i'm matt schultz, i'm one of the advisorsfor the club and i'm a teacher. i'm alec devlin, i'm a student from lakeview. and i'm eric sutkay, also an adviser and teacher at lakeview. we're in kenosha, wisconsin. about 10 minutes north of the border ofillinois so we're going to talk a little bit about what we do as a club just togive you skype kind of some background about what energy-efficient vehicles arein the state of wisconsin and how we can articulate that into our curriculum withour high school students we're going to talk about the hubadapter really that i think gained four
moks notice i'm going to talk aboutother things we do with the tormach sand in the classrooms i and eric smith startby talking a little bit about our high school and about the partnership in therelationship we have with gateway technical college so late few partnerswith gateway technical college we have dual credits students a choice highschool we are part of the ocean unified school district so we are public highschool we offer for different tracks one of those tracks is automatedmanufacturing we also have an engineering track and that's where a lotof where old man teach classes matter view of information technology alsoapply to medical engineering i did a lot
of being a freshman and sophomoreclasses students being knowledge on manual machining and then as juniors andseniors they take articulated classes track at the gateway and the school isthe same so we share the building to rotate the their regular classes thereas well as their classes throughout the thing a lot of the kids graduated withtwo paths with associates degree by the time there graduated two years and then go back inthe shop for dresses so i'm nice things like eric said having that partnershipwith gateway when we got the storm ox we split the bill half-and-half so we areinitially looking for just delayed at
the time but because tormach is such anaffordable great price we were able to get both laid and the middle for themoney that was allocated from both the university and from our from our schoolso we kinda kinda worked out well in our favor any questions about the schoolwhat we do so what is smb1 supermileage vehicle i'msuper manage vehicles are basically energy-efficient vehicles as we broughtone in here mostly people think that we're redoing real vehicles and makingthose energy efficient and naturally not the case where the students aredesigning and building these from the chassis up ought to get optimal fuelmileage we have three different types of
cars this year we have built our firsthybrid so we used 250 cc or 49cc i kicker motor pit bike from a pit bike anelectric motor to team up together get our first hybrid alec was on the seniorbuilding with that and he can talk a little more about that too when he'stalking about is some adapter we built to gas cars combustion engine gas cars those are getting around 300 miles pergallon and we built to electric cars i'm in this car right here that you'relooking at here this is the two-time while i should say to time it's the bestelectric car in the state as of this year we want both events at fox valleytech college and at road america race
wait i'm we switched over let me talk a little about how thecompetition works to get you guys a picture with the gas engines you get theway your fuel prior to the race you go into your laps and they wait your fuelafter and then that difference goes an equation to give us their fuel mileageso we do a coast and burn style driving where the kids will burn let's say it'sgoing downhill or uphill type driving strategy is and we won't run that enginecontinuously during the race and then the difference i said we'll go into acalculation an equation will get our calculation for mileage will get around300 miles per gallon
that's where abouts right around theaverage to where the cars are in the state i'mrunning a briggs junior 206 which is a racer race engine the reason we wentwith that engine even though it's giving us more power than we need is a kidengine so we can really we can put a electric fuel injection on there there'sa lot of parts that are modeled in and out that's the desire behind it otherschools are going with a honda three-horse really need the powerthey're getting much higher mileage so it's broken into classes so there's adifference in the mileage but wisconsin
right now is you have to break athousand high school level for mileage we got close this year i think bowlerhigh school got around 70 miles per gallon with their three or so i it's acool competition the electric and when we brought in here it's a littledifferent challenge they get one hour on the course depending on the batterystyle that you are using there's still that acids there's the lithium's i'mputting on your batteries in the power density that you're using you getdifferent weights so we ran with this car for a number of years sealed leadacid we got seventy-two pounds of batteries which made the back here whereour batteries which made the tail very
heavy so we were going through a lot ofrear wheels going through some of the terms especially at road america andthose speeds so we switched were able to work with a company out of texas and geton lithium agonies battery if you know anything about batteries the highestpower density we only get 16 pounds though i'm so we competed this year withthat and we i from the advisor standpoint i think we could had betterruns but we still went out got 28 miles per gallon are 28 miles per singlecharge which the second-placed car was a mile behind us we really pulled away i idon't think we had our best runs in i think one time the kid went out what oursenior driver went out in the battery
