Cabover Camper02.02.2016─

Priyanka ChandTyler CroissantNik RoetemeyerDavid StasiukRobert SuttonJonathan Wacker

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Table of Contents

Introduction………………………………………………………………………………………………………………2

Explanation of Document…………………………………………………………………………………………....2

Mission Statement………..…………………………………………………………………………………………....2

Summary of Design.………………………………………………………………………………………....2

Customer Base……...………………………………………………………………………………………....2

Completion Date…...………………………………………………………………………………………....2

Main Performance Criteria and Constraints………..…………………………………………….........3

Project Plan…………………...………………………………………………………………………..............................3

Identification of Customer..………………………………………………………………………..............................3

Product Design Specification Chart...…………………………………………………………………………….4

Conclusion……………………………………………………………………………………………………………….5

Appendix...……………………………………………………………………………………………………………….6

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Introduction

The Cabover Camper Team was presented the challenge of designing a roof-mounted sleeping system for an outdoor activity focused couple. The customer is looking for a 3-season capable system; Fall, Winter and Spring. The camper, as it will be called, is to be built and mounted on a 2011 Volkswagen Jetta SportWagen, is meant to sleep two people, be transportable, and is to be non-restrictive to typical car functions (e.g. opening the rear lift gate, rear passenger doors, et cetera). The camper also must have minimal effect on gas mileage of the car, to name a few.

Explanation of Document

This document outlines the assigned specification parameters by the customer. Also, it outlines the project plan, the customer base, potential competitors and our plans to maximize success.

Mission Statement

Summary of DesignDesign a cabover design that is aerodynamic and easily attaches to a

Volkswagen Jetta SportWagen. The cabover is insulated and made of rugged materials. The target market are outdoorsy folk who want to enjoy the perks of camping without extra camping gear. A full scale model is to be released in June 2016.

Customer BaseThe customer base is broad but the most interest for this product would

likely come from small car drivers that are outdoor activity focused.

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Completion DateA working prototype will be prepared by the time of project presentations in

June, 2016.

Main Performance Criteria and Constraints● Must sit atop a 2011 Volkswagen Jetta SportWagen, initially● Must have minimal impact to fuel efficiency via aerodynamic features● Must sleep two people● Should have sit up clearance for reading, cooking, et cetera ● May have peripheral door access and rear lift gate access● Must be be fully rigid● Should be insulated and ventilated

Project Plan

The main objectives of this project are the product design specifications and presentation, as well as evaluation of the concept based on our external and internal searches, and through meetings with our sponsor and advisor. The camper will be designed and a prototype will then be constructed for testing and theoretical models for material evaluation will follow. Detail design will come after the prototype is tested and the theoretical model is constructed.

Identification of Customers

I. Zdenek ZmurMr. Zmur is the primary customer and the sponsor. He and his wife are looking for a way to easily camp in the harsher climates the Pacific Northwest has. He requires

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a fully weatherproof, non-invasive, rooftop camping pod that will sit atop his Jetta SportWagen so that after a day of outdoor activity they can easily set up and rest.

II. Dr. Evan ThomasDr. Thomas is the Team’s advisor. Due to his obligations with his business and the SWEET Lab, Mr. Zmur is the stand-in advisor when Dr. Thomas is unavailable. As a result, the team is expected to check in on a weekly basis to provide updates on the design process to Mr. Zmur.

III. Cabover Camper TeamThe Cabover Camper Team is an internal customer and is composed of students whom are guided by the requirements of the ME 492 and 493 courses at Portland State University.

Product Design SpecificationsPerformance Outlined in Mission Statement and further defined in

Appendix

Environment Appendix

Maintenance Appendix

Quantity Outlined in Mission Statement and further defined in Appendix

Size and Shape Appendix

Weight Appendix

Materials Appendix

Laws, Codes & Standards

Appendix

Ergonomics Appendix

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Testing Appendix

Time Scales Outlined in Mission Statement and further defined in Appendix

Safety Appendix

Documentation Appendix

Installation Outlined in Mission Statement and further defined in Appendix

**Certain elements of the PDS have been deliberately left out as there is no applicability at this stage of the product development.

Conclusion

The customer (Mr. Zmur) has set out specific guidelines for what he would like to see from the cabover project. Mr. Zmur would like to keep the design simple and without complication to avoid any unnecessary issues, this goal is clearly defined within this document. The project poses a challenge, due to the constraints on size, weight, and fuel economy we must design to and build within. We are confident that we can design a cabover camper that meets or exceeds the customer’s needs.

