Self and Design Evaluation

Scope
For the capstone design project in Systems Engineering II, I designed a portable climbing system, nicknamed “The Porta-Boulder”. This object was intended for climbers that wouldn’t necessarily have access to rocks or climbing gyms. The design would be easily portable, yet allow a climber to boulder, and thereby keep him in shape in between visits to the rock gyms. The system would therefore be lightweight, yet sturdy, and an interim method of preparing for a day of climbing out on the rocks.

Solution
The Porta-Boulder is a solution to the problem that most rock climbers have, as mentioned above, with finding their ways out to the rocks. This system, which is a series of three panels covered in climbing holds. The outer two panels, or faces, were slightly longer than the center panel, to allow for greater stability. The outer faces, when canted off the center line of the wall as to create an outline not unlike a bent staple, would keep the wall from tipping to one side. To keep the system from tipping to the other side, a series of ropes attached to the corners is then clipped into a central block, which is then staked into the ground.

Discrepancies between Original and New Design
The first major difference between the original design and the final design is the lack of a hard support system. On the initial design the outer faces could be angled to create both outside and inside corners. Unfortunately, the final design only incorporates the outer corners, which only uses the soft, or rope based support system. The reasoning behind this would be the difficulty in finding stout enough support arms to keep the wall from tipping away from the climber. In addition, the final design has mostly manufactured holds, while the initial design had entirely self-made holds. This was due to the amount of time it took to create each hold, which didn’t nearly make up for the amount of money saved.

Successes and Failures
The biggest failure I encountered during the duration of this project was with the climbing holds, or the construction of my own climbing holds. The mix of sand, paint, fiberglass and hardener was never exact, which lead to several batches that never fully took. These batches also gummed up the molds, which lead to more time wasted with cleaning. Even when these holds were entirely hardened, they only had one substrate point, which leads to spinning. A spinning hold is one of the worst things a rock wall could have. On the other hand, one of the strengths that I encountered was my ability to employ carabineers and pitons, both commonly used climbing aids, in the construction of my final design. The carabineers attach the soft support systems to the block, which is then staked in using bent metal bars, which are essentially pitons.

Lessons Learned from Failures
From these failures, I learned that mixing some things, such as fiberglass resin, is an incredibly exact and meticulous science. I’ve also made a note that, sometimes, it is in fact better to spend a little more money to save time and effort. This taught me a lesson in two of the most valuable fields for a college student: time management and effort/cost analysis. Time management came into play when I realized that the holds were taking far too long to set completely, and that I’d never have them all finished by the time I needed. I also learned to analyze the effort I applied to the holds, versus how much it would cost me to buy professionally manufactured ones. In the end, these lessons helped me realize that, sometimes, it’s better to spend the extra penny than waste your time mixing, pouring, and waiting.

Additional Lessons Learned
In addition to the lessons I learned from my mistakes, I also learned plenty by just going through the process of construction. The first learning curve came when buying materials, and how items can be measured differently. I learned that hardware, such as bolts and nuts, are not only labeled in length and width, but also in the angle of the threads. Also, I found out the hard way that galvanized bolts don’t exactly match up with stainless steel nuts, and had to force the nuts on using a vice and channel lock. When it came time to apply the hinges, I had to learn how to balance them and drill through the steel. This wasn’t much of a problem, and I even managed to balance all six hinges and affix them in less than an hour.

Major Design Flaws
The only major design flaw I uncovered with the final Porta-Boulder was the tendency of the outer faces to close by themselves. This, I found, occurred only when the climber was pulling on the topmost horizontal bar of the central face. This flaw could be easily repaired by affixing an additional stake to the outside corners of the entire system, being the outermost corner of the left face and the right face. My initial repair involved inserting an additional eye-bolt into these corners, but I adapted this to include a rope loop through the inside of the joint between the lowest horizontal and the outer border.

Improved Skills: Problem Solving
This project helped to greatly improve my problem solving skills by presenting me with tasks that seem insurmountable. Problems such as the mold fiasco, as well as the trouble I had with drilling through the steel plates of the hinges all helped me improve my problem solving skills. I find that, if I sit and focus on a problem at hand, I am then able to discover a solution out of seemingly thin air. This was a skill that I had not mastered before taking on this project, but have since added to my most practiced methods of problem solving.