was that like eighty percent charge andthe other two races i it was arraigned and was verycomfortable drive so i we had clinched the victory so he didn't go out to setthe record but i think i'm excited next year to see that i think we're reallygoing to pull away from the other schools unless they get on the lithiumbandwagon did you have a question energy that's a yes i ok i'm so let'stalk a little bit about how now that you guys have any questions about that thecliq what we're doing with this ok so i got picture here just some ofthe pictures of what the students are doing i have 20 we have 20 kids on theteam and it's an after-school club it's
voluntary they may come and be a part ofanything alec was the only senior this year that was a party for all four yearsbut it seems growing we design and fabricate everything so using machineslike cnc the tormach we have a couple other machines at school that we use butwe have lasers we have for prototyping we have the plasma tables we do a lot ofour own custom fabrication of these parts i think that's cool because it's reallygetting the students into this new technology that is preparing them forthe workforce so my job and eric's job is not only to facilitate this club butto give students a direct opportunity to
future employment opportunities careerpaths and we're gonna tell some stories about some of our students who havetaken it beyond the classroom beyond the club and now have careers alec being oneof them in industry related to what they did with the club and you can see someof the stuff that we have here it's really unique because our school likeeric said is manufacturing and engineering but we don't teach thetraditional classes that you might think we would do to facilitate a club likethis we do teach the cnc so alec took home ec classes you take it took one butok so they they do they do have the option to take these fancy classes afterthey take erica nice classes i'm we
don't teach welding we don't teach smallengines we don't teach a lot of these fabricating things that you think whatwe needed to construct a club like this is we kind of make do with what we havewe have a great facility a lot of tools but we i think engineering with what wehave is makes us really strong i'm so this was our first year we like isaid when all-female teams we had five females and eric and i hand-selectedfrom different classes that were not manufacturing engineering studentsactually bio med students but they had great work ethic they were the top ofthe class they really shows the potential eric is leadin the state for enough for technique
technology girls from all the technologyengineering class kept equity is what he calls it so he's had at the state levelof this of this movement so he came and said let's get a girl's club going so wehave selected the girls they built a great car we had to teach him how toweld a machine i don't think some of them like to machine anymore because themodern machine that goes into this manual machining so hopefully we'll gethim into the cnc and change their mindset i'm we have these two students who areworking on the electric car changing out that you can see that large hundred and62 sprocket that they're they're
changing out at one of the practicesessions that we had i'm you can see them racing here inwelding everything is portable we move these cars we move all of our toolsremove the welders and we kinda have to make shift space to work and it's aunique unique working environment and then you can see us here at the race inthe state of wisconsin there's four avenues of places for us race we race atodd big one being elkhart lake road america and be more familiar withelkhart lake so they get to drive you driven on the track multiple multipletimes which is a really cool really unique experience out was just tellingus on the way up here he went up there
for an indy race and he was listening toone of the odd drivers talk about how his first time driving was in the sameposition alec was testing his energy efficient fields at road america nowhe's here racing wasn't india was broke the promos and stuff so it's kind of acool experience elkhart lake road america fox valleytechnical college we used to race at wisconsin international raceway we movedit now to fox valley technologies has a track on site that we removed to uwstout yuri platteville both have courses road courses i that offer differentunique challenges as well but really cool really unique experience that thesekids get to participate in so we utilize
the tour box before we had the tour maxwe had a cnc wasn't for excess sir there was no three access that little look for whitesand then be about a fryer so we had 16 see before we got the tour mocks i'm butwe be up to it and got two of the machines and now so you can see here i'mdecides what we do with the club the students in the classes have to come upwith projects with help of the gateway instructor or just basic needs withinthe community a lot of people from the community will call us and say we needthis prototype for apart and those students will make them in-house i'mright here these three students are
three seniors what not to do on the leftare actually club members i they made these are air bearings so they're tryingto design better air bearings as a project they made a couple differentprototypes which is pretty cool they utilize both the lathe and mill onthese projects were getting two processes going at once i'm in all threeof these students was their first time taking a cnc class so pretty coolprojects i bringing them in many people here have to box just a few of you howmany people with your hand . so how many ppl installed your own ok so we installed our own as wellyou're raising your hand person it i we
