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Trapped With A Kupholder Verify

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Final presentation from one of my student teams in my Design for Six Sigma class at RPI. Excellant application of DFSS to the design of a mouse trap powered vehicle.

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Trapped With A Kupholder Verify

  1. 1. “Trapped With A Kupholder” The Greatest Mousetrap Car Yet! Ayoob Ahmed Osvaldo Colon-Sandoval Amanda Learned December 14th, 2010 DSES-6960 H13 Design for Six Sigma Instructor: Bob Shemenski
  2. 2. Agenda Background of our vehicle concept Why customers want this kit Using CDOV process to enhance the car Packaging & Assembly Critical Parameters Accuracy & Precision of the vehicle Ease of use & Enjoying the beverage…
  3. 3. Background: The Team Ayoob Ahmed – Electrical Engineer in Non-Destructive Testing – Hoping to become a Lean/6 Black Belt to enhance test rig design & manufacturing – Loves optimizing for a challenge, especially one consisting of drink deliveries! Amanda Learned – Mechanical Engineer in Aero/Thermo Part Durability – Learning to apply DFSS concepts for proactive durability KPC monitoring in her route to hold a Lean/6 Black Belt title – As a true P&W Engineer, loves to see a gear added into the mix! Osvaldo Colon-Sandoval – Project Engineer in F119 Program - Exhaust System CIPT – Becoming a Lean/6 Black Belt to finally develop a logical & achievable scope, schedule, & cost for the company‟s most important engine program – Just happens to have an inner love for mousetrap powered vehicles!
  4. 4. Background: The Mission A frequent customer of DocFizzix tapped us on the shoulder, due to our love for mousetrap vehicles, optimization of drink delivery, and passion for creative solutions With the challenge in hand, our team spent countless* hours to develop just the right new kit to be marketed through the company‟s website, hobby stores, & educational product distributors Our sponsor desires to grow their market and is looking for a new product which customers, including students, teachers & hobbyists, can buy, build and use to compete in a new competition: “The Milk Run Challenge” * Actually not countless, please see actual schedule in the back-up slides
  5. 5. Customers: Why This New Kit Will Sell They talked… Simple mechanics We listened… - No strings/tangles - A gear driveNo more than a and followed through! - A screw-on break - Simple tools for build day to build, Interchangeable parts maybe even Something fairly - Customizable bodyjust a few hours simple to put - Multiple wheel choices together, but at the use only simple - Repairable same time somewhat mechanics in Easy to use open ended. design… yet make - Breaking independent of it technically drivetrain I‟d like to challenge my interesting.. but - Reliable for multiple uses technical skills… must doable in a day… - Safe to operate be more than just put a Design “Built to win!” couple blocks together. - Delivers large beverages - Consistent & quick - Abides by ground rules
  6. 6. CDOV: The Better Way to Design Since we are Black Belts in training, the first step taken to develop the new kit was to decide on a process to follow: – Concept: linking our product to the market – Design: translating the VOX into creative prototypes – Optimize: Concentrating the design to meet design goals – Verify: Ensuring our product is buildable, reliable, & marketable Our product has the customer in mind, with critical features optimized & verified in order for them to win “The Milk Run Challenge” Our team strongly believes that keeping the definition of our „Customer‟ open from the start and following the CDOV process with this base, has really helped us to create an innovative product that will be marketable, even amongst the many other Doc Fizzix mousetrap powered vehicle options
  7. 7. CDOV: How it Enhanced “Trapped With a Kupholder” During the concept & design phases we generated some great creative ideas to meet the customer‟s need; however, we kept a back-up concept just in case the lead design was overcome by new failure modes; repetitive testing was done to ensure “the gear” would be user-friendly & reliable At times, there may have been some “heated discussions” in regards to „what next?‟ OK, to verify, we need a GR&R with 3 users, 3 cars, and total distance No, we need the 3 cars, breaking, & wheels… … But “CDOV” pulled us together and kept us moving forward, which reduced R&D costs associated in the new kit & let us meet customer needs & desires Pull up our Critical Parameters to refer to, to answer this one!