Improved Skills: Communication
Unfortunately, I don’t feel that this project improved my skill of communication, at least as far as the art of conversation and speech. Writing is also a forte of mine, and was therefore not markedly improved by this project. However, I have learned new mediums of communication, such as the blog, and have learned new formats for writing, such as press releases. I believe that these new vehicles of the written word will help me immensely, not only through college, but in the real world and in my career.

Improved Skills: Organization
Organization is a skill that I’ve needed to improve upon all my life and I believe this project has helped me more than any other class I’ve taken throughout High School. The first instance of this would be the use of the blog, or more accurately the calendar of due dates which was posted on the blog. By plotting due dates, and then filling in work requirements between those due dates, I found myself on task and able to complete assignments much more efficiently. This will surely be of great help to me in the upcoming years, as will my ability to plan ahead and solve problems in advance, yet another skill I’ve learned through this project.

Conclusion
In summation, the Porta-Boulder design and construction have been quite a journey for me, as well as all those involved. The problem I’ve discovered was the inability for urban climbers to make it out to the rocks, or pay gym fees to keep in shape for the climbing season. My solution, the Porta-Boulder, was a portable boulder problem that rock climbers could use to stay in shape, during the off season or at the peak of climbing season. Though my final design did not look quite like the initial, the final design improved upon the flaws in the initial, such as the hard support system. Yet another failure in the initial design was the theoretical fabrication of my own climbing holds, while I succeeded in the employ of line and karabiners in the soft support system. I learned organizational skills, problem solving skills, practical skills such as drilling through steel, and philosophical ponderings such as: “Sometimes it’s better to pay for something, as opposed to slaving over it yourself.” All in all, this project and its lessons will stay with me through the rest of my life.

Testing and Testing Results

Introduction
One of the last stages of the Capstone Design Project for Systems Engineering II was the testing, as well as consummate report of the testing results. For the Porta-Boulder, testing was simply to climb upon the wall, and observe its stability. The tests were conducted on Sandy Hook, New Jersey behind Building 77, or in Old Bridge, New Jersey. The testing of the Porta-Boulder was a combined effort of Alex Rojewski, Mark Davidson, Steve Meyer, Lauren Keiser, and Nick Rojewski.

Testing Procedures
The final design of the Porta-Boulder is intended to be a free-standing climbing wall, which can fold upon itself to fit into the back of an extended bed pick-up truck. Upon arriving to the test site, the testers, who should be a pair of climbers between 150 and 250lbs, will remove the Porta-Boulder from the back of the pick up truck, where it fits comfortably. The testers must then carry the device 15', to meet specifications. Once at this final point, the testers with lift the Porta-Boulder into the standing position, and unfold the two wings. The Porta-Boulder should be able to stand on its own when the wings are turned within the 60 degree range and the supporting lines engaged. The wings will then be staked into place, and the support lines connected. One of the testers will then climb from one end of the wall to the other, while the second tester spots him. If the wall supports the tester's weight and the tester is capable of completing the run, the function test is complete. The testers must then release the supports, un-stake the wings, fold the device, and return it back to the vehicle for transportation. The device, upon fitting into the vehicle a second time, has completed all specifications and limitations on size and function. These tests can be preformed in any weather, on stable and firm ground, and require only a pair of climbers.

The testers will:
load the folded Porta-Boulder into the back of either a Ford F-250 or Dodge 2500 (comparable or larger) pick-up truck, with an 8' bed.
transport the device to the test site, where the testers will unload it.
carry the Porta-Boulder a minimum of 15', using handles attached to the closed wings.
lift the Porta-Boulder into the upright position.
unlock the folded wings.
unfold the wings to the 30 degrees from the face of the main wall, creating a "u"
attach the support lines to the support block behind the Porta-Boulder.
stake in the support block, leaving two stakes on the side opposite the Porta-Boulder.
climb from the far left side of the device, to the far right, alternating as spotter and climber.
disengage the support system.
fold the wings back to the device, locking them in place.
carry the Porta-Boulder back to the vehicle.
reload the device.
Test Complete.

