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Racing Wheelchair Frame Design Project

The project focuses on designing a lightweight and stiff frame for a racing wheelchair, aimed at enhancing performance for competitive athletes. It involves two phases: the Design Phase, which includes conceptualizing and optimizing the frame, and the Implementation Phase, which entails creating a prototype and testing its load-bearing capacity. The final deliverables include detailed design documentation, testing results, and a comprehensive report summarizing the entire process.

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21 views9 pages

Racing Wheelchair Frame Design Project

The project focuses on designing a lightweight and stiff frame for a racing wheelchair, aimed at enhancing performance for competitive athletes. It involves two phases: the Design Phase, which includes conceptualizing and optimizing the frame, and the Implementation Phase, which entails creating a prototype and testing its load-bearing capacity. The final deliverables include detailed design documentation, testing results, and a comprehensive report summarizing the entire process.

Uploaded by

xo.z100z
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Project – Design and Build of Racing Wheelchair

Project Overview:

This project is aimed at designing a frame structure for a racing wheelchair.


The performance of the design will be judged by how well it reduces both the
weight and stiffness of the frame. The frame should be able to carry the load of
a human.

The project will be executed in two phases: Design Phase and Implementation
Phase. Each phase will have specific deliverables, and we shall verify our work
with hand calculations. The structure shall be modeled in SolidWorks using
the model and the video presenting the method.

Project Statement
Racing wheelchairs are specialized athletic equipment used in competitive events
such as the Paralympic Games. Similar to racing bicycles, these wheelchairs are
designed to be extremely lightweight to enhance maneuverability and maximize
speed. The user relies on body movements to control the wheelchair effectively;
therefore, minimizing weight is essential for optimal handling. However, despite
the emphasis on lightness, the frame must also maintain exceptional stiffness
and structural integrity to ensure stability and durability under high-
performance conditions. Additionally, the frame should be capable of supporting
the weight of a typical human while maintaining aerodynamic efficiency. Our
objective is to develop a racing wheelchair frame that strikes the ideal balance
between lightweight construction and high stiffness, ensuring both performance
and safety for athletes.

Fig1. Racing Wheelchair


Our focus is solely on designing the frame of the racing wheelchair, excluding
the seat and wheels. The steering mechanism does not need to be designed or
built; therefore, the frame should be constructed as if the hinge near the
handlebar is welded, ensuring a rigid and fixed structure. We plan on designing
this with commonly available square sections we have access to. A simple yet
effective design (with members of cross section 80x80x5) that fulfills these
requirements is provided in the reference part files, which can be used as a guide
during the development process. Basically, you need to improve upon the given
design by designing a frame with 20x20x2 sections. The resultant structure must
be stiffer than the provided frame. In the frame given below, we will be converting
the 2 beams individually into 2D frames. The frame thus constructed may
consist of truss members but should have at least 2 beam members (they carry
bending moment in some loading conditions). In this frame shown below, the
points A and B are locations where the rear tires are connected by a hinge
support and C is the joint where the handlebar assembly is welded.

Fig 2. Basic Frame structure


Basic Frame and Design Instructions
A basic frame designed (SolidWorks part file) for a racing wheelchair is provided
in the folder, along with a basic analysis performed on it (Fig 2).

Your task is to redesign and improve the frame by adding more members.
These additional members shall have a 20x20x2 cross-section. The material for
the frame must be aluminum. You are free choose the space the structure shall
occupy with keeping in mind the space between the frame and seat (10 mm),
handlebar and ground (250 mm). The frame shall have as many members as
you choose, but must have at least 2 members that are beams (highlighted in
your report). You are not to change the locations of the 3 end points as that will
change the shape of the wheel chair assembly itself. You need to provide a
space of 20mm at the endpoints without any members connected for the sake
of clearances with the other components (wheel and handle bar). Your final
structure shall be designed and optimized for 2 design conditions, a) when a
load of 1000 N (a person’s weight) is applied at the center of the beam C, and b)
when a load of 1000 N is applied at 600 mm from C on the beam C and a
moment of 100 Nm is applied at C such that the stresses increase (extreme
analysis). Analysis of the final design on both these scenarios shall be
submitted in your report. Note that a design that beats the performance of the
provided frame shall be considered a successful design. This should be
highlighted by calculation the stiffness(Force/displacement) at the loading
point need to computed. The mass of the structure design shall also be less
than the design provided.