  8. 8. Project Plan:Actual hours spent on the project…Schedule Analysis for “Trapped With a Kupholder”Phase Schedule Actuals VarianceConcept 36.5 31 5.5Design 27 37 -10Optimize 37 50 -13Verify 47.5 46 1.5 180Totals 148 164 -16 160 140200 120 100150 80 60100 40 50 20 0 0 Concept Design Optimize Verify Totals Concept Design Optimize Verify CUM Schedule CUM Actuals Schedule Actuals
  9. 9. Packaging & Assembly:Getting StartedItems in your package Standard TWAK 57 individual pieces Kit contains 57 individual A Manual for assembly & operation Pieces Delivered in a priority mail small flat-rate shipping containerTools required for assembly Wood glue & Super glue 2 adjustable clamps Pliers Wire cutters A 5/8” drill bit Ruler
  10. 10. Packaging & Assembly:BOM, Part and “TWAK” Kit CostSale Price per kit @ $14.89 with a Profit Margin of 30% Description Size Location Qty Cost Total Cost Platform 3"x12"x.25" www.hobbylinc.com 1 $ 0.76 $ 0.76 Siderail 1.25"x12"x.25" www.hobbylinc.com 2 $ 0.65 $ 1.30 Front/Rear Axles 0.25" Brass www.hobbylinc.com 2 $ 0.39 $ 0.78 Metal Washers 4 x0.25"ID www.appliancepartspros.com 4 $ 0.10 $ 0.40 Chasis Plastic Washers 12x0.25"ID www.grainger.com 22 $ 0.04 $ 0.88 Mouse trap standard www.acehardware.com 1 $ 0.60 $ 0.60 Axle Gear Plastic www.SmallParts.com 1 $ 0.80 $ 0.80 Main Drivetrain Plastic www.SmallParts.com 1 $ 1.30 $ 1.30 Main Gear Brackets Plastic www.SmallParts.com 2 $ 0.25 $ 0.50 Drive Shaft 0.25"x 3" Brass www.hobbylinc.com 1 $ 0.39 $ 0.39 Drivetrain Gear Support Balsa 0.25" Square www.hobbylinc.com 1 $ 0.10 $ 0.10 Threaded Rod 1.25" of 8-32 Threaded Rod www.hardwareandtools.com 1 $ 0.05 $ 0.05 Wing nut 8-32 Wing Nut www.grainger.com 1 $ 0.40 $ 0.40 Balsa wood .125" x0.5"x3" www.hobbylinc.com 1 $ 0.10 $ 0.10 Braking System Balsa Rod 0.25" Rod www.hobbylinc.com 1 $ 0.02 $ 0.02 Cds 6 Standard CDs www.meritline.com 6 $ 0.12 $ 0.72 Empty Roll of tape www.rhinomart.com 1 $ 0.87 $ 0.87 Rubber Gromet 0.25" to CD ID www.docfizzix.com 4 $ 0.30 $ 1.20Wheels & Cupholders Balloons Assorted 6 www.amazon.com 4 $ 0.07 $ 0.28 Totals 57 $ 11.45 Sales Price per kit @ a Profit Margin of 30% $ 14.89
  11. 11. Packaging & Assembly:Simple Steps for a Fun Project This kit comes with clear, illustrated, step-by-step instructions for assembly and operation – Getting Started (1-3) – Building the frame (4-14) – Assembling the large gear (15-22) – Modifying the Mousetrap (23-29) – Fabricating the chassis (30-35) – Making Customizations (36) – Adding Wheels & a Cup Holder (37-46) – Affixing the break (47-52) – Using the Vehicle
  12. 12. Packaging & Assembly:The Final Product Drawing with critical features & dimensions – All critical features, like plastic gears and mouse trap, will be provided to the customer as part of the package. – Key assembly dimensions (drawing) will be provided to the customer on the assembly instructions to ensure proper performance of the car.
