Beruflich Dokumente
Kultur Dokumente
2008
Development
DriveTrain
Chassis
DriveTrainShielding
SingleWheelVerticalImpact
SteeringandBraking
SAEtechnicalpaper2006013626
StaticEvents:300ptstotal
KennethMandeville TeamLeader
DesignReport=50to100pts
GuillermoBarba
MalloryBerry
PaulBunkers
BrianHunter
JorgeMejia
DanMoline
CharlesPhelps
JeremySchenker
JesseSoto
MattWalter
CraigWilkinson
Design=100to125pts
CostReport=15pts
BendTubes
TubeBender
CutTubes
ChopSaw
CopeTubes
Prototype=85pts
TubeNotcher
WeldTubes
Presentation=50pts
ManufacturingTechniques
Competitions
Rackandpinionsteeringsystem
6:4:1steeringratio
DynamicEvents:700ptstotal
Discbrakes
7inchStainlesssteelcrossdrilledrotors
ManufacturingTechniques
Competitions
TheTeam
Comet780CVT
Durabletransmission
Reachtopspeedof35mph
Withstand14ftlbtorquefromengine
Use4130chromolyangleironmounts
Backboneofthecar
Endureasinglewheelverticalimpactwith
afactorofsafetyof1.5
Keepdriveraliveduringa7.9gimpact
Weighlessthan80pounds
Maxallowablestress:42100psi
BodyPanelsandskidplate
Createmoldforpanelandskidplateshape
Applymoldreleasesolution
Layepoxywithfiber(23layers)
Applyclearcoat
Polishandshinefinallayer
Acceleration=60to75pts
ProjectStatement
HillClimb=60to75pts
Maneuverability=60to75pts
Suspension
ChassisAnalysis
ANSYSwasusedforallFEAanalysis,ie.rollover,sideimpact,dropforce.
Figuresbelowsimulateashockforcewitha250lbdriver,tubing,and100lbengine
andtransmission.
TheSAEMiniBajaisanintercollegiatestudent
engineeringdesigncompetition.Theobjectof
thiscompetitionistosimulatearealworld
engineeringdesignproject.Ourteamis
competingtohaveourdesignacceptedfor
manufacturebyafictitiousfirm,duetoeaseof
manufacturing,pricing,andperformance.
(2008BajaSAECompetitionRules)
Objective
ANSYSFEAforfrontshockforceat0.2sec
ANSYSFEAforrearshockforceat0.2sec
MaximumVonMisesstressof39818psi
MaxVonMisesstressof27442psi
BodyPanelsandSkidPlate
SuspensionAnalysis
Thebodypanelsandtheskidplateprotectthe
driverfromobjectsflyingintothecockpit.
Theskidplatemustwithstanda
pointforceof650lbs.
Equivalentenergyabsorptionto1/8inchthickaluminum
FrontUpperSuspensionArmFEA
Kevlar/CarbonFiberBlend
RearUpperSuspensionArmFEA
RearLowerSuspensionArmRender
SuspensionVibrationAnalysis
Unsprungmass
Timeline
RearLowerSuspensionArmFEA
Themodeltobelowshowsdiagram
oftheminibaja.Thismodelwas
usedtosimulatethesprungand
unsprung massreactionasthe
vehicleencountersroughterrain.
Sprungmass
Applyclassroomknowledgetopractical
situations
AbidebyallSAEregulationsandbuilda
competitiveallterrainvehicle
Buildahighperforming,lowcost,anddurable
MiniBaja
Createanaestheticallyappealingvehicle
CompetewellattheSAEMiniBajacompetitions
Havefun
Task
Date
BodyPanelsinstallation
3/28/2008
FramePainting,finalwelding
4/1/2008
Dyno finished
4/1/2008
Finalcarassembly
4/4/2008
Enginebreakin
4/8/2008
Swaybardesign
4/25/2008
VehicleTesting
5/1/2008
Competition
5/20/2008
RockCrawl=60to75pts
EnduranceRace=400pts
SafetyConcerns
LessonsLearned
Workeffectivelyasateamtoaccomplishagiventask
usinggoodorganization.(i.e.workdistributedevenly
throughsubteams)
Designprocessappliedtorealworldsituations
TheimportanceofaccurateFEA,andtheabilityto
chooseanacceptablefactorofsafety
Maintainingadynamictimelineisessentialtotimely
completion
Welldefinedengineeringspecificationsaidindesign
Hazardousmaterials
Bodysuits
Respirators
Machiningsafetyconcerns
Metalshavings
Nolooseclothing
Safetygoggles,gloves
Driversafety
Rollcage
DriverRestraints
Helmet,racesuit
Fireextinguisherincockpit
Budget
Subteam
Cost
Chassis
$481.50
Suspension
$1850.37
Steeringandbraking
$643.75
DriveTrain
$2191.34
BodyPanels
$705.06
SkidPlate
$176.12
Total
$6048.14
TestPlan
Suspensionandchassis
Looserailroadtrackstests
Minibaja willbedrivenover
railroadtiestotunesuspension
Tracktests
Fillsmeres MesaParktotestthecarin
competitionsimilarareas
Speedtests
Testspeedtofindcorrectgear
ratiotohavethemaximum
amountofpowerwithamaximumspeedof30mph
Simulinkwasusedtoanalyzethe
responseofthesuspensionsystemto
findtheidealspringanddamper
constantsforthesystem(k2 andb2).
Theotherk1 andb1 areconstants
relatedtothespringanddamper
coefficientsofthetires.