Redesign the frame in SolidWorks and perform an analysis similar to the one
provided. Each design must be analyzed systematically, with the results neatly
documented. These findings should then be tabulated, discussed, and
concluded in your report. The analysis shall primarily be conducted on
Solidworks. Any hand calculations performed using Excel sheet shall be neatly
documented and submitted in the final submission (complete hand calculation
will be eligible for a bonus of 7.5 points).
3D print of the Frame
We will be testing a scaled down version of the frame in the class. For this all
the dimensions of the frame must be scaled down by a factor of 5. They also
need to be modeled as a solid cross section and submitted for 3D printing. The
frames shall be printed as 2D flat structures and assembled using acrylic glue.
The material for the print must be PetG. You may use the Cura software to
create the final files for printing in Rapid prototyping studio. Also take the
necessary support from RPS to print the structure.

Testing the printed structure


Printed structures will be tested by the TA in the loading condition “a” and
graded accordingly. The printed structures shall be compared to the basic
design scaled down similarly and compared for performance as described in the
Grading policy. Note that a poor build of the assembly shall result in lower
points in this section.

Phase 1: Design Phase


Objective

The goal of the Design Phase is to develop a conceptual frame structure for the
given problem, ensuring it optimizes weight and material usage while
maintaining structural integrity. During this phase, you will focus on creating
the design, performing calculations, and finalizing the structure.

Tasks and Deliverables

1. Problem Understanding and Requirement Analysis


o Identify the functional requirements of the frame model.
o Understand the load conditions and forces that the structure must
withstand (for the racing wheelchair).
o Research different frame structures and optimization techniques.
o Deliverable: A basic model that you believe will satisfy the loads,
forces, and other structural requirements. (provided)
2. Preliminary Design and Frame Configuration
o Sketch multiple design concepts for the frame structure of the
racing wheelchair, ensuring that each beam is individually
redesigned as a 2D frame.
o Choose an appropriate frame configuration based on function and
material efficiency.
o Deliverable: Initial concept sketches with annotations on frame
configurations.
3. Optimization of the Design
o Perform software and hand calculations (using an Excel design
sheet) to verify that structural efficiency meets the expected
standards.
o Identify critical joints, members, and areas for potential material
reduction.
o Verify the efficiency of the design by comparing the weight and
material usage to its load-carrying capacity.
o Deliverable: Final frame design with detailed calculations for both
load-bearing capacity and material usage.
4. Milestone 1: Design Documentation and Delivery
o A comprehensive report summarizing all the deliverables discussed
above, including necessary images for clarity and visualization.
o A SolidWorks part file of the final design
o A final Excel sheet containing the design calculations and results if
performed.

Phase 2: Implementation Phase


Objective

The objective of the Implementation Phase is to translate the design into a


physical or simulated model. The model will be tested for performance against
predefined criteria, such as load-bearing capacity, stiffness, and weight. This
phase will involve building a prototype and validating its efficiency.

Tasks and Deliverables

1. Prototype Creation
o The model (scaled down by 5) will be 3D printed using SolidWorks
and Cura software in the Rapid Prototyping Studio.
o Deliverable: A working physical prototype or a complete CAD
model of the truss or frame design.
2. Load Testing and Evaluation
o Perform load testing on the prototype, either physically or through
simulation software (e.g., finite element analysis). This will be
conducted in the classroom, and the results will be compared
between teams for competition points.
o Collect data on the structural performance, focusing on how the
truss or frame structure responds to loads and the efficiency of the
design (i.e., does it carry the required load with minimal material
use?).
o Deliverable: Test results highlighting the performance of frame
structure and a comparison between expected and actual results.
3. Final Report
o Prepare a final report summarizing the design process,
calculations, testing results, and optimizations for the final design.
o Deliverable: Final report documenting the design, its validation,
and performance outcomes.

Milestone 2: Design Documentation and Delivery

• A comprehensive report
o Edits made to the previous report based on the feedback,
o Summarizing all the deliverables discussed above, including
necessary images for clarity.
• A final Excel sheet containing the design calculations and results.
• A SolidWorks part file of the final design

Grading Policy.
Report Phase 1 – 25 points

• The Final design of the frame. Describing the deliverables given in Phase
1.

Report Phase 2 – 35 points

• The Final design of the frame. Describing the deliverables given in Phase
1 and 2. There is potential for the improvements to be made in Phase 2
that should be highlighted in the final report. The results of the testing is
part of the final report.