  13. 13. Critical Parameters:Design Score CardDesign score card documenting minimum of 3 system level Critical Parameters Critical Parameters Units LSL Target USL Mean Std Dev Cp Cpk Stop Distance (+/- 1 ft of desired distance) in -12 0 12 -0.61 2.13 1.87 1.78 Ultimate Distance (Able to move car min 16 ft.) ft 16 20 24 17.89 0.49 2.73 1.29 Straight Drive "Alignment" (+/- 1 ft after 16 ft.) in -12 0 12 2.97 5.79 1.18 0.97 Able to move 2 gal to dist of 16 ft in less than 30 min min 0 15 30 14.81 5.36 1.11 1.09 ˆ USL LSL Cp ˆ Min USL x , x LSL C pk 6ˆ 3ˆ 3ˆ
  14. 14. Critical Parameters:Capability Growth Index (CGI)• A CGI completed to account for overall subsystems(braking, stop, distance, time) and target Cp = 2• Cpi = min(Cp, 2) n 100 C p iCGI (%) i 1 n 2CGI (%) = 100/4*((1.87/2)+(2/2)+(1.18/2)+(1.11/2))CGI (%) = 77.0%
  15. 15. Accuracy & Precision:Design Validation Cpk‟s for the highest priority critical parameters, etc… – Optimized weight capability was set at… 32oz.  Distance traveled > 16ft… 18 ft.  Braking capability ± 12” … ± 2” from target.  Alignment capability ± 12”… ± 4” from axis.  Competition Time < 30min… 15 minutes.
  16. 16. Accuracy & Precision:Validation of All Design Requirements Process Capability of Distance Traveled (using 95.0% confidence) Distance: LSL USL P rocess Data WithinLS L 16 Ov erall Cpk of 1.29Target *USL 24S ample M ean 17.8906 P otential (Within) C apability Cp 2.73 Cp of 2.73S ample N 16 Low er C L 1.77S tDev (Within) 0.487589 U pper C L 3.70S tDev (O v erall) 0.598392 C PL 1.29 C PU 4.18 Overall Performance: C pk 1.29 Low er C L 0.80 0.08% total population to U pper C L 1.78 O v erall C apability be out of Limits Pp 2.23 Low er CL 1.44 U pper CL 3.02 PPL 1.05 PPU 3.40 16.25 17.50 18.75 20.00 21.25 22.50 23.75 P pk 1.05O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.64 % < LS L 0.00 % < LS L 0.01 % < LS L 0.08 U pper CL 1.46 % > U S L 0.00 % > U S L 0.00 % > U S L 0.00 C pm * % Total 0.00 % Total 0.01 % Total 0.08 Low er CL *
  17. 17. Accuracy & Precision:Validation of All Design Requirements Process Capability of Stop Distance (using 95.0% confidence) LSL USL Stopping : P rocess Data WithinLS L -12 Ov erallTargetUSL * 12 P otential (Within) C apability Cpk of 1.78 Cp 1.87S ample M ean -0.611111S ample N 18 Low er C L 1.25 Cp of 1.87S tDev (Within) 2.13809 U pper C L 2.49S tDev (O v erall) 3.07052 C PL 1.78 C PU 1.97 C pk 1.78 Low er C L 1.16 Overall Performance: U pper C L 2.39 0.01% total population to O v erall C apability Pp 1.30 be out of Limits Low er CL 0.87 U pper CL 1.74 PPL 1.24 PPU 1.37 -12 -8 -4 0 4 8 12 P pk 1.24O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.79 % < LS L 0.00 % < LS L 0.00 % < LS L 0.01 U pper CL 1.68 % > U S L 0.00 % > U S L 0.00 % > U S L 0.00 C pm * % Total 0.00 % Total 0.00 % Total 0.01 Low er CL *
  18. 18. Accuracy & Precision:Validation of All Design Requirements Process Capability of Alignment P rocess D ata LSL USL Within ALIGNMENT:LS L -12 Ov erallTarget *USLS ample M ean 12 2.13889 P otential (Within) C apability Cp 1.18 CPK of 0.97 C P L 1.39S ample NS tDev (Within) 18 3.38965 C P U 0.97 CP of 1.18S tDev (O v erall) 3.35106 C pk 0.97 O v erall C apability Pp 1.19 PPL 1.41 Overall Performance: PPU 0.98 P pk 0.98 0.16% total population to C pm * be out of Limits -12 -8 -4 0 4 8 12O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance % < LS L 0.00 % < LS L 0.00 % < LS L 0.00 % > U S L 0.00 % > U S L 0.18 % > U S L 0.16 % Total 0.00 % Total 0.18 % Total 0.16
