Pirates of the Caribbean Load Wheel

Disneyland Resort
Design Team: Vincent Rosas
Raul Arrieta
Chris Cordina
Rafael Follero
Justin Santiago

Faculty Advisor: Nina Robson PhD

Industry Collaborator: Manjit Sagoo- Disney Engineering

California State University Fullerton
Mechanical Engineering
December 5, 2013
Project Overview
4 load wheels per boat
Approx. 22 persons per boat
Ride cycle time 15 minutes
Full boat weight 6400lbs
2 drops at 13 and 8
Bearing life span 6-9 months
Current design used for 40 years
General Work Breakdown Structure
Pirates Load Wheel Project
Industry Collaborators
- Manjit Sagoo
- Steven Fremen
Faculty Advisor
- Dr. Nina Robson
Student Team Lead
- Vincent Rosas
Bearing/Bushing
Research
Raul Arrieta
Chris Cordina
Rafael Follero
Vincent Rosas
Justin Santiago
Testing
Raul Arrieta
Chris Cordina
Rafael Follero
Vincent Rosas
Justin Santiago
Solid Model
Creation
Raul Arrieta
Chris Cordina
Rafael Follero
Vincent Rosas
Justin Santiago
Materials
Research
Raul Arrieta
Chris Cordina
Rafael Follero
Vincent Rosas
Justin Santiago
Design
Raul Arrieta
Chris Cordina
Rafael Follero
Vincent Rosas
Justin Santiago
Functional Block Diagram
SEAL
LUBRICATION
SPINDLE BEARINGS
HUB
O-RING
BRACKET
BOAT
RAILS
Comes into Contact with Water
Design parameters
Design Challenges:
o Large PV values for bearings
o High corrosion rate
o Moisture Absorption rate
o Wear of materials
Constraints:
o Fit onto current wheel carrier
o No modification to wheel bore
and spindle dimensions
o Force to push empty boat 50-
60lbf
Current Bearing Issues
Pressure on seal from load
Zero relative translation wheel & bearing
components

Project goals
Performance (A-Specs)
Must have same or higher load carrying and performance
capacity.
Must not bind, gall or seize on shaft.
No modification to the wheel bore is desired.
Higher Corrosion resistance
Maintenance
Decrease frequency of wheel inspections
No need to replace bearings for >1 year
Eliminate lubrication

Brief Description of the Approach
Project Status
Design of Load Wheel
Analytical performance analysis complete for bushings and bearings
Continuing force analysis for bearing seal
Bushing Research
Found 3 self lubricating bushings
Igus H370, TriStar Ultraflon 601, TriStar Ultraflon 602e
Found 1 stainless steel roller bearing
Timken Roller Bearing
Materials Research
Hardness affects on mating components
Continuing research to decrease corrosion and wear rate
Using machinable rubber material for bearing seal
Tivar Ceram, Nylatron
Test Plan
6 tests to examine bearing, bushing, and seal performance
Procedures and CAD models are complete



Alternate Approaches: Pugh Chart

Datum 1 2 3 4

Name Weight Current Wheel Self Lubricating Disc Spring Lip Seal Breather
Load Capacity 3 0 1 0 0 0
Durability 2 0 1 1 1 1
Manufacturing
Complexity
2 0 -1 -1 1 -1
Corrosion Resistant 2 0 1 1 1 1
Waterproof 3 0 0 1 1 1
Lubrication 1 0 1 0 0 0
Life Expectancy 3 0 1 1 1 1
Maintenance 2 0 -1 -1 -1 1
Number Better - 0 5 4 4 5
Number Worse - 0 2 2 2 1
Number Same - 8 1 2 2 2
Total 0 3 2 2 4
Performance Analysis & Margins
Parameters per
wheel
Requirement
Projected
Performance
Predicted
Margin
Load Capacity >6400 lbf 8650 lbf 35%
Wheel Velocity >30 ft/s 60 ft/s 50%
Capability of
Seal
< 10% of the hub is
filled with water
<1% 90%
Corrosion
Resistance
<2% corrosion from
original mass
<1% 50%
Life Span 1 year of use 3 years 200%
Rationale for Concept Selection

CLIMBING THE INCLINE DESCENDING THE DROP
(6152 lb load) (10,000 lb load)
area P V PV P V PV
Max
Speed
Limit
Compressive
Strength
Max
Temperature
Usage
(Short term)
Modulus of
Elasticity
in^2 psi fpm
psi x
fpm
psi fpm
psi x
fpm
fpm psi F psi
Timken
(Current bearing)
1.542525 498.5332 60.6772 30249.6 810.3596 891.2099 722200.5


igus iglide H370
1.76625 435.3857 60.6772 26417.98 707.3553 891.2099 630402
295 11460 464 16610000

