Design package submitted for the SpaceX Hyperloop Pod Competition by Team Hyperlynx, an all student team from the University of Colorado Denver.

2. OVERVIEW
Team Hyperlynx will design, fabricate, and assemble a
pod to win the wheeled vehicle category of the SpaceX
Hyperloop Competition.
We intend to win by reaching the egress area as fast
as possible without crashing. Our design is tailored
to achieve this goal while featuring scalable, real-world
Hyperloop applications such as a modular payload.

3. John K. Bennett, PhD
Heather M. Underwood, PhD
RJ Duran
Mech. Engineering
Mech. Engineering
Mech. Engineering
Mech. Engineering
Design
Comp. Science
Architecture
Business
Mech. Engineering
Mech. Engineering
Mech. Engineering
TEAM HYPERLYNX
Connor Catterall
Ben Cooper
Nicole Garcia
George Kemp
Andres Lazo
Richard Michalka
Jack Nelson
Richard Paasch
John Spinelli
Mark Urban
Susan Waruinge
Chandler Lacy Mech. Engineering
Team Captain
CU Denver Advisors
Ron Rorrer, PhD
Doug Gallagher
Mech. Engineering
Mech. Engineering
Inworks Advisors
Sponsors
Supporters
Comp. Science
Comp. Science
Indust. Design

4. Design Description

5. TOP LEVEL DESIGN
The Hyperlynx Pod will be an
aluminum framed, rail-guided
wheeled vehicle. An ultralight foam
shell shapes the ten-foot long, two-foot
max profile, three-hundred pound pod.
A 12VDC battery powers networked
sensors and actuators, hydraulic disk
brakes, and real-time control systems.
A modular payload is featured
accommodating multiple
passenger/cargo configurationsExploded View

6. Exploded
Component View
Modular Payload
Body
Rotary Actuator
Master Cylinder
Brake Actuator
High Speed
Wheel Assembly
Secondary
Propulsion Motor
FrameSpaceX Propulsion
Interface
Brake Wheel
Assembly
Acrylic Canopy

7. DIMENSIONS / MASS
The pod will have a tip-to-tail length of 10.5 ft. The largest cross
section occupies 2.77 ft2
with a maximum height of 2.2 ft and width of
1.7 ft. The pod encloses and interfaces to the central I-beam,
traveling 1 inch above the aluminum sub-track.
10.5 ft 1.7 ft
2.2 ft
Pod Mass by
Subsystem
Total Mass: 300 lbs
Pod subsystems are designed to be as lightweight as possible. Several
methods realize this goal: lean manufacturing techniques reduce part
count and complexity, ultralight composite materials create structural
support at minimum weight cost, and system positioning leverages
natural strength points of the assembly.

8. MATERIALS
Aerospace Grade
Low Density Foam
1” x 2” 6061 Aluminum Bar
Acrylic
Stainless Steel
Linkage
Rubber Wheel
Aluminum
Brake Rotors
6061 Aluminum Wheel
Mount Assembly
Steel Mounting
Fixtures
Aluminum Wheel
with Polyurethane
Tread
Aluminum
Propulsion
Interface

9. STABILITY
20 custom machined wheels will hug the rail to keep the
pod laterally and longitudinally stable. The aluminum hub and
polyurethane tread will enclose a ceramic bearing rated up to
50,000 rpm. The design of these wheels was inspired by
technology found on high speed roller coasters.
Four vertical wheels on the flange and one horizontal wheel
on the web will be mounted to an aluminum assembly then
attached to the frame. Four of these assemblies, two
mounted in the front and two in the rear will ensure the pod
safely traverses the tube while traveling at high speeds.

10. BRAKINGA modified scissor jack linkage system will press four 10
inch diameter wheels outfitted with hydraulic caliper disk
brakes against the web of the central aluminum rail.
A rotary-actuated power
screw drives the linkage
system, allowing the desired
compression force between
the braking wheels and rail to
be adjusted in real time.
The disk brakes will receive
pressurized hydraulic fluid
from an electrically actuated
master cylinder. The master
cylinder actuator is spring
loaded, requiring power to
disengage the brakes, making
the system mechanically
safe.
Braking Assembly

11. AERODYNAMICS
The profile of the body is designed to accelerate the
air flowing around the pod. The nozzle geometry
created between the front of the pod and the tube will
increase the velocity of the air around the maximum
cross sectional area of the pod. The diverging shape
at the rear allows the high velocity air to expand more
rapidly, further decreasing drag.
Diffuser Nozzle

12. PAYLOAD
The middle section of the pod will
accommodate a fully removable
modular payload system capable of
housing the SpaceX test dummy.
A modular payload system in a full scale
Hyperloop design will significantly
reduce the cost of construction and
operation of the pods, support multiple
configurations, control weight
distribution, and allow rapid turnaround
of the pods at the station.
Modular Payload

13. PAYLOADThe payload will feature accommodations to support
the SpaceX dummy during its journey through the
Hyperloop.
Payload Canopy
with Graphic User
Interface
Features include integral
lighting, restraints and a
graphic user interface
featuring real-time pod data
projected directly onto the
canopy.