  19. 19. Accuracy & Precision:Validation of All Design Requirements Process Capability of Time_Total (using 95.0% confidence) Time: LSL USL P rocess D ata WithinLS L 0 Ov erall CPK of 1.09Target *USL 30S ample M ean 15.3467 P otential (Within) C apability Cp 1.11 CP of 1.11S ample N 20 Low er C L 0.76S tDev (Within) 4.49173 U pper C L 1.46S tDev (O v erall) 5.24807 C PL 1.14 C PU 1.09 Overall Performance: C pk 1.09 Low er C L 0.71 0.43% total population to U pper C L 1.46 O v erall C apability be out of Limits Pp 0.95 Low er CL 0.65 U pper CL 1.25 PPL 0.97 PPU 0.93 0 5 10 15 20 25 30 P pk 0.93O bserv ed P erformance E xp. Within P erformance E xp. O v erall P erformance Low er CL 0.60 % < LS L 0.00 % < LS L 0.03 % < LS L 0.17 U pper CL 1.26 % > U S L 0.00 % > U S L 0.06 % > U S L 0.26 C pm * % Total 0.00 % Total 0.09 % Total 0.43 Low er CL *
  20. 20. Ease of Use:Operation & Delivery In-person demo to be performed.
  21. 21. Ease of Use:Customization Deliver the beverage of your choice – Cup-holder fits all standard sizes – Steady enough to drive even with a Double Big Gulp! – Easily swap out cup-holder for “small glasses” Wheels easily swap out – Add balloon-wrap Bushing simply – Add rubber band wrap pops off of axel & – Double-up the CD‟s out of CD center Frame can be customized – Paint it with markers, crayons, pens, or paint – Add your logo! – Lengthen or shorten or make cut-outs in frame as desired
  22. 22. Ease of Use:Enjoying the Beverages For just $14.89 + $4.95 S&H you too could be winning “The Milk Run Challenge” Wow your friends & party guests! Draw a crowd into your business $$ Let students have fun & learn at the same time …Then you can relax and enjoy the beverages too!
  23. 23. Back-Up Slides GOOD BAD UGLY
  24. 24. Phase 4 RequirementsAction from Optimize Phase Updated design score card including Transfer Functions, predicted Capabilities and Capability Growth Index (CGI) for minimum of 3 system level Critical ParametersVerify Drawing with critical features and dimensions Satisfaction of VOC, both customer and stakeholder needs Validation of all design requirements generated in Concept phase BOM and parts cost Description of assembly, tools and process Demonstrate operating procedure Design Validation – Cpk for highest priority critical parameters Updated Design score card Critical Parameters, Capability Growth Index (CGI) Specific details: How DFSS tools and CDOV process influenced the development of your product design Project Plan (actual hours spent on Concept, Design, Optimize and Verify phases) Three working prototypes, materials and instructions for in-class competition. Verify phase gate scorecard
  25. 25. Verify Phase Scorecard
  26. 26. A Missing Anecdote from the Optimize Phase Report: The Original Cup Holder was to carry 2 beverage containers, on either side of chassis Market research was completed to determine standard cup holder sizes & requirements: 4.25” & 3.75” diameter should fit most all cups (except “Nalgene” bottle type) As the design evolved, we were able to optimize the design by carrying more beverage in a single cup holder, in the center of the chassis Testing & analysis showed small cups needed no further support than what the 4.75” standard cup-holder delivered: stability was consistent with repetitive testing A cylinder provides simpler assembly than a 4- or 3-sided design, which requires multiple pieces and more locations for failure (FMEA) Design 1: Design 2a: Design 2b:
  27. 27. Packaging & Assembly:The Final Product Drawing with critical features & dimensions
  28. 28. Packaging & Assembly:The Final Product Drawing with critical features & dimensions
  29. 29. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Distance Traveled I Chart Capability Histogram LSL USL UCL=19.353 19 S pecificationsIndividual Value LS L 16 _ 18 X=17.891 U S L 24 17 LCL=16.428 1 3 5 7 9 11 13 15 16.25 17.50 18.75 20.00 21.25 22.50 23.75 Moving Range Chart Normal Prob Plot 2 A D: 0.855, P : 0.021 UCL=1.797 Moving Range 1 __ MR=0.55 0 LCL=0 1 3 5 7 9 11 13 15 16 18 20 Last 16 Observations Capability Plot 19 Within Within O v erall S tDev 0.487589 S tDev 0.598392Values 18 Cp 2.73 Pp 2.23 O v erall C pk 1.29 P pk 1.05 17 C pm * S pecs 5 10 15 Observation
