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					TechnoPush 2008
        Year 7
Ungarie Central School
                     Design Briefs
Our task is to design and construct a push cart to participate in a series
    of performance challenges.
Participating classes will bring our vehicles to the KDC-NRMA
    TechnoPush Challenge
for a joint celebration, where we will demonstrate and trial them in action.


                       Our Design Brief
For our design brief the push cart will be constructed of timber for the
   frame.
The front wheels will be 220mm pneumatic steel 110kg and the back
   wheels will be 275mm pneumatic plastic 120kg.
The steering will be designed with a steel mechanical design. All safety
   aspects will be covered with a roll bar, seat belts, brakes and a
   bumper bar. The overall design of the cart will aim to be constructed
   light for easy pushing and increase speed and quick assembly.
       Research




We researched some photos to
   get an idea on what our
  pushcart could look like.
                         Internet and other search

                 We looked at books in the library and found a traditional and simple design
                 Billy Cart

                                           Innovative ideas for constructing our Billy
                                           Cart
When considering how we might build
our Cart we wondered if used
Aluminium cans could be used. But
after looking at how this could be
done, it was decided to much time
was needed to try and achieve this.



                                       Trent successfully joining two
                                       cans that would have been part
                                       of the Aluminium frame if we
                                       had gone ahead with the
                                       Aluminium idea.
Researching ideas for the different Billy Cart components

            We looked at last years            PLACE A
            “Bushrangers” Billy Cart for a     PICTURE OF
            steering wheel idea, but one of    STEERING
                                               WHEEL
            the team members, Chase
            came up with the great idea of
            using a old chain from a piece
            of farm machinery.


               Last years two Carts
               used retractable seat
               belts. Talking to students
               from last years teams,
               they told us how these
               were terrible and lost
               them valuable time in the
               change over of drivers           Josh testing out the
                                                retractable
               and pushers.
                           After investigating other
                           seat belts we decided
                           on a racing type belt.




Caitlin and Jesse working on the folio.


                                          Looking at last
                                          years bumper
                                                            Our 2008 bumper
                                         (Left) “Bushrangers” steering
                                         column and steer system, ours
                                         will be similar.




                     Last years “Little Cow” used an old plastic
                     seat, we decided this would fit with our
                     support for recycling.


These are pneumatic tyres, tyres that
require air. We are going to put them
on the front and the black tyres below
on the back our Cart.
                        This brake system was what the
                        “Bushranger’s” and “The Little cows”
                        used on their carts last year.
                        Speaking with the members of those
                        teams, they were not happy with how
                        the brakes stopped the carts.
                             Safety
For safety a few areas needed to be considered.
• Safety aspects of the Billy Cart
The safety aspects of the Cart needed to consider stability and braking.
• Safety of the drivers, pushers and others
For safety of drivers, pushers and others the carts needed the roll bar
    to be 100mm above the tallest driver, sharp edges removed, seat
    belts, working brakes, covered in floors and a bumper.
• Safety in making the Billy Carts
In the making of the Billy Cart many things needed to be known about
    to protect the student and others during this construction. We
    worked with Mr Sheriff to better gain this knowledge by doing a on
    risk assessment. (See following page slide).
                      KDC-NRMA TechnoPush Challenge-HIGH SCHOOL
                                 Risk Management Plan
Name of school:                                               Group/class: Number in group/class:
Name of principal:                                            Name of supervising teacher:
Description and purpose of activity:                          Contact number:
Date(s) of activity:                                          Staff, parents, caregivers, volunteers assisting:
   Activity         Hazard Identification         Risk             Elimination or Control          Who       When
                       Type/Cause                 Matrix                 Measures
Disc sanding      •Damage fingertips if they         3        •Don’t sand anything under 100     The        Always
                  are in the wrong position                   mm                                 user
Chiselling        •Cut someone/yourself              2        •Keep your hands behind the        The        Always
                                                              blade                              user
Moving around •Tripping over                         2        •Walk around the work shop do The             Always
in workshop                                                   not run                           user
                                                              •Pick up any objects of the floor
Grinding          •Getting sparks in other                    •Use the grinding bay or a         The        Always
                  peoples eyes                       3        curtain                            user
                  •Getting metal filings in                   •Wear safety glasses and use
                  users or some one else’s                    the grinding bay.
                  eyes
Venue and safety information reviewed and attached: Yes/No
Plan prepared by:              Position:                   Date:
Prepared in consultation with:
Communicated to:
                         KDC-NRMA TechnoPush Challenge-HIGH SCHOOL
                                    Risk Management Plan
Name of school:                                               Group/class:       Number in group/class:
Name of principal:                                            Name of supervising teacher:
Description and purpose of activity:                          Contact number:
Date(s) of activity:                                          Staff, parents, caregivers, volunteers assisting:
    Activity           Hazard Identification      Risk             Elimination or Control                Who      When
                          Type/Cause              Matrix                 Measures
Welding             •Welding Flash to users                   •User wears Welding shield               The        Always
                    eyes                             2        •Welding takes place in                  user
                    •Welding Flash to others                  welding bay or a welding
                    eyes                                      screen used.
                    •Burns to hands, legs and                 •Wear long sleeve short and
                    arms                                      long pants.
Oxy Cutting         •Sore eyes                                •Be properly Instructed in the           The        Always
                    •Burns                           2        use of Oxy heating and cutting           user
                                                              •Wear oxy goggles
                                                              •Wear correct clothing
Test Driving        •Tipped out of cart                       •Wear seat belt                          The        Always
                    •Cart rolls over                 3        •Make sure roll bar meets                user
                    •Running into others                      specifications
                                                              •Test drive in a clear open area
Venue and safety information reviewed and attached: Yes/No
Plan prepared by:              Position:                   Date:
Prepared in consultation with:
Communicated to:
               Construction of Billy Cart
After researching different designs and discussing between the team and with
Mr Sheriff about a design for our Cart, we decided to go with a similar design
as last years “Little Cow”, using as much recycled material as possible. The
main chassis would be made from wood and metal. Any bolts or steel parts
needed for the cart would at least be good recyclable material.
Below shows the basic
design we would go with.           Right, De-nailing old
                                   hardwood for the frame