installed our own as well which was afun ah lot of work experience i'm theinstructor of that gateway course i'm eric and i an instructor we rented aforklift and we got in the building and we put everything into place and then ithroughout they came right when the school year started so when when theschool teachers in here nope ok i kept it is hectic once theschool year starts when you're getting machinery delivered and in place beforethe season even before the year starts so the instructor chose to for a greatlearning experience and the students to help set up the machine which could winnot a lot of ways but i think the
caliber students we had really got intoit and were able to set this machine up so you can see them here with an enginehoist actually put in the turn into place on the late and you notice there'sno 1i think the instructors taking the picture so we really put a lot on thestudents i'm first before they even knew how toc&c they're building the machines in the equipment which i think you can speakbehalf of did that help the process or just learning on the side everything allthe tools and put him in the experience the experience and release they had todo some shimon and they learned a lot about it
so why we're here today is this hubadapter and i'm going to pass them around here and i'm going to talk alittle bit about it and then alex is going to talk about how we manufacturethis and how he specifically you can just pass in different directions i'malso going to pass some stuff around about the club just feel free to take alook this is one of our incentive packages that we use for the for theteam i'm so first of all this started with aneed not come back to the previous slide it started off as a need so as imentioned before a lot of what we're trying to do is prepare these studentsfor industry for careers for pathways
colleges you know trying to tap on someinterest so three years ago i worked with a gentleman in will lamber he nowworks at owens industries as a consultant but he owned a company calledfor by design i met him at parent-teacher conferences is hisdaughter was in one of my classes she didn't i couldn't get her into the carclub but i choose a bio med student but him and i kind of hit it off right atconferences and he was telling me what he does with engineering and designconsultant and he said i really like to get involved in your club what can i do to help so i startedtalking about some of our needs and at
the time one of our biggest needs wasretrofitting a rear bicycle fly pattern to fit i'm use the typical to set off the rearto to fit in mount these thicker sprockets ok we're running number 40chain something about a 35 i'm but to get this mount onto a bicycle rear it'snot the easiest task we ended up doing a lot of things trying to weld concentrixsplines on the existing assets we did that for anumber of years were throwing chains across the state it's huge huge problems what do you guys do at mit for this
you spilled the whole thing all rightbut what difference a skill set i i i suppose but actually if it's real or notpass this around you can see where this to the diameter of this whole will fiton this is set existing here and then you could weld on attack well not notthe most efficient and be careful this is a little bit sharpening into birdsbest did . passed around so we got yourself a suit or michael i'm so we satdown with this design engineer and he said with my students and we startedspeaking out a solution to this and they went through the whole design processthe students with the engineer on how we can come up with a solution and thesolution was in a sense obvious develop
something that's gonna fit into thisflying pattern this is a shimano bike rear end problem i'm pretty standardconfiguration it does have a keyway so when i passed around if you take it offand it doesn't make back in it's because there is a key so you gotta be smarterthan the adapter but the solution was obvious edm a pattern that's gonna matchwhat highschool is also high schools have done in the past with their cnc wastake a small eighth inch drill bit and they would just extend out a little bitpast but there are slot and when you're dealing with the amount of torque andforces that these especially the electric motors put out you're gonnashare it instantly so it's very
problematic these cars on the track tryto come up with a solution so that the key was getting this medium broached out ok i'll pass this out so we came up withthe design everyday a prototype we 3d printed i don't have this 3d printedpart here i was looking for yesterday a mad dash to bring up and i i can find it i'm we sent it off to get machine atalways so owens i'm is a custom manufacturing facility in milwaukee andit was who he was who he was currently work with kill was currently work withan enemy machine there so they designed the first1i think the first one is on this car
right here they designed it with a sixvolt or a pattern to fit the sprockets ok and they sent me two of them we putthem on the car and they work beautiful will come back to the hobbit after asecond the sprockets themselves i we have we partner with a companycalled biotech our bio fan technologies and kenosha and they have a laser andthey were able to we start designing sprockets which i until we found a autorendering system that automatically we're doing it manually never everdesign a sprocket manually it was so we'll actually purchased a sprocketmaking software now you can find my mind free but three years ago before thiswhole cnc kind of automated movement