  30. 30. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Alignment_1_1 Xbar Chart Capability Histogram LSL USL UCL=9.19 S pecifications Sample Mean 6 _ _ LS L -12 X=2.14 U S L 12 0 LCL=-4.91 -6 1 2 3 4 5 6 7 8 9 -12 -8 -4 0 4 8 12 R Chart Normal Prob Plot UCL=12.25 A D: 0.328, P : 0.489Sample Range 10 5 _ R=3.75 0 LCL=0 1 2 3 4 5 6 7 8 9 -10 0 10 Last 9 Subgroups Capability Plot Within Within O v erall 5 S tDev 3.32484 S tDev 3.35106 Values Cp 1.2 Pp 1.19 0 O v erall C pk 0.99 P pk 0.98 C pm * -5 S pecs 2 4 6 8 Sample
  31. 31. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Stop Distance Xbar Chart Capability Histogram 1 5 LSL USL UCL=4.35 S pecificationsSample Mean _ LS L -12 0 _ X=-0.61 U S L 12 -5 LCL=-5.57 1 2 3 4 5 6 7 8 9 -12 -8 -4 0 4 8 12 R Chart Normal Prob Plot UCL=8.613 A D: 0.781, P : 0.034 8 Sample Range 4 _ R=2.636 0 LCL=0 1 2 3 4 5 6 7 8 9 -10 0 10 Last 9 Subgroups Capability Plot Within Within O v erall 5 S tDev 2.33692 S tDev 3.07052Values Cp 1.71 Pp 1.3 O v erall 0 C pk 1.62 P pk 1.24 C pm * -5 S pecs 2 4 6 8 Sample
  32. 32. Accuracy & Precision:Validation of All Design Requirements Process Capability Sixpack of Time_Total I Chart Capability Histogram LSL USL 30 UCL=30.90 S pecificationsIndividual Value LS L 0 _ 15 X=14.81 U S L 30 0 LCL=-1.27 1 3 5 7 9 11 13 15 17 19 0 5 10 15 20 25 30 Moving Range Chart Normal Prob Plot 20 UCL=19.76 A D: 0.179, P : 0.905Moving Range 10 __ MR=6.05 0 LCL=0 1 3 5 7 9 11 13 15 17 19 0 10 20 30 Last 20 Observations Capability Plot Within Within O v erall 20 S tD ev 5.3627 S tDev 6.03241Values Cp 0.93 Pp 0.83 O v erall 10 C pk 0.92 P pk 0.82 C pm * 0 S pecs 5 10 15 20 Observation
  33. 33. “Trapped With A Kupholder” Build InstructionsParts, Assembly, & Usage Manual for your new mousetrap powered vehicle* *Proprietary information of Ayoob Ahmed, Osvaldo Colon- Sandoval & Amanda Learned
  34. 34. What is Standard TWAK Kitincluded in contains 57 individualyour kit Pieces2 chassis side rails (balsa wood sheet)2 chassis spacers (balsa wood blocks) 1 large gear with spokes (plastic)1 chassis platform (balsa wood sheet) 1 small gear (plastic)4 reinforcing blocks (balsa wood rectangles) 1 bent metal tube1 break arm (thin wood piece) 2 wheel axels (long metal tubes)1 round wooden rod 1 gear axel (short square metal rod)4 standard CDs 1 threaded rod (round metal)2 balloons (std 8”, optional for assembly) 2 gear mounting feet (plastic)1 cardboard flattened roll (packing tape 20 spacers (plastic disks)size) 4 bushings (rubber)1 mousetrap (standard “Victoria” brand) 4 washers (optional for assembly)1 wing nut
  35. 35. Assembly steps 1-3: Getting Started1. Lay out the entire contents of your kit2. Check that all of the parts listed in the “What is Included in Your Kit” section are accounted for  If any parts are missing, please visit our website and submit a communication; please include your kit bar code and the name of the specific missing kit piece(s)3. Gather the required equipment needed for assembly, not included in your kit: a. Wood glue b. 2 adjustable clamps c. Pliers d. Wire cutters e. A 5/8” drill bit f. Ruler g. Super glue h. Cup of your choice to carry liquid
  36. 36. Steps 4-14: Building the Frame4. Insert a wheel axel through one hole 9. Slide one end of the 2nd wheel axel of each chassis side rail through the hole at the other end of5. Stand the side rails on their edges, as a chassis side rail shown and align short ends with a 10. When the inserted end is in the secure straight edge or T-square middle of the 2 side rails, slide the6. Place a chassis spacer between the small gear onto this end of the axel two bars, up against the straight edge 11. Continue pushing axel through the and ensure it is not touching the axel last chassis side rail pre-drilled hole7. Glue the chassis spacer ends to the 12. Push the small gear towards the inner side of each chassis side middle of the assembly, until the rail, with the wood glue back axel looks similar to that shown8. Secure a clamp on the outer edges of in the picture the chassis side rails, aligned with the 13. Follow steps 5. through 8. again, for glued intersections this end of the assembly 14. Set Frame aside to let the wood glue 5. 12 dry . 8. 14 .
