Design Project #1 – The Sure Stopper SE

Engineering 10B – Course # 001

D.I.M.D. Engineering Group

Denise Fordham, Ivan Chiu, Michael Spangenthal, Daryl Shee
City College of San Francisco, San Francisco, CA
October 10, 2006

Table of Contents
List of Figures ----------------------------------------------------------- 2
List of Tables ------------------------------------------------------------ 2
Abstract ------------------------------------------------------------------ 3
Introduction -------------------------------------------------------------- 4
Procedures ---------------------------------------------------------------- 5
Results --------------------------------------------------------------------10
Discussion --------------------------------------------------------------- 11
Conclusions --------------------------------------------------------------11
Appendix A --------------------------------------------------------------12
Appendix B -------------------------------------------------------------- 13
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List of Figures
Figure 1: Scheduling chart for design project #1.---------------------------------------------------- 5
Figure 2: Initial sketches of first ideas. --------------------------------------------------------------- 6
Figure 3: Assembling the Sure Stopper -------------------------------------------------------------- 6
Figure 4: Version 1 of the Sure Stopper -------------------------------------------------------------- 7
Figure 5: First tests of the Sure Stopper -------------------------------------------------------------- 7
Figure 6: Version 2 of the Sure Stopper -------------------------------------------------------------- 8
Figure 7: Mockup of a “Friction Inducer” for the Sure Stopper ----------------------------------- 8
Figure 8: Drawings for the “Friction Inducer” for the Sure Stopper ------------------------------ 9
Figure 9: Version 3 of the Sure Stopper with “Friction Inducer” ready for testing ------------- 9
Figure 10: Mission accomplished – the Sure Stopper SE stops on the mark -------------------- 10
Figure 11: Detail drawing of spindle mechanism --------------------------------------------------- 12

List of Tables

Table 1: Tracking and Stopping Performance Week of September 30 - Test at School ------- 10
Table 2: Performance of Car Components ----------------------------------------------------------- 13
Table 3: Tracking and Stopping Performance Week of September 16 --------------------------- 13
Table 4: Tracking and Stopping Performance Week of September 23 --------------------------- 14
Table 5: The Sure Stopper SE Materials List -------------------------------------------------------- 14
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Abstract
Our mission is to design and manufacture an automatic car-stopping device that activates
when the vehicle becomes a runaway car. This report details the design, fabrication and testing
of the Sure Stopper SE, a car designed to stop automatically at any configured distance. This
design can be applied to the vehicles on the road today and incorporated into the manufacturing
of vehicles for tomorrow to insure pedestrian and driver safety.
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Introduction
Runaway cars are a deadly problem in San Francisco. They are responsible for injuries
and death and create property damage that can exceed hundreds of thousands of dollars every
year. While it is entirely possible for someone to stop a rolling car while sitting inside the
vehicle, there is very little one can do to stop a runaway car when outside of the vehicle.
The focus of our report is to present a device that will automatically stop a runaway car
by sensing there is no driver or passenger inside and thereby locking the rear axle and wheels,
stopping the car before it can cause damage and harm.
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The Sure Stopper SE

Procedures

The design group begins by brainstorming ideas. The group’s focus is to develop a
stopping mechanism that can be incorporated into a car design to prevent it from rolling out of
control. Our brainstorming generates the idea to create a device that stops the car once it senses
movement of the wheels. After a specified number of revolutions of the wheel the mechanism
locks the axle preventing the car from further rolling.
The group identifies tasks and develops a schedule to help meet our deadline (Figure 1).

Engineering 10B - 1st design Project - Runaway Car!

September October
12 thru 18 19 thru 25 26 thru 2 3 thru 9 10
Brainstorm Session

Web and Lit. Search

Prototypes

Test Prototypes

Redesign and Test Final

Drawings

Write Power Point Presentation

Write Paper

Competition & Presentation

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Figure 1. Scheduling chart for design project #1.

A prototype design is constructed incorporating some of our initial ideas (Figures 2 and
3). The stopping mechanism is a string wound around a spindle assembly that is attached to the
back of the car. The string is cut to a specific length and secured to the rear axle at the other end.
When the car rolls it can only travel a certain distance before the string stops the car. For a
detailed schematic of the spindle assembly see Appendix A Figure 11.