14. PAYLOAD CONCEPT
Conceptually, the payload modules would support multiple configurations and a variety of user types.
Single Person / ADA Sleeper Two Person Group / Family / Economy Cargo / Luggage / Freight
Controlling the arrangement of the modules will allow for optimization of weight distribution
according to the loads, improving the pod’s overall stability and performance.

15. PAYLOAD CONCEPT
A modular payload system would drastically improve turnaround
time once a Hyperloop pod arrives at the station.
This reduces the number of pods required to maintain the
operating schedule of the route, thereby reducing overall cost.
These modules will also optimize maintenance
and upkeep of the system by allowing time for the
modules to be maintained between use in the
system while keeping all pods in circulation.
Hyperloop Station
Concept

16. POWER
Component Power (Ah)
Linear Actuators 0.5
Rotary Actuator 3.1
Electric Motor 7.5
Controls and
Sensors
1.9
Total 13.0
One Power Stream 12V 22AH Lithium Iron
Phosphate battery outfitted with a quick-clip
terminal will interface into the modular payload.
This terminal will clip into the control board on the
pod, providing power to all components.
Battery Pack
Mounted to Modular
Payload

17. COMPUTING
Navigation Data
Environmental
Data
Microprocessor
LCD
Display
Brake Actuation
Output
Command
Signal
Light
Gyroscope
Accelerometer
Temperature
Barometer
Sensor Input
Signals
Network
Access Panel
External
Command
Center
SPM Control
Functional Block
Diagram
State Diagram
The embedded computer system
will continuously assess and
manage the condition of the
pod by utilizing real time data
gathered by onboard sensors to
control the pod’s critical
subsystems. The system will also
provide external communication
capabilities allowing for remote
control of all pod systems.

18. COMPUTING
The BeagleBone Black microcontroller was
chosen for its built in Ethernet/WIFI capability,
as well as the large number of GPIO ports.
The SpaceX provided communication board, an
LCD screen, accelerometer and gyroscope will
be mounted inside an acrylic control box.
This box will be placed underneath the modular
payload, connecting all actuators, motors,
sensors, and the battery. Two antennas will
be mounted at the top of the body and will
interface with the communication board.
Controls Systems Box

19. CC
C
ABD
D
E
COMPUTING/NAVIGATION
Position Sensor Frequency Picture
A Accelerometer 5.376 kHz
B Gyroscope 400 kHz
C Barometer/Thermometer 3.4 mHz
D Range 400 kHz
E Light 400 kHz
Sensor Map
A network of sensors will communicate
in real time with the microprocessor to
dynamically control the actuators and
motors.
The temperature will be recorded at the
front and top of the pod as well next to
the battery housing.
The gyroscope will measure yaw, pitch,
and roll. The acceleration, light, and
range sensors will feed real time
positioning and speed data to the
microprocessor.

20. PROPULSIONThe tube integrated propulsion system will interface with the frame
through a machined aluminum disk fastened at the rear of the pod.
This interface sits 10 inches above the aluminum sub-track. This
system will provide the initial impulse and will accelerate the pod at
2.8 g’s for 800 feet.
A pinned link connected to an electric actuator with a 2 inch stroke will
lower a roller outfitted with an electric motor. This system will allow
the pod to travel in and out of the ingress and egress holding areas.
This secondary system will allow the pod to travel up to 5 mph.
Propulsion Interface and
Secondary Propulsion Motor

21. SAFETY
The Hyperlynx safety package is redundant
and incorporates electrical and mechanical
mechanisms to prevent damage to the pod,
tube, as well as avoid injury to all personnel
operating the pod.
A complete safety plan has been assembled to
highlight safety features of the pod, both
mechanically and electrically. It also explains
hazardous material handling procedures in
addition to safety, health and environmental
considerations.
The FEMA identifies several modes of failure
and lists actions to mitigate failures.

22. SAFETY FEATURES OVERVIEW
Several sensors mounted within and
around the pod will monitor pressure,
speed, temperature, battery life and
overall pod health. If any of these
become critical, the pod will execute a
braking sequence to stop then enter a
low power state to prevent damage to
the pod or the environment.
In the case of complete power loss, a spring, mounted
between the rear dust cylinder and the end of the push
rod, will manually actuate the master cylinder. This will
apply brake pressure and slow the pod to a stop.
Spring Loaded
Brake Actuator

23. HAZMAT / STORED ENERGY
Our operational pod will contain brake fluid and
a single Lithium Iron Phosphate battery.
Team Hyperlynx will be trained in proper
handling and spill procedures of all hazardous
materials.
All documentation, MSDS, and a complete spill
kit, will be present during all transportation and
testing of systems that contain the hazardous
materials.
For complete hazardous material considerations
see the Safety Plan.