really kicked it it wasn't free so we bought somesoftware design sprockets and now we have a company who made these for freeso we saw when i talk about selling these remember that name they made abunch of us for free not pass this around here ok so for the first year we had thiscompany making for us and i invited will and some other members of the team tohelp or two to the race to see what we were doing what is this competition wasto kind of just show them their part in action and when will came you startedlooking at all the other cars so there's
about if you look in that packet here'sa picture an aerial view of road america from the top there's about 80 cars thatcompete as well as this competition so he was looking at these other carstrying to see what these solutions were and no one had a solution that was hisrigid and durable and strong as us so you said matt why don't you allow whydon't we make these and sell these michael that's great because you did allthe work you want to make sure so for that second year he made us i think 15donate always donated the machine time the edm time i think i think we'll mighthave paid for the delays work to get that turned out and then they donated tous to be sold for a fundraiser
ok so it was going great we had about 10to 15 we sold 10 of them two different cars in the states we have 10 cars withour part sauna which is real cool when you're arace to see another school running your parts on your car that next year we gotthe tour marks and i spoke with the instructor mr. john nelson who is agateway teacher who couldn't make it up your days at the cabin lucky i thought ispoke with him about trying to integrate this into the class how can we do thisand spread the word about cnc to your students and have an apical applicableapplicator or a real-life application to this so short of design and that iswhere alec came it
yeah so we got these are for microwaveand we got to let me just got during the year and so basically mr. schultz cameto me and said hey i want you to machining the economic and i was justkind of doing my own thing is this analysis class so basically we alreadyhave one machine so we pretty much and it's me told me go not so he orderedstock order 24 inch discs our cut up into two insurance labs and so ibasically took those and i wrote my own program on and machine scratch sothere's this code you wrote up all know camp yeah so i wrote all that there'sactually three step process because
these this are two inches he had a little late so basically iwrote one program for the first side and then i machine 24 parts on the firstside and then i flip it and i the other side i had a time plus orminus five thousand with jefferson wasn't easy to hit but once i startedworking with four marks a little bit they have built-in we're off so theyhave uttered constable in which i thought was really nice it's a nice talk and so after shooting about peace oneside so it took me a little while but they were good morning i definitely hada lot and i chapter after a machine both
sides of our love we wrote anotherprogram controlling tab so i wrote a can cycle is pretty much all i did was icame around and made lightning balls and then i will upload pockets so you cansee full-size and even so i basically i have the right to programs for that ihad a little radius we're here and that chance at the top other than that pretty much justbasically turning your talk about the milling application yes sure so the milling application sobasically i made a set of my own job links i wrote a program that would comein and it would machine the radius of
this part in order to get properdistance into the job links that we had a four inch gauge wash and all i had todo is i have machine come around machine radius part but then we ran into aproblem where the machine is drilling and tapping but it's gonna crash intothe job is all ended up i came in and i just took up a one-inch and no nicecouple that's a lot of chips and cooling topass through without the tap crash to the jaws those jobs really like 60bucks by me in terms of being able to hold hard and my 24 parts accuratelyaway with just granted regular license definitely haggle touching off time
ok so big shock any questions for alec about making thisvery present seniors first year coming in writing the instructor we have can weuse magic and uj such at hsn from autodesk but the instructor wanted himto do it manually so part of you yes so we i'm going to talk a littleabout the edm process what did you do did you drill that out before they edmdid ya arm while i was doing the castle on the hill all i had to do was justroll three-quarter inch hole not before you told quarter inch hole sothat way my reading operation in florida you have a question
suite 102 days / code i think i lovethis class it all two hours so up what's the shower and why did you hand write iton my hair except time i didn't know we just got and i had on the computers wehave our program policies helps you throughout tribution a rehearsal and write code sosomething so something cool that i think is the yeah this parts awesome in theselling it was great but i think that i take away from the coolest part of thestory is alec now works at slater slater incorporating kenosha as a cnc operatorso he's got a job there working during school and you would have to removehimself from the aa from work to