3D Print and Testing – 40 points

• Ability to carry a prescribed load without failure. (15 points)


• Stiffness of the measured the method of testing. (12.5 points)
o It needs to be better than the basic design’s stiffness.
• Mass of the frame. (12.5 points)
o It needs to be better than the basic design’s mass
• Bonus points – Top three teams achieving highest efficiency
(stiffness/mass ratio) will receive a bonus of 5 points. Similarly, top three
teams with lowest weights will also receive a bonus of 5 points. However,
all designs must meet the first three criteria to be eligible for these
bonuses.
Peer Evaluation
You will be working in groups of 4 of your choice in this project. Peer
Evaluation for all the stages will be conducted and monitored. Poor points on
Peer evaluation will lead to redistribution of points among the team mates as
per the evaluation of the instructor.

Timeline
The following are the timeline to be followed for this project.

Phase 1 report – April 4, 2025.

3D print testing – April 16, 2025.

Phase 2 report – April 30, 2025.


Appendix
Take a look at these as an inspiration for what we are trying for this class.

[Link]

You may use these AI generated examples as an inspiration😊

Common questions

Powered by AI

The cross-sectional dimensions directly influence both the stiffness and weight of the frame. Larger or thicker sections can enhance stiffness but increase weight, whereas smaller sections might reduce weight but compromise stiffness. Therefore, the project requires selecting a 20x20x2 cross-section for members to balance these characteristics. Moreover, material choice, such as aluminum, contributes significantly to this balance, offering a lightweight yet sufficiently stiff structure to uphold performance parameters effectively .

Scaling down provides an efficient and cost-effective way to validate design concepts before full-scale production. Advantages include reduced material usage, quicker iteration, and easier handling for physical testing. Challenges include accurately replicating mechanical properties in scaled models due to material differences (e.g., PetG for 3D prints), potential loss of detail affecting performance predictions, and ensuring that scale factors do not introduce significant errors in structural insights. These challenges require careful calibration of the scaling and printing process to maintain validity .

The methodologies for validation include both analytical and physical testing approaches. Analytical validations are performed using SolidWorks simulations to evaluate structural performance under specified load conditions. Additionally, hand calculations are conducted to verify these results. Physical testing involves 3D printing scaled prototypes to test under loading conditions and comparing against baseline designs. These methodologies ensure comprehensive validation through simulated and real-world conditions, confirming the design's efficiency in terms of stiffness, load-bearing capacity, and weight .

SolidWorks can be used to model the frame structure, allowing for precision in the design phase by utilizing simulations to understand how different designs perform under load conditions. Designers can modify variables, such as dimensions of structural members, to optimize stiffness and weight. The software helps in visualizing stresses and deformation, enabling iterative design processes that improve frame efficiency by testing various configurations before finalizing the mechanical properties like stiffness and weight .

The critical tasks include understanding functional requirements, analyzing load conditions, researching optimization techniques, sketching design concepts, and performing calculations. Deliverables encompass a basic model for load requirements, initial sketches of frame configurations, finalized designs with detailed calculations of load-bearing capacity, and design documentation summarizing the process. These deliverables ensure a structured approach to fulfilling design objectives efficiently .

The primary engineering considerations include minimizing weight for enhanced maneuverability and speed, while maintaining high stiffness and structural integrity for stability and durability. Weight reduction is essential to facilitate effective control through body movements. However, the frame must support the load of a human and offer aerodynamic efficiency. Achieving a balance between lightweight construction and stiffness is crucial for performance and safety in high-performance conditions .

Optimization techniques ensure that the frame design not only meets but exceeds basic performance criteria by minimizing material while maximizing stiffness and stability. This involves analyzing different configurations and stress distributions, adjusting geometrical and material parameters, and systematically reducing non-essential material. The application of optimization allows for achieving superior stiffness-to-weight ratios, enhancing both performance and safety, consequently offering competitive advantages in racing contexts .

Peer evaluations influence team dynamics by promoting accountability and fair contribution to the project. They can motivate team members to engage actively and share responsibilities equitably. However, they may also lead to tension if not properly managed or if perceived as biased. Effective evaluations encourage collaboration and can improve project outcomes by balancing input and fostering a cooperative environment, which is vital for complex engineering projects like frame design .

Maintaining specific clearances is crucial to ensure there is no interference between the frame and other components, which could impair functionality or cause damage under dynamic conditions. For instance, the project requires a 20mm space at endpoints for clearances with wheels and the handlebar, avoiding unintended frictions or structural constraints that might arise during operation, thus ensuring smooth performance and durability .

Comprehensive documentation ensures transparency and facilitates continuity between phases. During the transition from design to implementation, documentation records design rationales, calculations, testing results, and optimizations. It serves as a reference, aiding team communication, project tracking, and quality assurance, thereby reducing scope for errors or miscommunication. This underpins successful prototyping, verification, and eventual product development, maintaining alignment with project goals .

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