                     Mr Sheriff discussed the idea of mortise and tenon joints
                     being strong for the construction of the frame. Everyone
                     agreed, and Mr Sheriff cut the depth of the mortises on the
                     drop saw for us.




                      Chiselling out the mortises required
                      a team effort.
                       Marking out for the tenons.           While the Mortise
                                                             and tenon join
                                                             would be strong.
                                                             Some of the team
                                                             assisted in making
                                                             corner brackets for
                                                             extra strength.


Completed mortise and tenon joints




Frame assembly and fitting corner brackets.


                         Cutting out mortises for the roll
                         bar
After deciding to construct the same steer system as last years carts, Mr Sheriff
showed us how to do 3 dimensional drawings for us to copy




  Marking out of metal parts using steel rule, square and
  scriber




                      Making part of the steering required helping Mr Sheriff
                      heat the steel with the Oxy-Acetylene then bending it in
                      the vice
This slide shows the process taken to construct the new brake
system. After researching last years carts our design was discussed
with Mr Sheriff and we decided to go a very different way. The main
braking system was mounted under the chassis and worked by a
centre brake handle that pushes forward. To lock the brake into a set
position, two old springs were set into the design.


                         The arrow shows
                         where the springs have
                         been set in to keep the
                         handle locked in place.
               Testing out our Cart
(Below) Realising our roll bar was not   Practising assembly
high enough above the tallest driver.
We had to add an extra piece of timber
to the top of our roll bar.




            Test pushing the cart
                                Evaluation
I like the way
                                           I think that the steering
we have                                    system is a bit hard to
recycled                                   use because of the
nearly                                     steering wheel (which is a
everything on                              bit uncomfortable) and
the cart that is                           the actual steering
                                           system (which when
why I like it.                             turning is really sudden
Because I am                               for the person who is
little and light,                          pushing the cart and the
that means                                 steering system is hard to
the cart will                              turn at times)
have lightning                             I’ve had fun making the
speeds.                                    cart with everyone else,
“Chase”                                    mainly because it has
                                           given me the chance to
                                           learn more and
                    I like the way it      experience more. I learnt
                    drives and the way     a painful experienced,
                    we made it using       that is, don’t fool around
                    recycled timber and    in the workshop! But I’m
                                           certain I’m going to have
                    metal. Our brakes      a lot more fun at Eastern
                    didn’t work when we    Creek.
                    tested them so we
                                           “Callum”
                    had to make brake
                    pads. I also enjoyed       I enjoyed making the Cart, especially working on
                    working at night and       Tuesday nights at the work shop. I like how the
                    at school on the           brakes work now. And how it runs and how light it
                    Cart. “Brock”              is. “Josh”
                                  My favourite things on the
                                  Cart are the brakes and the
                                  steering because you hardly
                                  have to move to use it.
                                  “Caitlin”

                                          When we first test drove the
                                          Billycart, we noticed that the
                                          bottom of the back wheels
                                          started to draw closer towards
                                          the cart. We replaced the
                                          back wheels with thicker
                                          wheels. Because we changed
                                          the wheel we had to make the
                                          brake pads, so we put leather
                                          on for better stopping, this
                                          made them work better.
                                          Everyone agrees that since
                                          we changed the wheels, the
                                          billycart has been easier to
                                          push. “Renae”




I liked driving and pushing the cart, I have                    Good – Our construction time, our seat belt,
always wanted to help make something like                       night time workshop. Bad – steering needs
this. ”Jesse”                                                   greasing/oiling and the back wheels (slant)
                                                                OK – our experience, our safety equipment.
                                                                “Trent”

				
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