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Appendix

High Priority Medium Priority Low Priority

Performance

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Aerodynamic to minimize MPG

impact

Zdenek Zmur

<6 MPG Reduction

MPG <3 MPG Reduction

Defined by Customer

Testing

Must sleep two people

ZdenekZmur

Product width and

length

Inches 50 in wide at the head

Defined by Customer

Testing

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Must be able to sit up at head

ZdenekZmur

Product Height

Inches 36 in height at head

Defined by Customer

Testing

Must sit atop 2011 Jetta SportWagen

ZdenekZmur

Product Length/Car

Length

Inches To be defined

Defined by Customer

Testing

Environment

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Three Season Capable (Fall,

Winter, Spring)

ZdenekZmur

“Warm” sleeping

quarters/Insulated

TBD TBD Defined by Customer

Testing

Fully waterproof ZdenekZmur

Hard outer shell

N/A Waterproof Defined by Customer

Testing and Material Selection

Maintenance

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Car washable/Power washable/Spray off

ZdenekZmur

Hard outer shell

N/A Waterproof/No Canvas

Defined by Customer

Testing

Minimal Moving Parts

Zdenek Zmur

TBD TBD TBD Defined by Customer

Manufacture/Modeling

Quantity

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

One-off initially Zdenek Zmur

Count N/A One Defined by Customer

Constructed Prototype

Size and Shape

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Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Defined by Jetta dimensions

Zdenek Zmur

H-36 in @ head

L-5 ft 8 inW-50 in @

head

Inches H-36 in @ head

L-5 ft 8 inW-50 in @

head

Defined by Customer

Measuring

Weight

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

<300 lb on the side rails

Zdenek Zmur

<300 lb Pounds <300 lb Defined by Vehicle

Specification

Weighing

Minimization of overall mass

Zdenek Zmur

Secondary to 300 lb

max requiremen

t

Pounds Reduction through

modeling, et cetera

Function of 300 lb max requiremen

t

Modeling/Testing

Aesthetics

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Streamlined shape Cabover Camper

Team

CFD Analysis for

minimal MPG

impact

CFD <3 MPG impact

Defined by Customer,

Jetta dimensions

and Camper

dimensions

Testing/ Modeling

Painted and styled Cabover Camper

Team

N/A N/A Painted and styled to

match the target vehicle

Defined by Cabover Camper

Team and Customer

A painted prototype

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Materials

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Steel frame structure

Zdenek Zmur

Jetta Dimensions

Inches Match Jetta dimensions

Defined by Vehicle and Customer

Prototype/ Modeling

Tri Lam Inner/Outer Covering

Zdenek Zmur

Camper Dimension

Inches Match Camper

Dimension

Defined by Camper

and Customer

Prototype/ Modeling

Laws, Codes and Standards

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Meet all applicable DOT laws regarding license plate and tail light visibility

Zdenek Zmur and Cabover Camper

Team

DOT Regulations

DOT Regulations

Meet all standards at time of

testing.

Defined by laws and

regulations of DOT

Pre-test inspection

Ergonomics

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Interior length Zdenek Zmur

78 in inches 78 in Defined by customer

Measuring

Interior width Zdenek Zmur

48 in @ shoulders and head

inches 48 in @ shoulders and head

Defined by customer

Measuring

Interior height Zdenek Zmur

36 in inches 36 in Defined by customer

Measuring

Testing

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

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Test drive with mock up of clamshell

Zdenek Zmur

< 6 mpg reduction

MPG < 3 mpg reduction

Defined by customer

Testing

Time Scales

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Working Prototype by June, 2016

Zdenek Zmur

N/A N/A Working Prototype by June,

2016

Defined by Customer

and ME Sequence

N/A

Safety

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Setup is safe and easy

ZdenekZmur and Cabover Camper

Team

N/A N/A N/A Defined by Cabover Camper

Team and Customer

N/A

Appropriate lighting addition

Cabover Camper

Team

TBD TBD Light inside of Camper

Defined by Cabover Camper

Team

N/A

Appropriate ventilation

Cabover Camper

Team

TBD TBD Ventilation for

condensation and

fresh air

Defined by customer

and Cabover Camper

Team

Testing/ Modeling

Documentation

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Documentation of Zdenek N/A N/A Full product Defined by Implicit

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dimensions Zmur documentation and drawings

Cabover Camper

Team

Material List Zdenek Zmur

N/A N/A Material manufactur

ing list

Defined by Cabover Camper

Team and Customer

Implicit

Installation

Requirements Primary Customer

Metrics & Targets

Metric Target Target Basis Verification

Ease of Installation

Zdenek Zmur

TBD N/A Fully built structure

with anchor points on

the vehicle

Defined by vehicle, Cabover Camper,

Team

Testing

Camper functionality for one-time installation

Zdenek Zmur

N/A N/A Camper allows

access to all peripheral doors and

rear lift gate

without removal of

camper

Defined by vehicle

dimensions and layout, Customer

and Cabover Camper

Team

Testing