Testing Stages
Consulting the above testing procedure, there are three main phases of testing: mobility, ease of use, and stability. The first phase, mobility, involves moving the system using either a vehicle or by hand. Steps 1-4 and 12-13 all measure mobility, for they require the Porta-Boulder to be moved either by the vehicle mentioned in the previous paragraph, or by the climbers themselves. The second phase of testing measures ease of use, particularly in the case of setting up the Porta-Boulder. Steps 5-8, where the testers set the system up, as well as steps 10 and 11 during break down, all measure how easy it is for a climber to use the system, regardless of climbing ability. The final stage of the process is stability, which is measure by the climber during step 9. While actually climbing the wall, the tester can determine whether or not the wall will support his weight, by observing how much the system tips, if at all.

Recording Results
While the test is being completed, a third individual should be observing the procedures. At each phase, the observer shall record the scores in the displayed area, on a 100 point scale. Any additional comments may be written in the right hand column. After the test is complete, all scores should be averaged. If the Porta-Boulder earns a score of at least 77, it is a success. All scores should be recorded in the following chart:

Phase of Test Score (out of 100) Remarks
Ease of Mobility
Fit in Truck
Support Climbers
Stability

Ease of Set-up
Total


Testing Results
There were three tests of the Porta-Boulder. The following are the results:
Test 1
Phase of Test Score (out of 100) Remarks
Ease of Mobility 80
Fit in Truck 75
Support Climbers 90
Stability 80
Ease of Set-up 90
Total 415 83%
Comments: “Great success. The wall held strong while both Steven and I climbed, and only the front panel hang showed any issues. I will have to add additional eye-screws/bolts to the bottom corners of the outside wings. Then I will test again.”

Test 2
Phase of Test Score (out of 100) Remarks
Ease of Mobility 82
Fit in Truck 80
Support Climbers 90
Stability 85
Ease of Set-up 90
Total 427 85.4%
Comments: “Yet another successful run. I never made it to the hardware store, so the outside corners weren’t staked in. However, I did run a loop of cord through the joint in the lumber, and staked the loop to the ground. This managed to keep the corners in well enough, but I'd much rather have hardware for the final design.”

Test 3
Phase of Test Score (out of 100) Remarks
Ease of Mobility 85
Fit in Truck 90
Support Climbers 99
Stability 99
Ease of Set-up 92
Total 465 93%
Comments: “This final test was simply the best yet. The wall experienced zero tipping, and was a dream to load up.”

Conclusion

In summation, the testing of the Porta-Boulder went off without a hitch. Not only did the system perform precisely as it was intended, but it did so regardless of soil condition. The testing, performed in both the sandy soil of Sandy Hook and the sand/clay mix in Old Bridge, New Jersey, was flawless, giving the Porta-Boulder a final average of 87.13%. This, being a full 10 points higher than the minimum required score, would lead one to believe that the Porta-Boulder was successfully designed and constructed

Testing Pictures

This was one of the earliest stages of testing: Securing the support blocks.

In this shot, I'm actually bouldering my way across the wall. Note that I'm using the edges of the slats, to simulate cracks and jams found on an actual rock face.

And finally, after a few good climbs, my fellow tester Steve and I relax on top of the wall, showing it's stability and strength.

Testing Results

The final design of the Porta-Boulder is intended to be a free-standing climbing wall, which can fold upon itself to fit into the back of an extended bed pick-up truck. Upon arriving to the test site, the testers, who should be a pair of climbers between 150 and 250lbs, will remove the Porta-Boulder from the back of the pick up truck, where it fits comfortably. The testers must then carry the device 15', to meet specifications. Once at this final point, the testers with lift the Porta-Boulder into the standing position, and unfold the two wings. The Porta-Boulder should be able to stand on it's own when the wings are turned within the 60 degree range and the supporting lines engaged. The wings will then be locked into place, and the support lines connected. One of the testers will then climb from one end of the wall to the other, while the second tester spots him. If the wall supports the tester's weight and the tester is capable of completing the run, the function test is complete. The testers must then release the supports, unlock the wings, fold the device, and return it back to the vehicle for transportation. The device, upon fitting into the vehicle a second time, has completed all specifications and limitations on size and function.