participate in the club because i wantto leave club but he would work mondays and wednesdays to work second shift sountil they will have to stay til ten not to the one that goes to right i'm hestarted and he's the cnc programmer there and now he works there full timein the summer and then he's gonna be going to school back at in the foggateway and they agreed to help him there be be good with his schedule soyou can do both i'm it gets better though so we eat weoutsource this 20 instill that last year too edi because we don't have an atmmachine in the school i'm that that the edm operator at owensis his brother derek and derek was on
the club for three or four years prior i to alec being on the club and wetoured owens or him and his dad and his brother to work owens with will justkind of showing the process well derek liked what he saw i'm will who was our mentor really likedderek and his work ethic the game a job now he's the head edm operator so lastyear when he was when alec was making these in-house we are sending off to histo take him home to his brother his brother with edm shadowins for free isis brother working together armprocess with industry and it was just
super cool so we sold these other highschools i'm here some of the marketing material that we have we have we do i tostop digitally now because i'll send out stuff to the on the state our listservand the instructors will go on they'll fill out a google form that i have withwhat they want these are some paperback copies i'm but they would throw out what theywould want here's our marketing material and i the orders would come in and acertain sale date that we needed him by so we can start making them i had alexstarted here's a picture of alec i'm working in front of the machine
ah with them i had alex start makingbefore we even sold because i knew that they were to be popular so we made 24 wesold 20 of them the material i i'm just a just a basic breakdown to see how itworks as a fundraiser because we're self-funding i we none of us right noware wearing this year's shirts but we have 36 corporate industry sponsors thisyear we got last year we had 20 this year we have 36 and tormach is one ofour sponsors that god now i so we can do some cool stuff with mostly text serviceyou know getting them to come down and answer some complicated questions thatwe have on but other than that were self-sufficient self-funding i this yearwe raised $operand thirty-six thousand
dollars to run the club i and some ofthat came from this so we baked 3300 dollars from this we had initialinvestment on 670 dollars and basically the aluminum was the biggest cost we hadto buy some some hardware from the hardware store but we sold them for twohundred dollars apiece we did sell sprockets separately so some of thispractice i passed around we had from 42 206 tooth in increments of 20 plus skiptooth sprocket available for people to buy some people actually bought thisbrackets and didn't find a habit after they want to make their of adapterthemselves but we sold those for twenty bucks apiece which was we could havesold it for far more but i hope they
have donated all the material and timeon that so we ended with this 30 30 30 3330 dollars so not bad forwe're not doing carwashes we're not doing big sales we're doing things thatare real giving these kids some experience so talk about a coolexperience for the team the club and helping out the other schools anyquestions on the hob adapter itself race ya and we didn't reasonable it'ssuper reasonable especially with you if we were to char do a price for the edmoperator would be far more to twitter box because i had donated we were ableto and really we the wisconsin supermileage vehicle association orweeba wisconsin energy-efficient
vehicles we all those advisors we reallywant to work together help out we piggyback were like any other engineerwe piggyback off of everyone success and what they're doing we share secrets were kind of like anopen source in the hopes that we'll just continually to advance and breakthousand miles per gallon at the high school level in wisconsin what we sharestuff at the races is cool guys were coming up to me kids were coming up tomy kids saying hey we had a 52 sprocket but we wanted we need to get down alittle bit can we get a different sprocket we're changing sprockets andgiven teams tracks i think we're gonna
get some back but whatever i just a realcool experience to get these kids doing this any other questions about the done aboutthat so this summer eric and i hosted at our school a a campfor the advisors every summer the the association tries to host a camp whetherit's building cars which we've done before we've built two cars for the lastthree years at different high schools across statement of a week-long builderadvisors get together we can follow me cookout we spend 15 hours literally inthe shop building two cars in one week i'm real cool real neat experiences likethe monster garage high school teachers
it's neat but this year we opted to hostone at our school a two-day workshop where we designed we already designedbut we fabricated put together we called i know but it's really not a dinobecause we're not really getting too much feedback yet that's that stage twobut basically it's a roller set that goes on the bottom of the vehicle so wecan apply its we just hold up and short off ok so it's two roller or 23 inch rollersi have a duty pillow blocks and then if we flip hear anybody know what this isand if i told you already don't answer her
