Blue Team Go Kart Colin Bishop

Day 1

We were doing the planning of our go kart on the wipe board, along with Ethan's crazy idea for a transmission. We also shopped for wheels from Harbor Freight, $6 dollars a wheel. We divided up the system as well, Colin: electronics, Ethan: drive system, Ryan: steering, Nolan: On shape and Don: Braking.

Day 2

We choose our plywood, a beautiful not very warped piece of plywood to create our cart from.

OnShape

is coming along very well, the seat pieces are beginning to be created and then exported to VCarve

The start of the electronics dashboard, it is going to house all of our electronic buttons and outputs, it's going to be very well cable managed to avoid error.

Day 3

The Arduino dashboard began getting wired. There are 3 buttons, a pedal, 2 leds, 1 potentiometer, along with a servo for the throttle. Our $6 dollar Hazard Fraud (Harbor Freight) wheels we were able to get, they look great, if only they were rated for above 5 mph. The front wheel frame was also began to be constructed.

Day 4

The primary go kart 2 x 4 frame was under construction today, the seat was tested to snap fit together. The electronics dashboard was also completed today.

Day 5

The wheels were mounted to the axle positions today.

Hey look! The majority of the go kart has been constructed, axles in place, steering shaft in place,and seat mounted. Life is going good.

Day 6

A new piece was shopbot'ed! A new bottom gusset to strengthen the 2 x 4 frame. I did this one personally and it worked perfect.

A metal strut piece was added to the side of the go kart to make way for the steering lever. As well as a brake and spring on a hinge to stop the rear axle.

Day 7

Don inlay-ed a brake pad into the brake 2 x 4 to add more friction. You can see a piece of plywood on the shopbot to make even more gears for the transmission. Lastly is a beautiful image of teammate Don after he was using the drill press to inlay the brake pad.

Day 8

Here you can see the go kart in great shape. A dowel rod was mounted for the transmission to ride on, the steering PVC pipe was adjusted and secured to the side of the kart, we now need to attach a lever to it. We had to use a sander to shave down our gear stop plate on the rear axle. You can see the final result of the brake on the rear axle and a great picture of teammate Don using a sander.

February 24

Attached a mount for our electronically actuated throttle.

Mounted the electronics dashboard and control system on the GoKart

The completed OnShape drawing that we based the entire design on.

February 28th

We attached a handle for the steering system on the steering rod, but this one broke. We will have to make a fresh one.This is the start of the transmission getting mounted to the GoKart.

March 2nd

The continuation of mounting the transmission system on the GoKart. We found a piece of black pipe to act as the super strong axle for the transmission to ride on.

Progress By system

4th Marking Period

The body

The rear frame of the seat was quickly adjusted and cut out more to allow for further engagement and meshing of the gears of the transmission
We were also experimenting with getting our rear wheels completely locked with our axle. They kept spinning otherwise with just the nuts.
The solution? Punch out and remove the cheap harbor freight bearing and with replace with wooden spacers. These can be easily drilled into and thus locked to our axle.

The Most Important Bodily Modification

We made one very major adjustment to the body as well, something that added function, form, appeal and brought the whole cart together.

That's right! We added cup holders! One for Don and one for his Guest. Stylin'!

Also completed was the styling DEL. MC 2501 license probably recognized from the latest "The Fast and the Furious" movie, yeah our car can go that fast.

(Note: Note actually featured in a movie.)

The steering system

Perhaps to be named the most trouble free and reliable system. Since last featured in this portfolio it has gone largely unchanged. The only modifications have been tightening of connector and rotation axle, and shortening and trimming of pieces on the handle.

This side piece, protecting us from protruding screws was thinned to allow for more space and comfort for the driver.
It also got a sweet rounding job to add more comfort and appeal to the cart.
A third holster for the steering shaft was also added to eliminate the droop of the rod when turned far.
The finished steering handle in all of it's glory.

Towards the end of this video you can see the steering system in action.

The Braking System

The braking system, the simplest system on the cart. Since installed it has worked great. The brake cord was traded for high quality Kevlar cord as seen above, and other than the occasional realigning of the brake pad it has been rock solid. Now if only we can stop the brake pad from wearing down...

It has been so reliable that we have only taken one picture of it.