The testers (two 150-250lbs climbers) will:


1) load the folded Porta-Boulder into the back of either a Ford F-250 or Dodge 2500 (comparable or larger) pick-up truck, with an 8' bed.


2) transport the device to the test site, where the testers will unload it.


3)carry the Porta-Boulder a minimum of 15', using handles attatched to the closed wings.


4)lift the Porta-Boulder into the upright position.


5)unlock the folded wings.


6)unfold the wings to the 30 degrees from the face of the main wall, creating a "u"

7)attatch the support lines to the support block behind the Porta-Boulder.

8)stake in the support block, leaving two stakes on the side opposite the Porta-Boulder

9)climb from the far left side of the device, to the far right, alternating as spotter and climber.

10)disengage the support system

11)fold the wings back to the device, locking them in place.

12)carry the Porta-Boulder back to the vehicle.

13)reload the device.

14) TEST COMPLETE



Spec/Limit: Score
Ease of Mobility:
Fit in Truck:
Support Climbers:
Stability:
Ease of Set Up:


While the test is being completed, a third individual should be observing the procedures. At each phase, the observer shall record the scores in the displayed area, on a 100 point scale. Any additional comments may be written in the right hand column. After the test is complete, all scores should be averaged. If the Porta-Boulder earns a score of at least 77, it is a success.

Marking Period 4 Calendar

20 April- Affix Carabiner
21 April- Begin forming rebar into stakes
22 April- Calendars Due
23 April- Attempt to use wall while staked
25 April- Begin work on Evaluation
4 May- Test #1
4 May- Mentor Contact
5 May- Adjust prototype
6 May- Test #2
7 May- Adjust prototype
8 May- Test #3
8 May- Mentor Contact
9 May- Complete Evaluation
10 May- Outline FPU4
12 May- Self and Design Evaluation due
12 May- Testing, Results, Product due
13 May- Begin work on exhibit
13-15 May- Formal Progress Updates
16 May- Mentor Contact
18 May- Send invitation to Jamie
19 May- Exhibit Due
21 May- Exhibit Night
22 May- Mentor Contacts due
10 June- Journal Article due

Marking Period 3 Calendar

February 3 MP3 Calendar Due
February 4 Finish Hold Analog w/ Bolt Assembly
February 6 Complete Torque Testing of Hold Analog
February 9 Begin Hold Construction
February 21 Gather Materials for Climbing Faces
February 23 Bring Materials to School
February 25 Complete Hold Construction
February 26 Begin Lumber Sizing
February 27 Complete Lumber Sizing
February 28 Begin Work On Press Release
March 4 Complete Press Release
March 5 Press Release Due
March 6 Begin Assembly of Center Face
March 10 Complete Construction of Center Face
March 11 Begin Assembly of Left Face
March 16 Complete Construction of Left Face
March 17 Begin Construction of Right Face
March 18 Construction/Production Info Due
March 20 Complete Construction of Right Face
March 23 Begin Affixing Holds to Center Face
March 25 Complete Affixing Holds to Center Face
March 26 FORMAL PROGRESS UPDATE 3
March 30 Mentor Contacts Due
March 31 Begin Affixing Holds to Left Face
April 1 Logs DueApril 3 MARKING PERIOD ENDS

Assembly Procedures

The assembly of the Porta-Boulder is exceedingly easy, because there are very few parts. First, the climbing faces must be constructed by fastening the climbing face boards to the support posts. The climbing faces are then affixed with climbing staples at the corners, to attach lines to the anchors. The climbing staples are then affixed to the anchor pieces. The final step is to affix the climbing holds to the climbing faces, approximately one every square foot.

1. Attach long face boards to support posts.
2. Attach short face boards to support posts
3. Attach staples to anchor and faces.
4. Attach faces using hinges
5. Attach holds to climbing face.
6. Attach all anchor points using static lines