Figure 2. Initial sketches of first ideas

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Figure 3. Assembling the Sure Stopper

With prototype in hand testing begins. We note the flaws and strengths of the design.
Over the next three weeks we make modifications to maximize its performance.

Figure 4. Version 1 of the Sure Stopper

Special consideration is given to using strong yet lightweight materials. First tests involve
the use of wooden wheels with a cloth string as the stopping element. The body is constructed
out of Gatorboard, a lightweight yet strong material made out of paper and foam. Gatorboard
allows us to easily attach car components mechanically or by gluing (Figure 4).
From our test results we immediately see that the wood wheels do not give us the traction
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needed to control the car during stopping (Figure 5). The cloth string also poses a challenge by
not consistently performing well during the tests. For detailed results see Appendix B Table 2
and 3.

Figure 5. First tests of the Sure Stopper

The wood wheels are replaced with wheels with rubber tires and the cloth string is
replaced with 25 lb test monofilament (Figure 6). Tests are then repeated.

Figure 6. Version 2 of the Sure Stopper

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Solving these problems allows us to identify the next problem, which is controlling the
momentum of the car while it is rolling down the incline. If the car is allowed to pick up speed,
stopping performance drops. See Appendix B Table 4. Controlling the speed of the car is now
the major challenge. A mock-up (Figure 7) and drawings (Figure 8) are created to address this
problem and modifications ensue.

Figure 7. Mockup of a “Friction Inducer” for the Sure Stopper

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Figure 9. Version 3 of the Sure Stopper with

“Friction Inducer” ready for testing.

Figure 8. Drawings for the “Friction Inducer” for the

Sure Stopper

The final modifications include addition of a back panel called the “Friction inducer” that
drops down and engages the road to slow the car’s momentum (Figure 9). Strengthening and
reinforcing the back end of the car with aluminum is necessary to accommodate the
modifications. For a complete materials list see Appendix B Table 5.
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Results

With these modifications and the balancing

of weight we are able to successfully control
momentum and stop the car exactly at our
predetermined distances of 12 feet, 24 feet
and 36 feet (Figure 10).

Figure 10. Mission accomplished – the Sure Stopper

SE stops on the mark.

Table 1 below shows the results of our testing in detail and efforts to fine-tune the
stopping mechanism to achieve the desired results.

Table 1. Tracking and Stopping Performance Week of September 30 – Test at School

Modification Trials Notes
-added friction inducer 34in string: 278in, 308in, 256in, 281in, -8oz weight at the back dragging
320in, 307in
-big and 8oz weight in front, metal plate 34in string: 309in, 314in -Not consistent
at back
-32in string 32in string: 307in, 282in, 296in, 267in -Not consistent
-Lengthen string .5in 32in string: 267in, 284in, 285in, 287in, -Let the friction inducer catch our hand
285in, 288in when releasing
-Very consistent
-Our best result
-51in string 51in string: 420in, 367in, 413in, 384in, -Careful with winding
400in
-lengthen string 1 in 52in string: 450in, 420in, 429.5in, -Careful with the angle
441in, 436.5in
-shorten string.5in 51.5in string: 432in, 453in, 441in -Take one rubber washer off
-shorten string .5in 51in string: 445in, 441in -Consistent
-shorten string .5 in 50.5in string: 442in, 435.5in, 453in, -Consistent
445in
-shorten string .5 in 50in string: 445in, 419in, 453in, 431in, -Consistent
439.5in, 448.5in
-shorten string .5 in 49.5in string: 435in, 437in, 434in, -Faster speed longer distance
435in, 429.5in, 415in, 437.5in, 437.5in -Slower speed shorter distance
-shorten string .25 in 49.25in string: 431.75in, 432in, -Best result
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431.5in, 432in -Start angle at 2.5 in

Discussion

Controlling momentum to accurately stop the car became the biggest obstacle. Adding
the friction inducer component that slows down the car’s speed helped us to achieve positive
results. Improvements to this design would include the ability to more accurately control both the
force of friction applied and its timing.