The electronics & throttle

Reliable as well is the electronics. It is mounted on a central dashboard near the driver, all cables run from here to their location. This picture is me correcting a wiring issue after somebody messed with it.
All of our turning signals and servo throttle use servo extensions to easily extend wherever we needed them too. This is me gluing up those extensions to keep them tucked into the frame of the cart.
As just mentioned our throttle is electronically actuated. The servo on the side of the drill here pulls a rope around the trigger, thus turning on the drill. It allows for smooth startup and acceleration.
The new and improved code for controlling the throttle servo. After dealing with issue about slow startup and having to wait for the entire startup sequence, we changed it. There is another if statement to make sure the pedal is still pressed while accelerating and more delays to make the startup gradual.
Another plaguing issue was the battery powering the Arduino system. 9 volts kept dying and ran out, not enough AAA or AA. And the generic large 12 v batteries the Arduino did not like. Out most recent solution? Get 6 of the C batteries and duct tape them together into a mega battery with 9 volts and a 9 volt connector to allow for easy interface with the cart. One of our best ideas yet, this thing is rock solid. Unfortunate is, it earned the nickname "Dynamite," because it looks like dynamite and performs like it too.

In this video the servo can be seen activating the drill and driving the gears.

And the most plaguing system on the cart...

The motor drive system otherwise known as Ethan's transmission.

Riddled with too many problems to list, but we have been assured will work (by Ethan.) Although when it does work, it is very cool.

Where do I start? Well, a starting problem is that it shifts when the nuts on either side are not locked down tight enough and causes alignment problems. The piece Ethan is holding in the second image continually breaks. The small plywood gear in the last image broke, replaced with an oak gear seen above. The connection for the drill had to be grinded down.

This video shows the transmission's most amazing failure. Yeah, we had to fix that. (At least we got it on camera!)

Trying a collar to stop slop on the slot of the gear's various axles.

This whole operation of fixing the transmission has been called "Stop the slop." Namely because the primary cause of failure is weakening of the wood and thus 'slop' in our gears causing jams. (Yes I came up with the name, thank you.)

We replaced most of the wood making the support pieces for the gears with a 'Mystery Wood' that even EDBWood couldn't identify, but testifies that it is very hard.

But after numerous times remaking the piece above and screwing it into place, we had to be more ambitious in stopping the slop.

Enter APRIL 24th 2017, the day we though we solved the slop.

We thought we had done it, and we had. We attached and drilled metal collars to the holes for the axles, excellent that was. Then we made an epoxy bearing on the lathe, that was fun. This bearing was to hold the clutch assembly, and it did. However even this amazing bearing developed, *gasp* slop.

The bearing put into place.

However, the slop was still less that it had ever been before.

And say, the cart did look better with these slope reducing measures.

Let's see how it turned out...

That was pretty good. Now if only we can keep it working that well, and get it to run even better. (Without a push maybe) Right now, our new biggest enemy has been the drill, it simple does not have enough power for this and the battery keeps dying. The last class period the battery suffered 'weird smell' syndrome. It can't be good. We'll have to keep working on it.

Until next class period, our go kart is still pretty cool.

Final Few Days Before Race Day

Firstly, it was time to abandon the wooden transmission, far too unreliable and install a fixed transmission, with only one hear ratio.

A complete change of the drill support structure was in order to fit the new system.

Since we had now learned an unmaned ghost ride was in order, we, I, decided to add wireless WiFi controls to the go-kart by use of a spark core, it is a mini arduino listening for commands on the web, then triggering outputs to the main Arduino for use.

Next class we added an air cannon, because why not? It is fully functional and controlled via voltage and control from.the Arduino and also WiFi enabled via the spark core.

Ready for Race Day

The most successful test prior race day, we were prepped for success.

Race DAY

I don't have the video of our most successful race day run, but it was incredible. A full length run on the tennis court from end to end, WiFi controlled and no problems with the cart, it was fantastic.

A mishap, on the steering test we we're first not so great,our driver Ryan got fljnd from the cart in a spectacular event, he was okay but we need to make less sharp turns. We need to keep that in mind.

Our other tests we successful as well, a strong unmaned break test and coast test showed off our cart's superior court construction and durability. While we didn't get to fire the cannon WiFi controls we're superb we working, but glitches did occur. Race day was pretty great for us.

END

Credits:

Ryan Cummings

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