  37. 37. Steps 15-22: Assembling the Large Gear15. Slide the gear axel through a gear 19. Inject glue in-between the gear mounting foot, then 3spacer, then the axel and the hole of the mounting center hole of the large gear, then 2 foot, on both sides of the assembly more spacers, and finally the 2nd gear mounting foot, as shown in the 15 picture. This is the large gear . assembly. 20. Glue a reinforcing block adjacent to each flat outer edge of the mounting foot, such that the long side of each block aligns along the long edge of the chassis platform16. Align the large gear assembly in the upper surface, as shown; ensure middle of the rectangular hole of the the inner edge of each block is chassis platform flush with the edge of the mounting foot 1917. Place the foot adjacent to the outer “nub” of the gear‟s center hole, on the 21. Repeat step 18. to .secure the wide surface of the platform; and other mounting foot place the opposite foot on the thinner surface of the platform, as shown 1618. With the large gear assembly aligned . 17 centered in the platform‟s cutout, & . glue the flat surface of each mounting 22. Set chassis platform assembly foot to the surface of the chassis aside to let the wood glue dry platform
  38. 38. Steps 23-29: Modifying the Mousetrap23. Using pliers, remove the mousetrap‟s 26. Place the mousetrap on the locking bar top of the chassis24. Using wire Cutters, cut the platform, adjacent to the lever/snapper arm of the standard mounting foot for the large mousetrap at the location marked in gear, on the wider side of green on the mousetrap the platform, as shown; supplied, approximately ½ across the ensure the lever arm is horizontal portion pointing to the shorter end of the chasses25. Using pliers, bend the remaining arm 23 length ~90-degrees, toward the . outside, as shown 27. Align the center of the 25 spring on the . mousetrap, with the center of rotation for the large gear; as such, the bent arm 24 length should now be . almost (but just shy of) touching the gear‟s surface; mark the front & back of the mousetrap 28. Once the location is defined, glue the bottom of the mousetrap to the top of the chassis platform; remember to use plenty of glue! 29. Insert the bent metal tube
  39. 39. Steps 30-35: Fabricating the Chassis30. Once the glue on the frame and 33. Place glue on the outer edges of large gear assembly on the chassis the chassis platform then re-align platform are dry, place the assembly in-between the side rails, using platform between the 2 chasses side the marks from step 32; slight rails; ensure the large gear and small forward/aft shifts may be made to gear are at the same ends of the ensure a good chasses 34. Secure a clamp on the outer31. Shift the platform forward and aft, edges of the chassis side until the teeth of the two gears meet; rails, towards the front of the the small gear may have to be shifted platform & then secure a second along the wheel axel clamp towards the rear32. Once the assembly is placed such 35. Set chassis assembly aside to let that the teeth of the two gears 33 the wood glue dry intersect and are able to rotate and . 31 catch on each other, mark the . location of the front & back edges of the chassis platform on the side rails; 4 marks should be made it total 32 . 35 .
