Date post: | 22-Jan-2018 |
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Engineering |
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Immortus EVX Solar Carfront suspension mount
Josh Patterson
Jai Cornes
Steve Taylor
Anthony Campana
Introduction
Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “
Introduction
Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “
What is Immortus and what makes it different?
Grid independent electric vehicle
Introduction
Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “
What is Immortus and what makes it different?
Grid independent electric vehicle
Limitations and considerations
Mass: less mass equals greater overall efficiency
Space:
Enclosed wheel well
Passenger/driver comfort
Performance: Immortus is a performance car, and must be design as such
Existing suspension design: We must design a mount for an existing suspension system
Introduction
Our design statement
“Design and build the front suspension mount of the Immortus EVX solar car. “
What is Immortus and what makes it different?
Grid independent electric vehicle
Limitations and considerations
Mass: less mass equals greater overall efficiency
Space:
Enclosed wheel well
Passenger/driver comfort
Performance: Immortus is a performance car, and must be design as such
Existing suspension design: We must design a mount for an existing suspension system
Specific challenges
Getting the required strength while keeping weight down
Acquiring useful materials knowledge.
Focus Areas
Material Selection
Titanium
Focus Areas
Material Selection
Titanium
Carbon Fibre
Focus Areas
Material Selection
Titanium
Carbon Fibre
Aluminium (galvanic corrosion)
Focus Areas
Material Selection
Titanium
Carbon Fibre
Aluminium (galvanic corrosion)
Manufacturing Techniques
Carbon Fibre Rod (Stock)
Focus Areas
Material Selection
Titanium
Carbon Fibre
Aluminium (galvanic corrosion)
Manufacturing Techniques
Carbon Fibre Rod (Stock)
Carbon Fibre Moulding (Custom)
Focus Areas
Material Selection
Titanium
Carbon Fibre
Aluminium (galvanic corrosion)
Manufacturing Techniques
Carbon Fibre Rod (Stock)
Carbon Fibre Moulding (Custom)
3D Titanium Sintering
Focus Areas
Material Selection
Titanium
Carbon Fibre
Aluminium (galvanic corrosion)
Manufacturing Techniques
Carbon Fibre Rod (Stock)
Carbon Fibre Moulding (Custom)
3D Titanium Sintering
Mechanical Design
FBD
Initial Design
Titanium buttress
Carbon fibre buttress
Carbon fibre truss (space frame)
FEA
Existing Knowledge Base
Existing information sources
SAE prior research
Technical Papers and Product Guides
3rd Party research papers
Existing Knowledge Base
Existing information sources
SAE prior research
Technical papers and product guides
3rd Party research papers
Conventional wisdom
Race car suspension design
Double Wishbone (Double A Arm)
Laterally mounted suspension
Space frames
Existing Knowledge Base
Existing information sources
SAE prior research
Technical Papers and Product Guides
3rd Party research papers
Conventional wisdom
Race car suspension design
Double Wishbone (Double A Arm)
Laterally mounted suspension
Space frames
Conventional materials used in modern performance vehicles
Carbon Fibre
Titanium
Aluminium
Steel
200.0
147.9
375.0
220.5
0.0
356.3
T I T A N I U M A L L O Y
( T I - 6 A L - 4 V )
A E R O S P A C E
A L U M I N U M ( A L -
C U 4 - S I M G )
C F R P ( 1 2 0 D E G
E P O X Y C U R E )
YEILD STRENGTH VS
DENSITY
Tension Compression
Our Design Journey
Initial mind map
Our Design Journey
Iteration 1: Titanium Buttress
Pros Cons
Relatively simple design Too much material used
Meets strength requirements
Too heavy
Chassis Mounting Issues
Our Design Journey
Iteration 2: Carbon Fibre Buttress
Pros Cons
Very light Too much material used
Unconventional Shape will be costly to manufacture in CF
Too much deflection
Chassis Mounting Issues
Our Design Journey
Iteration 3: Carbon Fibre Truss
Pros Cons
Extremely Light Too much deflection under compression
Uses off the shelf CF tube
Occupant interference
Plenty of designliterature
Chassis mounting issues reduced
Our Design Journey
Iteration 4: Titanium truss with carbon fibre core ( or wrap).
Pros Cons
Extremely Light Little to noconventional wisdom
Meets initial designload requirements
Unconventional design may lead to unforeseen issues
Minimises titaniumusage
Chassis mounting issues reduced
Current DesignTubular Titanium Truss with CF Core
Innovative design synergising existing modern materials and design techniques
Conventional wisdom did not seem to meet our requirements
Modern manufacturing techniques require new design paradigm.
Additive vs subtractive manufacturing
Must investigate behaviour of composite members
Literature does exist for individual elements
Must combine elements in conventional wisdom
Incremental improvement: Pre or post tensioning members
Potential new type of high performance design element
References1. Carbon fibre sheet:
https://www.acpsales.com/images/C/DL%20-%20Flex-08.jpg [viewed: 30/03/2016]
2. Carbon fibre tube:
https://www.acpsales.com/images/C/Roll-Wrapped-Tubes.jpg [viewed: 30/03/2016]
3. Titanium mesh ball:
https://i.materialise.com/blog/wp-content/uploads/2012/10/Titanium-ex03.jpg [viewed: 30/03/2016]
Galvanic corrosion bike frame: http://i1023.photobucket.com/albums/af358/masterquang/Giant%20Cadex%20980c/IMG_4040_zps97dac39c.jpg [viewed: 30/03/2016]
Carbon fibre truss node:
http://www.teleskop-express.de/shop/Bilder/shop/ts-ritchey-chretien/rc-truss-tubus-1000.jpg[viewed: 30/03/2016]
Sintered titanium light sabre handle thing:
http://s3files.core77.com/blog/images/2013/10/4cDesign-QBR-6-Prepolish-Full.jpg [viewed: 30/03/2016]
Double wishbone suspension:
http://www.motor-car.co.uk/images/Suspension/sping/multi-link-suspension.jpg [viewed: 30/03/2016]
Questions