Conclusions

• The heavier the car the faster the momentum especially over longer distances.
• On steeper inclines the car gains more momentum and becomes harder to control.
• At faster speeds more stress is put on the stopping components.
• It is important to control speed first and then control stopping.
• The design and maintenance of the spindle/braking system is critical for the consistency
of the stopping power of the car.
• Application of friction is an important component to controlling and stopping the car.
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Appendix A

Figure 11. Detail drawing of spindle mechanism

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Appendix B

Table 2. Performance of Car Components

Material Effect Good Bad
Wood wheel Skid too much Easy to make, cheap little friction with
concrete ground
Rubber wheel Produce good friction with Good friction none
concrete ground
Cloth string (Thin) Wind up very good, very Wind up good on the axle Easy to break
consistent on the runs Stretch a lot
Cloth string (medium) Wind up good and tougher wind up good on the axle Tends to break
than thin Cloth string
Cloth string (Thick) Not consistent run Tough string Did not wind up good
Monofilament String Produce consistent runs Tough string none
(Thin)
Monofilament String Not consistent run Tough string Bad winding
(medium)
Monofilament String Not consistent run Tough string Winding up not good
(thick)
Weight (2.5lb) Make the test car heavier, none Too heavy, easily go
thus more skid on the hill over 3 lb
Weight (8ounces) Good additional weight Make our test car just pass Not enough of these to
added to fulfill the weight 3 lb mark and not over too make up to 3 lb
requirement much, easy to handle
Weight (1.0lb) Weight requirement Good combination with 8 Not enough of these to
ounces weight make up to 3 lb
Rubber Washers Hold string, slow the car Easy to install and take none
apart
1/4” wood dowel Give control on the string Easy to take apart and none
install

Table 3. Tracking and Stopping Performance Week of September 16

Modification Trials Notes
Cloth string, rubber tire back, wood 24in string: 181 in -Skid
tire front, 19in and 24in cloth string 19 in string: 147.5in, 150in, -Not consistent result

-2lb Weight added
-18 in Monofilament string
-18 in thick cloth string
-18in thick cloth string, retighten the
knot
-18in thick cloth string, retighten the
knot
Rubber tire front and back, screw
string on to axle, recalculated string
19.65in
19in string: 149.5in, 135in, 133.5in, -Tested on flat surface
140in -A little push
18in string: 140in -String did not wrap up nicely
18in string: 121 in, 121in, 120in, -Knot got loose so we get more
131in distance out of the string
18in string: 114in, 119in -Skid a little
-Not consistent
18in string: 135.5in, 133.5in, 138in -Skid
-Not consistent
19.65in string: 127, 128.75in, 128in, -Rubber tire produce good result
129.25in, 133.5in, 130in, 136in,
135in, 132in

Table 4. Tracking and Stopping Performance Week of September 23
Modification
Test at school:
-weighted 2lb 1.9 oz
2.5lb weight, fasten tires, medium
cloth string, 19in string
-adjust the wood dowel to bring
closer
-adjust the wood dowel farther apart
-new big cloth string 20.125in
-new medium monofilament string
Table 5. The Sure Stopper SE Materials List
1/2” Gatorboard
1/2” MDF
1/4” MDF
1/4” wood dowel
5/16” Ø Brass Tubing
1/2” Brass Flat Stock
1/8” Brass Round Rod
1 1/4” Brass Hinges
1/8” Aluminum Flat Stock
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Trials Notes
19.65in string: 162in, 141in, 139in, -Skid
144in, 139in the tire got loose
19in string: 114in, 118.6in, 121.5in, -Winding rule: clockwise, keep to
124in, 122.5in, 126.5in, 118.25in one side neatly
-Calculate string length
19in string: 107in, 103.5in -Shorter distance
19in string: 135.5in, 135.5in, 136in -Longer distance
20.125in string: 142in, 140in, -Adjust the string
138.5in
17in string: 103.25in, 99.5in, 144in, -Bring the dowel closer so the string
142in, 142.5in, 141.5in, 141.5in, does not get loose
142.5in, 143.25in, 143in, 142.75in
2” Ethafoam
4 Rubber Tires
25 lb. test Monofilament
Brass Washers
Rubber Washers
#6 x 1/4” Sheet Metal Screws
#6 x 32 Machine Screws and Nuts
2 1/2 lb. Steel Weight
3/16 x 1 1/2” Steel Weight