Document Type

Restricted Campus Only

Publication Date

4-28-2026

Abstract

This report details the final design produced by the ASME e-HPVC senior design team at the end of a year-long design project. The overall task given by the ASME president is to create a vehicle capable of competing in the ASME e-Human Powered Vehicle Competition (e-HPVC) at the end of two year long design projects. The key goal of this year’s project is to design the vehicle and key safety features and confirm that they meet the specification in the rulebook for the competition.

The final design has two key subsystems, the bike and the Rollover Protection System (RPS). Work on the bike subsystem was composed of research and comparing vehicle types popular in the specific e-HPVC and types popular in similar sports. The RPS subsystem was designed based on requirements and constraints specified in the ASME e-HPVC rulebook [1], including applied loads and the ability for the vehicle to start, stop, and turn within prescribed distances. When both subsystems were completed one subsystem must not compromise the safety of the other subsystem.

The RPS subsystem was designed and fabricated from scratch, whereas the vehicle was externally purchased. The working criteria used to examine possible vehicle types were: the cost of purchasing the bicycle, the ease of modification to attach RPS and electronics, the stability of the bicycle when ridden, and the weight of the bicycle. For the RPS, hand calculations were performed during the design process. The team decided upon a “side hoop” design, where a singular hoop is placed behind the seat of the bicycle. The team also researched three common materials used in bicycle manufacturing for the RPS: Aluminum 6061, Low Carbon Steel, and AISI 4130. In order to determine the best material to use, the team compared the cost, strength, weight, and stiffness, with the final material chosen being AISI 4130. When planning the fabrication process, additional supports were welded to the rear of the RPS to provide additional support and an additional load path.

Three vehicle tests were performed (Braking and Egress test, Drivetrain test, and the Steering test), alongside one Finite Element Analysis (FEA) Applied Load test. The goal of the vehicle tests was to confirm that the vehicle met all driving and use requirements in the rulebook, while also confirming that the vehicle can be utilized by a large variety of people. The goal of the FEA Applied Load test was to confirm that the FEA model was accurately reflecting the behavior of the real vehicle. For the applied load test, the RPS was loaded with a known weight and the deflection was compared to the FEA model under the same load. For each of the vehicle tests, a simple course was marked in chalk and the steering, braking, and drivetrain of the vehicle was tested. The vehicle passed all tests and meets all requirements defined by the project sponsor, and the team considers the project a success.

Comments

Dr. Michael Enright, Team Adviser

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