Tristar Tristeel PR
2000 20000 550 160000

Thordon Thorplas
15300 230 350000

Detailed Design of Complete System
Spring Seal & Tapered Roller Bearing Design
Self Lubricating Bushing Design
Spring Seal
Tapered Roller Bearing
Test Mat r i x
Performance
Measurement
Requirement
Design Parameters to be
varied
Range of variation Diagnostic
Impact Forces
(Tensile Strength)
able to withstand 2500 lbf,
only allows less than 10% of
the hub to be filled with
water
Type and size of bearings and
seals
B: Igus, 0.75 to 0.85 inch diameter
Roller Bearings, S: Disc Springs,
Rubber Spring Seal
Load Frame, Drop Container, Sample
Water, Weights
Height of drop 5, 7.5, 10, 12.5 ft
Load Frame, Drop Container, Sample
Water, Weights
Angle of decent 25, 45, 60 degrees
Load Frame, Drop Container, Sample
Water, Weights
Amount of additional weights
100 lbs, 250 lbs, 500 lbs (dependent
on the height of drop)
Load Frame, Drop Container, Sample
Water, Weights,
Corrosion rate of
materials
Sample Material weight loss
of less than 5% (depending
on the size of the material
used)
Sample Materials,
Materials: Stainless Steel, Igus Bearing,
Original Carbon steel roller bearing,
Undetermined Spring Seal Material
Individual Containers, Small Samples
of each material, a waterproof heat
source, scale to measure the
difference in weight, thermometer
Temperature of the water 70, 80, 90, 95 degrees F
Individual Containers, Small Samples
of each material, a waterproof heat
source, scale to measure the
difference in weight, thermometer
Rolling under load
While going up and down
the ramp, the wheel must
not seize
Bearings, Seals
B: Igus, Roller Bearings, S: Disc
Springs, Rubber Spring Seal
Load Frame with roller attachments,
Weights, Ramp,
Water tight seal test
Expectable amount of water
would be less than 10% in
the hub
Type and size seals S: Disc Springs, Rubber Spring Seal
Container, Sample water, graduated
cylinder,
Preload force
Optimizing the bearing in
order to hold the 2500lbf
Diameter of the bearing 0.75 to 0.85 inches in diameter Calipers, strain gages,
Preload Force Less than a 1000 lbs of torque Calipers, strain gages,
Strain test for pressure
within hub with
lubrication
Releases 5% of the
lubrication through the seal
while in motion
different amounts and types
of lubrication, each of the
designed seals
TBD
Container, Sample water, air
compressor (simulate the
lubrication), lubrication, strain gage
Testing Models
Impact Test Apparatus
Load Frame
Guild Cylinders
into Guild Rails
Container
Testing Models
MTS Insight Tension Machine
Load Frame
Wheel attached
from the Spindle
Wheel Durability
DC Motor
Roller Frame
Budget
No. Description Part Number QTY Status Cost (ind)
Cost
(Final)
1
O-Ring
Retainer
PRMC-101 2 No Action $20.00 $40.00
2 Spindle PRMC-102 1 No Action $10.00 $10.00
3 Hub PRMC-103 1 No Action $100.00 $100.00
4 Lock Nut PRMC-104 2 No Action $10.00 $20.00
5 Test Fixtures PRMC-105 1 No Action $300 $300.00
6
Load Frame:
Side Bracket
PRMC-106 2 No Action $86 $172.98
7
Load Frame:
Middle Bracket
PRMC-107 1 No Action $20 $20.00
8
Load Wheel:
Spring Seal
PRMC-108 2 No Action RFQ RFQ
9
Container: Drop
Test
PRMC-109 1 No Action Donation Donation
Total $662.98
No. Description Part Number QTY Status Cost (ind) Cost (Final)
1 Wheel MEPC-001 1 No Action $35.00 $35.00
2
Carbon Steel
Bearing
MEPC-002 2 No Action $50.00 $100.00
3 Bearing Cone MEPC-003 2 No Action $10.00 $20.00
4 Bearing Cup MEPC-004 2 No Action $10.00 $20.00
5 Bearing Seal MEPC-005 2 No Action $10.00 $20.00
6 Rubber O-ring MEPC-006 1 No Action $5.00 $5.00
7 Spacers MEPC-007 5 No Action $8.79 $43.95
8 Load Frame: Bolts MEPC-008 2 No Action $7.00 $14.00
9 Load Frame: Nuts MEPC-009 2 No Action $8.00 $16.00
10
Load Wheel: Roller
Bearing
MEPC-010 2 No Action $92.10 $184.20
11
Load Wheel:
Lubrication
MEPC-011 Varies No Action Donation Donation
12
Wheel
Durability:Spring
MEPC-012 1 No Action $35.00 $35.00

Total $493.15
Purchased Parts:
Manufactured Parts:
Schedule for Testing & Manufacturing
Description Date
Corrosion Rate of Materials January 7, 2013- January 21,2013
Manufacturing January 21,2014 -February 8, 2014
Testing the Preload Forces February 9, 2014- February 15, 2014
Pressure Strain Test February 16, 2014- February 22, 2014
Water Tight Seal Test February 16, 2014- February 22, 2014
Impact Test February 23, 2014- March 8,2014
Rolling Under Load Test February 23, 2014- March 8,2014
Wheel Durability Test March 2,2014- March 15, 2014
High level Schedule
Conclusion & Innovation
Reduce Cost
Eliminate bearing lubrication and maintenance
Increase corrosion resistance of components
Decrease number of components
Multiple design paths
Increase the probability of meeting the design goals
Use bushings in new application
Similar applications

References
SAE Handbook. Vol. 3. Texas: SAE International, 2005. 41.121. Print.

Tuthil, Arthur H. Nickel Institute. FNACE, n.d. Web. 29 Oct. 2013.
<http://www.nickelinstitute.org/~/Media/Files/TechnicalLiterature/Effect
ofChlorineonCommonMaterialsinFreshWater_14049_.pdf>.