power steering pump anybody know thatmight make model and all these general motorcycle 87 suburban 480 suburban andwe picked this because we could get a bunch of women bulk i'm but basically wehave our power steering pump we have a pressure regulator then we have a valveso we can get the flow so we can get more force and we can get more we canapply more load to the electric motor to the gas engine or we can just use it todrain our battery recycling your batteries when you're working with a gmor on ceylon acids your batteries are awesome when you first buy any action tocondition them which most people you look surprised right did you knowthat yeah yeah so we were running
lithium i are not with him we wererunning yellowtop optimas when you buy them they're not they're not at peakperformance you actually recycle minutes afterwards you don't get the best poweruntil about twenty five cycles in such a charge to cycle those batteries if youhave a kid driving around for an hour every day the party not sure he's gonnalove it but your nerves are going to go nutso putting something especially withwisconsin weather being something that you can test in house with your car'snone of the advisors had so we put our heads together and we designed this wemade a prototype on this is actually piggybacking off of high school ateacher named wayne offering it article
is what we know duane often no brilliantguy i he's the the backyard mechanic farmer he actually took the powersteering pump out of a car and put this together and that's how we kind of gotthis idea but we kind of polish it up and made it into a camp that we could doit i'm so what we did with the tour box waswe had to make these rails for the pillow blocks to fit in and this plateis still weak on our plasma table the the blocks that raise it up to allow theground clearance for the rollers to work we had to raise themup so this is steal this is steel and we didn't want to have steel up herebecause the machining process so this is
actually aluminum so this is the perfectapplication because we wanted the time we already had tied and laser we'retight and some welding we tied in our plasma table we want to tie in the cncit was a lot other than just getting instructors you know to come togetherand do this we want to share our knowledge on the equipment that we haveand let other people know that there's things you can do with the equipment youhave to make parts so we wanted to really tie in a cnc aspects so that'swhere we return these down with aluminum and there's different it's hard to seebut there's three holes here so we can actually move these as well if you'rerunning like a 20 inch rear verses 26 so
you can actually move these rollers andthe tour marks i we started out with square stock they're just drilling andtapping so it's pretty simple pretty easy but for a lot of these instructorsthe first time setting up there in the machine and they might not be runningthe same equipment as us but getting them to run through and we actually . wewere we made this code which with inventor hsm might use that i sawsomething on fusion 360 here so i'm going to start this year that could beadaptive in but the hsn is it's a cam software that's a piggyback on theinventor download it's free but you make weird auto that's cool so the kids arereally savvy with autodesk so trying to
teach them all these other differentapplications sometimes can bog it down i don't know about you guys but eric andi probably have 30 different programs that we need to know what operate to usethe equipment in arming our lab and it's it's a nightmare so hsn was a greatsoftware for the kids to the kids learn but also the advisors to see it's veryeasy to write to pass for basic simple parts like this we did that we turnthose down and you can see i this is the guy a number on the left side here thisis matt benton he couldn't be with us today ah but he kind of led that project andevery guy we had what how many to send
you that we have 16 attendees so we hadto search so all day girls two days we return out these parts so it's prettycool this is another part i i'll just wait toplay on it this was a seal polar for i don't knowwhat you're 55 cadillac that i one of the fathers of arts for my teachers saidhey i need this part made you know i don't want to spend this money it seemspretty simple can you guys make this part of the great learning project so ithey brought in one of the one of the students made a couple of attempts at itcouldn't get it right so alec had to come in and i made this part you weretalking about it
yeah so basically parker's killer cameto me like my dad a christmas you have all this trouble restoring 55 catalog sohe gave me a drawing those from germany's it's all in german andtelomere so after i got some reading it over i basically i went in and i shouldget out of school started i had a balanced customize my thousands and thenbasically it was pretty much just all do not believe all that needs to be donewith the outer diameter and they have more and you'll be done so i did thatand that after that he had a lot to people across all those edge we are alot of top that you would try to bolton that we hold the two job part so i didthat on the mill couple slot and i drill
tab we're really trying to prepare the kidsfor this next level whether it's industry whether it's the workforce buttrying to give him some experience on the equipment that we have so that's ourstory any questions nope will feel free to see either of us to stop and ask usbut definitely come up here i don't think that i think it's lunch after thisyou're probably run out we got 15 minutes so come up check out the car i ask me questions you have thanks rose
Post a Comment for "best small suvs for gas mileage"