandardsAppendixErgonomicsAppendixTestingAppendixTime ScalesOutlined in Mission Statement and further defined in AppendixSafetyAppendixDocumentationAppendixInstallationOutlined in Mission Statement and further defined in Appendix**Certain elements of the PDS have been deliberately left out as there is no applicability at this stage of the product development. ConclusionThe team was able to create a one-of-a-kind Cabover Camper to fit Zdenek’s Jetta while meeting the criteria outlined in the design specifications. The project, as of the current bids received, does not meet the budgetary constraints outlined but that may change based on further bids from fabrication shops. All in all the camper will sit atop the 2011 VW Jetta SportWagen, have minimal impact to fuel efficiency via the collapsible feature of the canopy, it will sleep two people with a sitting clearance of more than three feet, it will also allow for peripheral door and rear hatch access and be fully rigid while still being insulated and ventilated appropriately. Appendix A: Product Design Specification Priority MatrixHigh PriorityMedium PriorityLow PriorityPerformanceRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationAerodynamic to minimize MPG impactZdenek Zmur< 10 MPG ReductionMPG< 10 MPG ReductionDefined by CustomerTestingMust sleep two peopleZdenekZmurProduct width and length, 50 in wide at shouldersInches50 in wide at the headDefined by CustomerTestingMust be able to sit up at headZdenekZmurProduct Height, 36 in sit up heightInches36 in height at headDefined by CustomerTestingMust sit atop 2011 Jetta SportWagenZdenekZmurProduct Length/Car LengthInchesWill sit on roof with support from hitchDefined by CustomerTestingEnvironmentRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationThree Season Capable (Fall, Winter, Spring)ZdenekZmur“Warm” sleeping quarters/ InsulatedTBDTBDDefined by CustomerTestingFully waterproofZdenek ZmurNonporous outer shellPlastic, metal or compositeWaterproofDefined by CustomerTesting and Material SelectionMaintenanceRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationCar washable/Power washable/Spray offZdenekZmurNonporous outer shellPlastic, metal or compositeWaterproof/No CanvasDefined by CustomerTestingMinimal Moving PartsZdenek ZmurCollapsible design with 3-4 fold out panelsHinged wallsEasy fold open designDefined by CustomerManufacture/ModelingQuantityRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationOne-off initiallyZdenek ZmurCountN/AOneDefined by CustomerConstructed PrototypeSize and ShapeRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationDefined by Jetta dimensionsZdenek ZmurH-36 in @ headL-5 ft 8 inW-50 in @ headInchesH-36 in @ headL-5 ft 8 inW-50 in @ headDefined by CustomerMeasuringWeightRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerification<300 lb on the side rails Zdenek Zmur<300 lb Pounds<300 lbDefined by Vehicle SpecificationWeighingMinimization of overall massZdenek ZmurSecondary to 300 lb max requirement PoundsReduction through modeling, etceteraFunction of 300 lb max requirementModeling/TestingAestheticsRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationStreamlined shapeCabover Camper TeamCFD Analysis for minimal MPG impactCFDDecrease MPG impact as much as possibleDefined by Customer, Jetta dimensions and Camper dimensionsTesting/ ModelingPainted and styledCabover Camper TeamN/AN/APainted and styled to match the target vehicleDefined by Cabover Camper Team and CustomerA painted prototypeMaterialsRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationSteel frame structureZdenek ZmurJetta DimensionsInchesMatch Jetta dimensionsDefined by Vehicle and CustomerPrototype/ ModelingPlastic Inner/Outer CoveringZdenek ZmurCamper DimensionInchesMatch Camper DimensionDefined by Camper and CustomerPrototype/ ModelingLaws, Codes and StandardsRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationMeet all applicable DOT laws regarding license plate and tail light visibilityZdenek Zmur and Cabover Camper TeamDOT Regulations: FORM 734-2359 (6-15) STK# 320853DOT Regulations, will not cover tail lights, or protrude more than 4ft in the rear. See FORM 734-2359 (6-15) STK# 320853 for detailsMeet all standards at time of testing. Will not cover tail lights or protrude more than 4ft in the rear. See FORM 734-2359 (6-15) STK# 320853 for detailsDefined by laws and regulations of DOT:FORM 734-2359 (6-15) STK# 320853Pre-test inspectionErgonomicsRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationInterior lengthZdenek Zmur86 in (Fig 1)inches78 inDefined by customerMeasuringInterior widthZdenek Zmur50 in @ shoulders and headinches48 in @ shoulders and headDefined by customerMeasuringInterior heightZdenek Zmur42 in(Fig 1)inches36 inDefined by customerMeasuringFigure 1. Spatial capacity of the interior of the cabover with a 90in footprint, and 42in of head spaceTestingRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationTest drive with mock up of clamshellZdenek Zmur< 10 mpg reductionMPG< 10 mpg reductionDefined by customerTestingTime ScalesRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationWorking Prototype by June, 2016Zdenek ZmurN/AN/AWorking Prototype by June, 2016Defined by Customer and ME SequenceN/ASafetyRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationSetup is safe and easyZdenekZmur and Cabover Camper TeamUser Defined, Fold-up