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MANUFACTURABILITY CHAPTER

Group 11 – Hydrofoil Boat

March 2, 2018

INTRODUCTION

The following chapter will explain how the team practiced concurrent engineering in the

design phase to design for manufacturability. This includes designing with regard for

manufacturing and accompanying processes, designing for adjustability, and designing for safety

of the canoe’s pilot. Each of these topics will be explained and build instructions will follow to

show how the team manufactured the completed design.

DESIGN FOR MANUFACTURABILITY

From the beginning, Dr. Peters had spoken to the team stressing the importance of

concurrent engineering. Concurrent engineering is at its core, designing for manufacturability. It

is important to keep in mind during the design phase how feasible a product will be to

manufacture. This feasibility includes manufacturing processes, available resources, skill

required in labor, tools and equipment.

For the team’s final design, the cross sections of the foil and struts were developed using

a staggered layering technique. The stepped layers of the foil and struts were smoothed out using

an epoxy filler, ensuring a low drag shape and surface. This technique allowed the cross

sections’ shape to be created without the need for an excessive amount of material removal. This

allowed the team to reduce the amount of material waste which would be created as a result of

sanding the positive, teardrop cross section from a blank rectangular cross section. Additionally,
using a staggering technique reduces the potential for human error in creating a uniform cross

section. An example of the staggered layering technique can be seen in Figure 1 below.

Figure 1 above depicts the layered cross section of one of the struts before epoxy was applied.

Epoxy filler will be used on the “steps” to smooth out the cross section and sanded to shape.

Additionally, the materials selected for the construction of the foil and struts themselves

are an example of concurrent engineering. While a material arrangement such as fiberglass over

a foam core would have had its own benefits, it was deemed that a wooden laminate structure

would be more easily manufactured and could be easily repeated if necessary. If a second

iteration were to be created using wooden laminate layering, the mold could easily be reused,

saving cost on parts and materials.

DESIGN FOR ADJUSTABILITY

Seeing that there are several variables at play in testing the design - such as weight and

weather conditions - it is necessary to be able to control the angle of attack, the position of the

foils on the boat, and the position of the pilot within the boat. These adjustments can all be made

using the same apparatus. The angle of attack can be adjusted using a cable and pulley system.

The entire mounting bracket of the foils themselves can be positioned at different locations on
the boat. The pilot can be repositioned so as to redistribute weight appropriately. Sketches and

pictures of this apparatus can be found in the figures below.

Figure 2: This side view of the control apparatus depicts the cable and pulley mechanism which

will be used to adjust the angle of attack. This piece of the apparatus will be mounted to the outer

surface of the canoe.


Figure 2 & 3: The figures above depict how the control apparatus will be mounted. The

apparatus will be mounted using an angle bracket spaced to hook onto the “lip” of the canoe. The

bracket accommodates the curve of the canoe. This will allow the control apparatus to slide onto

the canoe and be secured in place, maintaining the position of the apparatus while allowing for

easy removability when the hydrofoils are not in use.


Figure 4 & 5: The figures above depict the top view of the pulley system and control apparatus.

The crank will be located by the pilot’s right hand. The pulley system will be implemented such

that both foils will be linked to the same operational system. Therefore, any adjustment which

may be made to angle of attack will affect both foils simultaneously.

DESIGN FOR SAFETY

The hydrofoiling watercraft will have two primary safety features, one centered on the

front hydrofoil and the other on the motor. The front hydrofoil has a mechanism for adjusting the

angle of attack. This mechanism also allows for the implementation of a failsafe in the event of a

control failure. In this scenario, a control failure would result in the angle of attack being set to a

predetermined position. This position would then allow the craft to steadily lower back into the

water.
The other failsafe is a cutoff switch for the motor. In the event of any issue which may

arise, the pulling of this switch will immediately cut power to the motor. This will steadily

decrease the velocity of the canoe and allow for the inherent drag of the craft to bring it to a stop.

BOOTHROYD AND DEWHURST TABLE

The following table is the “Boothroyd and Dewhurst” table to design for assembly. This

table will be used to determine whether or not the parts involved in the final assembly are

essential to the product. Those parts which are not essential may be removed, reduced, or

grouped separately to reduce cost and assembly time. Questions answered are as follows:

1. Does the part move relative to other parts?

2. Is the material of the part different from the majority of the product?

3. Is the part removable or modifiable, does it need to be separate or can it be combined?

If all answers to the questions are “no” for a part, it could be a candidate for elimination.

Table 1: Boothroyd and Dewhurst - “Design for Assembly”

Different Removable or
Part Moving?
Material? Modifiable?
Curved Front Foil Yes No No
Vertical Struts Yes No No
Canoe Yes Yes No
Mounting Apparatus (Clamps,
Wooden Structure, Mounting Yes Yes Yes
Points)
Angle of Attack Controls (Cables,
Yes Yes Yes
Pulleys, Crank, Safeties)
Motor Yes Yes Yes
Steering and Throttle Controls
(Controls, Throttle Cable, Steering Yes Yes Yes
Arrangement)
For the sake of simplicity, parts which comprise a separate assembly have been listed as

an assembly in this table. For example, the angle of attack controls explained in the “design for

adjustability” section of this chapter are comprised of a series of pulleys and cables attached to

the mounting apparatus. This system moves dynamically within itself but also affects other

components within the overall design. Each piece of these assemblies has a “yes” in the category

of movement and material, and is essential to a greater system. Since there is not one component

which has “no” in all three columns, there is no component immediately eligible for elimination.

CONCLUSION

In this chapter, it was explained how the team took concurrent engineering practices to

heart. The team kept manufacturability and feasibility of manufacturing processes in mind while

establishing a final design. Additionally, the team designed for manufacturability, adjustability,

and safety.

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