  40. 40. Step 36: Making Customizations Balloons are provided, if it is  Washers are provided, these may desirable to have additional friction be used to reduce friction between on your wheels – and if you want to your axel and the chassis add some fun color  Super-glue the washer to the  Slice the balloon such that just the outside edge of the chassis middle is left, creating a thick rail, such that the axel hole in the rubber-band shape wood is visible through the washer  Force balloon band around the  the use of washers will minimize outside lip of the CDs the contact surfaces – and they  These may be added to none, give your car a nice finished look some, or all wheels; or you may  Another suggested alternative (not even put multiple CDs underneath included) is adding ball bearings to the balloon wraps really minimize any losses due to wheel friction Another easy suggestion for  And of course, Don‟t forget your customization is to wrap the cup license plate! holder with ribbon or any light- weight decorative material of your choice
  41. 41. Steps 37-46: Adding Wheels & Cup Holder37. Insert a rubber grommet into the 42. Once the large gear is centered on center of each of the 4 CDs the small one and there is enough38. On the wheel axel away from the room on either edge for the gears, insert a few spacers onto the wheels, glue the small gear to the end of the axel and then “cap” it by rear axel pushing the axel end through the now rubber center of the CD 43. Take the flattened cardboard strip39. Repeat step 38, using the opposite and curl it into a loop, such that it end of the same axel; this is now the once again looks like the center of front wheel assembly 39 . a tape roll 44. Apply glue along the seem adjoining the two ends of the loop; this is now your cup holder 45. Place the cup holder on the top surface of the chassis platform, in40. Attach the last two wheels to the 2nd the middle of the front wheel wheel axel to form the rear wheel assembly assembly in a similar manner as the front wheel assembly 46. Ensure the cup holder edges are not in contact with any moving41. Once the rear wheels are attached parts of the vehicle and then 41 to it, the wheel axel or the small gear . secure the cup holder on the 40 in the middle of it, may need to be . chassis with glue along the bottom shifted; spacers may need to be edge added/removed to either side to adjust
  42. 42. Steps 47-52: Affixing the Break47. Using pliers, Insert the threaded 50. Insert the round wooden rod into rod into the end of the hollow axel this whole and glue at the seem in the front wheel assembly, on between the rod and the chassis 50 the side of the vehicle opposite of . the large gear side; turn and tap in to ensure a tight fit48. Next, measure 3 inches from the threaded rod (or the center of the CD), in the direction of the rear 51. Glue one wing of the wing nut wheel assembly and make a onto “the break” (the small thin mark; keep it at approximately strip of wood provided) and let the same vertical height as the dry axel 47 . 52. Once the wooden rod and strip are stuck in place, the wing nut can be screwed onto the threaded rod sticking out of the49. Using the drill bit, manually turn front axel; note when spun, the the bit by hand into the soft balsa 49 52 rod should come into contact with wood at the marked location, until. the break . a whole is made through the side rail
  43. 43. Using the Vehicle Once all of the assembly steps have been followed and all glued joints are dry (we recommend over-night), your new mousetrap powered vehicle is ready to be tested out Drive Spin wheel Release train forward to gear to see starting engage it zoom location spring forward To set the break up, tighten the wing nut Feel free to by spinning the wheel, until the break engages, then untwist the wing nut and deliver the count the number of turns the CD makes beverage of Translate the # of turns into feet of travel your choice, up with our translation sheet provided to 44oz
  44. 44. Reference Sheet # Turns 0.8 1.6 2.4 3.2 4.0 4.9 5.7 6.5 7.3 8.1 8.9 9.7 10.5 11.3 12.1 12.9 Dist (ft) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16Use 32 Oz for 16‟ RunsFor 12‟ or Shorter Runs use 40 OzThe Good:•¼ Turn for 11‟ Empty•1/3 Turn for 16‟ Empty•2nd Spoke for 11‟ Loaded•¼ Turn for 6‟ LoadedThe Bad:•Start Bad with offset of 1‟ to the left for 16‟•2nd Spoke for 11‟ EmptyThe Bad & The Ugly:•Need Full power when Loaded

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