24. Pod Analysis

25. THERMAL PROFILE
The thermal profile on the outer shell of the pod is seen
below. The thermal simulation was performed after the
initial acceleration impulse at a speed of 260 mph, with
a tube pressure of 0.02 psi, and a ambient temperature of
100 ℉. The temperature of the pod remained under 105℉.
Temperature ℉
Thermal Simulation Results

26. AERODYNAMICS
The aerodynamic coefficients
of the Hyperlynx Pod were
found using computational
fluid dynamics and verified
with wind tunnel
experiments.
CD = 0.247 CL = -0.00467
CFD and Wind Tunnel
Prototype

27. TRAJECTORY
The pod will accelerate for the first 800 feet
and reach a speed of 260 mph.
At a distance of 800 feet from the end of
the tube, the power screw and disk brakes
actuate slowing the pod down at a rate of
1.7 g’s.
The braking sequence will take 5 seconds.
Coast Brake

28. Tscrew
FclampFclamp
FclampFclamp
BRAKING
The braking system will use a
series of linkages and a central
power screw to gain mechanical
advantage and compress four
braking wheels against the rail.
This symmetrical system ensures
equal force is applied on both
sides of the rail. The central
screw (Tscrew) provides up to 13 ft-
lbs of force, and transfers rotary
motion to a linear clamping force
(Fclamp) up to 1000 lbs.
Finite element analysis
of the linkage system
shows under maximum
loading conditions, the
linkage will not fail.
The maximum stress is
located on the center
link where the power
screw is threaded.
This linkage will be
manufactured out of
stainless steel.
Braking Linkage
Free Body Diagram /
Stress Analysis

29. VIBRATIONUsing software-based mode shape and frequency analysis,
part features are optimized by reinforcing critical points
tending towards unwanted shapes at resonance.
All vibrations that do transmit through the pod will be
damped using a 0.125-inch layer of natural rubber
between contact points of the pod, module and frame.

30. Structural Design Cases

31. ACCELERATION
A stress study was performed on the
frame to determine if the frame would
withstand the large force applied at the
rear of the pod during the acceleration
phase. The brake mount cross
beam had the highest stresses and
will not fail or yield under maximum
loading conditions.
143 lbs from Front
Caster
158 lbs from rear
caster
870 lbs from the
propulsion interface
98 lbs from Support
Beam
855 lb-in from braking
torque
Maximum Stress = 4,830 psi

32. NOMINAL DECELERATION
169 lbs from Front
wheels
131 lbs from rear
wheels
98 lbs from support
beam
4400 lb-in from
braking torque
In the deceleration stress study, the brake
support cross beam yielded the highest stress.
This was due to the large loading on the cross
beam from the torque generated by the braking
assembly. This stress is within the yield
strength of 6061 aluminum alloy.
Maximum Stress = 24,540 psi

33. END-OF-TUBE NOMINAL CRASH
255 lbs from front
wheels
4000 lbs on front of
frame
45 lbs from rear
wheels
3720 lb-in from
braking torque
For the end-of-tube-nominal crash a
force of 4000 lbs was applied to the
front of the frame to simulate the crash
scenario. These force values were
based on a deceleration rate of 400
ft/s². The frame stress exceeds yield in
the front.

34. Pod Production

35. PRODUCTION SCHEDULE
Preliminary Production Schedule

36. CONSTRUCTION COST
Pod Construction Cost
$8,455
Transportation & Misc. Expenses
$9,250
Total Project Cost
$17,705
Funds Raised
$9,663
Remaining Funds Required for Project
Completion
$8,042

37. Scalability Comments

38. INFRASTRUCTURE
With respect to the proposed Hyperloop route from Los
Angeles to San Francisco, a longer pod outfitted with
multiple payload modules would increase efficiency
while traveling longer distances.
The shape of the pod would be scaled to accommodate
a larger tube and bigger payloads. Full-scale pods of the
current design would weigh 1000 lbs unloaded. The pod
design allows for easy and low cost upgrades such as a
front facing compressor, rotor-stator system, or levitation
system. The high speed wheel assembly offers lateral
stability that non-wheeled Hyperloop pods lack.
Full-scale Hyperloop pods using this design can be cost
effective, with an estimated build price of under $100,000
per pod, excluding payload modules.
Full Size Pod
½ scale competition pod

39. OPERATION / MAINTENANCE
Features such as the modular payload, battery
location, and material choice allow for seamless
operation and maintenance of Hyperloop pods.
When a hyperloop pod arrives at the station, the
modules will be loaded and pre-staged with fully
charged batteries, passengers and freight. This will
provide fast turn around time, minimizing time in
the station. .
Maintenance would include periodic changing of
braking wheels, calipers, brake fluid, and high
speed wheel assemblies.
Hyperloop Station Concept

40. VISION
The Hyperloop has many potential crossovers with other emerging technologies, such as
virtual reality, vehicle automation, and ever-growing consumer access to powerful smart
telecommunication technology. These concepts, when considered as part of a larger
hierarchy, could lead to a paradigm shift.
The automation of
transportation infrastructure
allows us to envision a
conceptual “physical
internet” in which our ability
to traverse our real world
would become as effortless
as browsing a web page.
This system would create
entirely new ways for users
to live their lives.

41. Thank you.
www.denverhyperlynx.com