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Moonbuggy - Technical documentation

moonbuggy-differential-3.0

Today, the new differential gear of the Moon Buggy on the intec subcontracting was presented in Leipzig. The German engineering companies and Madler IGUS had accompanied the 5-year development of this transmission with material. The development was supported by an international team of students (14-18 years old), headed by a young engineer from Moscow (22) and the auspices of the "International Space Education Institute" conducted in Leipzig. Involved in the production and processing of individual parts to the CAD templates were, the Saxon company: Machine Shop Günter Jacob, Wittenbecher engineering, mechanical engineering Aischmann, Holl GmbH and 1st Mould. The development was funded by the association on its own power with the assistance of Messrs. Bruno Banani and the Space Hotel Leipzig.

The 5 - year development was primarily based on the high standards required for success in the NASA Moonbuggy Race. There were 16 high performance races recorded with a variety of data sensors and data telemetry. Through the data collection we were able to significantly optimizes the transmission in three generations. There was a scientific circle between development - test results - evaluation and development. During this time, two team members completed their preparatory course with this subject in high school with top grades.

maedler-stand-2013igus-stand-2013

At the INTEC-Subcontracting Fair in Leipzig chief designer Evgeniy Zakutin (ISEI) and the producers Ronny Hessel (turnery Günter Jakob) and Siegfried Aischmann (Aischmann engineering) presented the new Moon Buggy transmission. At the stands of Mädler and IGUS hit the freshly assembled core of successes. It was remanded to the director of the Fa IGUS, Mr. Ing Thomas White. This gearbox is part of the 6th manus ® competition for plastic plain bearing applications of the Fa. IGUS and will be presented to the public on April 10th 2013 at the Hanover Fair.

The special features of the rugged and lightweight transmission include the use of maintenance-free polymer bearings, the use of reinforced carbon fiber by injection of molding and of course the young average age of the developer - 17 years. The production-ready gear is now has a variety of applications and is not just for NASA's Moonbuggy Race, but also a design competition for high-performance teams. So it is particularly suitable for light electric vehicles, electric quads, trikes, Ped-Mobile, wheelchairs and automatic guided industrial mobile equipment. It is fit to use up to a torque of 300 Nm (ca. 220 Pound-force foot). 

The long and difficult road to a flawless product requires all teamwork, integrity, excellence, ideas, dedication and patience. Here is a summary of annotated images with large photos of the laborious development in 5 years. All those involved have grown so beyond itself:

differential-problem

erster-entwurf

erste-produktion

pruefstand

most-improved-award

rohloff-award

analysis

winning-team

improvement

evgeniy-drawings

igus-bearings

maedler-intec2011

race-2011

snowbuggy

serientest

max-flight-2012

 belastungstest2011

igus-cologne

 

 

maedler-2012

hand-drawing

cad-2013

fem-analysis

production

cad-2013

 

 

 

 

 

 

 

 

 

 

Application for the manus®-contest (PDF, 24 MB),  
flickr collection as documentation since 2008


The designerteam:

highschool student (age/participation in years):
Thommy Knabe (15/7) Fabian Hoffmann (16/2) Anne Geyer (13/3)
Tobias Meier (14/3) Christoph Eibeck (15/1) Eric Meinel (15/2)
Max Frank (17/3) Nadin Rößler (16/3) Jasmin Haack (17/1)
Araceli Zeller (14/1)

college students and young engineers:
Christian Hein (22/1), Deutschland,  zeichnete den Entwurf der 1. Generation
Evgeniy Zakutin (22/4), Russland,  zeichnete die Getriebe der 2. und 3. Generation

supervisors/idea/financiation/correktur:
Ralf Heckel - International Space Education Institute
Yvonne Heckel - International Space Education Institute

supporting people (materialdonators & help):
Ronny Hessel - Turnery Günter Jakob
Herr Wittenbecher - Wittenbecher Engineering
Siegfried Aischmann - Aischmann Engineering
Frau Rathmann - Holl GmbH
Dr. Schmidt - Bildungs- und Technologiezentrum der Handwerkskammer Leipzig
Kent Prelle - Singlespeedshop

and many other privat persons and handicraft workers, who are supporting the Moonbuggy-Project in Germany

supporting industrial companies (materialdonators & help):
igus® GmbH, Mädler GmbH, 1ST MOULD GmbH,

supporting companies (money donations):
Bruno Banani, Space Hotel Leipzig, Dekra Leipzig

 
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Moonbuggy - Technical documentation

telemetry-2009

Over the last years the telemetry/electronics Award was introduced because of Ralf Heckels suggestion. This award is being promoted, encouraged and supported by the AIAA (American Institute for Aeronautics & Astronautics). The first winner of this 500$ prize was the Moonbuggy Team Russia of the ISEI. During the years 2008-2012, the data was collected with components made by HinzTec. It was sent via CB radio every second to a receiver (laptop with evaluation software). This basic principle has constantly been improved and especially made more robust.

With the analyzed data the overall Moon-Buggy design had become far more understandable and therefore enabled further improvements. A direct result of this is the construction of the Moonbuggy differential gear. The goal is now to use the advantage of our team in this technology and further expand the telemetry. Additional sensors and the use of microcontrollers are already planned.
 

The NASA requirements
demand that either one of these two options is fulfilled:

1. Transmission of a real-time video
2. Transmission of real-time sensor data

telemetry-cad

telemetrie-2013

Also an on-board-logging-system can be used in order to save the transmitted data additionally in higher quality right inside the buggy. Extra credit will be given for recording the boardcam-video as well. The final score will consist of 50% written presentation and of 50% performance during the race.

We decided to transmit real-time sensor data such as GPS, 3D-acceleration and speed. The method of transmission we use is called APRS (Automatic Packet/Position Reporting System), which is a special form of packet radio. The transmission of the digital signals is done using AFSK (Audio Frequency Shift Keying). In course of this the binary information 0 and 1 are transmitted as sounds with 1200 Hz and 2200 Hz. The sounds are switched with a baud rate of 1200 Hz. The data is received using a hand radio device, which is connected to the Mission Control Laptop. The information is analyzed using UI-View program.
 

telemetrie-unit

analysis-2009The telemetry consists of several parts. Attached to the back seat of the buggy is the high-gain antenna as well as the GPS-sensor. There are two boxes beneath the seat. Inside the main telemetry box are SMD (short message display) and anyfrog, which together are responsible for processing and transporting the sensor data. Consequently the GPS-sensor and the speed sensor are connected to the box. The acceleration sensor is connected directly to the SMD and therefore in the main telemetry box, too. There is also the on-board-logging-system in the box. To record the data we use an Arduino MEGA. After the race we can further analyze the recorded data with suitable software. The goal is to play the recorded sensor data and the boardcam-video at the same time in order to ensure a good analysis. The power supply is a rechargeable 12V lithium-ion battery. In the second box is the transmitter. It is connected to the anyfrog (main telemetry box) as well as the high gain antenna. Besides the transmitter is yet another power supply which provides the 12V for the transmitter.

photogalery of past activitiesmovie for explaining of the telemetry 2009

 
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