designUser DefinedFold-up designDefined by Cabover Camper Team and CustomerN/AAppropriate lighting additionCabover Camper TeamTBDTBDLight inside of CamperDefined by Cabover Camper TeamN/AAppropriate ventilationCabover Camper TeamNot included in prototypeTBDVentilation for condensation and fresh airDefined by customer and Cabover Camper TeamTesting/ ModelingDocumentationRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationDocumentation of dimensionsZdenek ZmurSketches, meeting notes, documentationN/AFull product documentation and drawingsDefined by Cabover Camper TeamImplicitMaterial ListZdenek ZmurFull material list in progressN/AMaterial manufacturing listDefined by Cabover Camper Team and CustomerImplicitInstallationRequirementsPrimary CustomerMetrics & TargetsMetricTargetTarget BasisVerificationEase of InstallationZdenek ZmurTBDUser definedFully built structure with anchor points on the vehicleDefined by vehicle, Cabover Camper, TeamTestingCamper functionality for one-time installationZdenek ZmurCamper allows access to all peripheral doors and limited rear hatch without removal of camperN/ACamper allows access to all peripheral doors and rear hatch without removal of camper Defined by vehicle dimensions and layout, Customer and Cabover Camper TeamTestingAppendix B.1: External Research SummaryMost of the external research resulted in designs for pick-ups and SUVs. Some examples we found are seen here. External research for sedans resulted in designs that included 5th wheels, a trailer, or a canvas tent. The customer is against using any canvas in the design. Ease of maintenance and fully weatherproof is a high priority.Appendix B.2:Internal Research SummaryDuring the internal research, it was decided that the cabover be made of a rugged and stiff plastic rather than sheet metal. Due to the 300 pound weight restriction, and desired ease of installation, sheet metal was too heavy for both applications. After some alternative materials research and customer approval, coroplast was chosen. Coroplast is rugged, waterproof and has excellent insulation. The foldable nature of the coroplast gave way to a better collapsable design.An origami fold seemed most attractive until it proved to change shape and to be too bulky in its collapsed form. See examples below from cardboarigami shelters. Appendix C:Finite Element Analysis In order to house two bodies in the structure and maintain appropriate clearance to the roof and rack system of the car, the deflection needed to be minimized to less than one-half inch in the z-direction. Also,this would validate material selection made for the base of the superstructure. This was done using Abaqus FEA modeling software and results are in (Fig D.1). -57149990600Figure D.1: Finite element model of the base and ladder of the superstructure done in Abaqus FEM software. The design requirements of the structure limited the deflection in the z-direction was not to exceed one-half an inch. Material selection was also validated by meeting this requirement. Appendix D: Mass AnalysisIn order to house two bodies in the structure and satisfy loading conditions on the suspension and structure of the car, the total weight of the camper could not exceed 300 lbs . This was validated using Siemens NX 10 modeling software and results are in (Fig E.1) and (Fig E.2)Figure E.1: Mass analysis of the base of the superstructure using Siemens NX 10 software. The combined weight of the structure is not to exceed 30lbs static weight. -13334957150Figure E.2: Mass analysis of the base of the superstructure using Siemens NX 10 software. The combined weight of the structure is not to exceed 30lbs static weight. 32385057150Appendix E: Fabrication DrawingsAppendix G: Bill of MaterialBill of MaterialPartDescriptionManufacturerPart NumberQuantity1Orafol Pressure Sensitive TapeOrafolN/A325ft. x 12ft. Plastic SheetsCoroplastN/A3350in. Cross BarsInnoIN-B12724415 Railing FootThuleTH-100415451.00in x 0.500in x 92.00in Tube Steel (0.065in wall thickness)N/AN/A261.00in x 0.500in x 41.00in Tube Steel (0.065in wall thickness)N/AN/A171.00in x 0.500in x 42.25in Tube Steel (0.065in wall thickness)N/AN/A181.00in x 0.500in x 45.38in Tube Steel (0.065in wall thickness)N/AN/A191.00in x 0.500in x 17.50in Tube Steel (0.065in wall thickness)N/AN/A2101.00in x 0.500in x 22.50in Tube Steel (0.065in wall thickness)N/AN/A1111.00in x 0.500in x 23.75in Tube Steel (0.065in wall thickness)N/AN/A1121.00in x 0.500in x 21.50in Tube Steel (0.065in wall thickness)N/AN/A113Angle, 1.00in x 1.00in x 1.50in (0.125in wall thickness)N/AN/A3414Plate, 1.00in x 4.00in (0.065in wall thickness)N/AN/A215Plate, 1.00in x 0.50in (0.065in wall thickness)N/AN/A416Tube, 1.25in x 1.25in x 6.00in (0.188in wall thickness)N/AN/A117Tube, 1.25in x 1.25in x 25.00in (0.188in wall thickness)N/AN/A118Tube, 1.25in x 1.25in x 18.00in (0.125in wall thickness)N/AN/A119Tube, 1.25in x 1.25in x 15.50in (0.125in wall thickness)N/AN/A320Tube, 1.25in x 1.25in x 23.00in (0.125in wall thickness)N/AN/A221Tube, 1.25in x 1.25in x 17.00in (0.125in wall thickness)N/AN/A222Tube, 1.00in x 0.50in x 10.00in (0.065in wall thickness)N/AN/A223Plate, 1.25in x 1.25in (0.065in wall thickness)N/AN/A224Rivets, Domed Aluminum with Steel MandrlMcMaster-Carr97524A1083254ft x 8 ft Sheet of ACP - 3mmMulticraftPF2 White1 ................
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