07formulasaeweb

8/6/2019 07FormulaSAEWEB

1/38

AET

Formula SAEFormula SAE

04/27/2007


2/38

Team Members

Andrew Tyler

Shawn AlbertsonPaul Vandevender

Adam Pompa

Matt Davied

Jake Speilbusch


3/38

Introduction

PSU Racing is embarking on its inauguralFSAE competition. Our team of six

members was formed August 2006 andhas been diligently working to meet thegoals set forth by the FSAE Rulescommittee to compete in the west

competition June 2007.


4/38

Objective

The objective for the 2007 PSU racingteam is to complete the build of the vehicle

and finish all dynamic events at the westcompetition as well as laying a foundationto ensure success and continualimprovement by the team at future events.


5/38

Manufacturability

Our vehicle design utilizes commerciallyavailable products except for the frame,

uprights, fuel tank and drivers controlcomponents. This ensures replacementparts availability if needed, as well asproperly engineered parts for the

application.


6/38

Reliability

Designing our vehicle to use commerciallyavailable products minimizes design risk

by utilizing proven designs to meet thecriteria of the event. Our fuel injectionsystem, E.C.U. and drive-train were allassembled from commercially available

components designed to meet ourapplication.


7/38

Cost Efffectiveness

As stated above, we are a first year teamand have an initial budget of $15,000. Wehave chosen designs that meet the criteriaset forth by the rules committee andsatisfy our goal of producing a low-costvehicle. This approach will also help us to

meet the goal of building a vehicle under$15,000.


8/38

Conceptual Designs

The first conceptual design utilized sidepods housing two radiators and electronicequipment. The second conceptualdesign utilized a single rear mountedradiator with no side pods. After carefullyanalyzing cost and manufacturing time

projections, the second conceptual designwas chosen to be produced.


9/38

AET

Two Basic Body Designs

Side Louver Design

Consists of bullet type car but with sidelouvers.

Space for radiator and electronics.

Added Weight


10/38

AET

Two Basic Body Designs

Bullet design

Consists of a straight through body with nowings or side louvers.

Streamline design.


11/38

Frame

The vehicle utilizes a tubular space frame that is composed of T.I.G.(Tungsten Inert Gas) welded 4130 chrome-moly steel tubing.

The cockpit was designed to give the driver room for entering andexiting the car, as well as provide room for steering and shifting

motion of various sized drivers. The front portion of the frame provides ample room for drivers with

different leg lengths.

The rear portion of the frame was designed using the engine as arigid component.

A-arm and suspension mounting points of the frame were analyzedusing Pro-Mechanica and designed to have a safety factor of 3.

Throughout the frame, the members have been triangulated toincrease rigidity and reliability.


12/38

Impact Attenuator

The guidelines set forth by the SAE were met by utilizingproprietary soy-based foam from Pittsburg StateUniversitys organic polymer research center.

The foam, through finite element analysis as well asdestructive testing, showed an average deceleration of9.17g. Substantially lower than the 20g maximum.

The foam was chosen because of superior performanceto other materials as well as cost. The foam material

used in the attenuator was purchased for $3.24, a costthat is well below other material with similar properties.


13/38


14/38

Upright Assembly

Both the front and rear uprights are green sand castingsof 356 aluminum alloy with a T6 heat treatment.

The uprights were analyzed using Pro-Mechanica and

designed to have a safety factor of 3. Using pre-manufactured hubs and bearings from

commercially available vehicles allows the owner topurchase replacement parts from various suppliers.

Each upright assembly includes the same hub andbearings, this simplifies the manufacturing process.


15/38


16/38

Suspension

The suspension utilizes double a-arms in both the frontand rear.

The a-arms are comprised of 4130 chrome-moly steel

alloy round tubing. The material allows our safety factorof 3 to be met.

A single vertical coil-over shock with push rod activationis used on each corner of the vehicle for the dampeningsystem.

The a-arms attach to the uprights and frame using 3/8I.D. heim joints. The heim joints are installed in doubleshear to ensure a safety factor of 3.


17/38


18/38

Engine and Transmission

600 cc Honda Sport Bike Engine

Fuel Injected

6 speed Honda Transmission Linked to mechanical ratchet shifter


19/38

Engine Control Unit

An engine control unit (ecu) manufactured byDynojet research is used to control the fuelinjection system.

This system uses the stock ecu in conjunctionwith the unit from Dynojet.

This allows use of the factory spark curve andonly change the fuel map which is most effectedby the restricted intake.

The unit costs substantially less than a standalone ecu.


20/38

Restrictive Intake

An intake was manufactured using widelyavailable polyvinylchloride (pvc) piping.

The 20mm restrictor was manufactured out ofaluminum billet.

The intake system uses 2 pvc to connect therestrictor to the factory air box which containsone set of the factory injectors.


21/38

Drive-Train

A Torsen differential was selected and modified toaccept a 38 tooth 525 sprocket input.

This unit will provide traction to each rear wheel

proportionally, but allow one side to free wheel duringturns to prevent wheel hop.

Power is transmitted from the differential via splinedconstant velocity shafts which are then splined tocommonly available wheel hubs.

The constant velocity shafts used are from acommercially available vehicle and cost effective topurchase rather than manufacture.


22/38

Ergonomics

Drivers comfort was a major concern during design.

This matter was addressed by utilizing a movable pedalassembly to ensure drivability by drivers with crotch

height of anywhere from 30 to 36. This range waschosen to accommodate male drivers who fall betweenthe 5th and 95th percentile according to the DesignCriteria for Military Systems, Equipment and Facilities.This range also accommodates female drivers within the

50th-99th percentile.


23/38

Competition

Static Events

Cost and Manufacturing Analysis

Presentation

Design


24/38

Competition

Dynamic Events

Acceleration

Skid Pad

Autocross

Fuel Economy

Endurance


25/38

AET

Customer Requirements

Minimum 60 inch wheel base

Must have 4 wheels that are not in a

straight line. Wheels must be a least 8 inches in

diameter.

Must have dry (slick) and wet (treaded)tires to compete.


26/38

AET

Customer Requirements

Steering must affect at least two wheels.

Brakes must act on all four wheels from a

single control. Must be equipped with 5 point safety

harness.

Engine is restricted to 610cc or less. Air intake restricted to 20 mm.


27/38

Frame

PRV


28/38

Analysis

Static loading using Pro-Mechanica

Loads-

650 lbs Car and Driver

2 Gs Lateral

2 Gs Braking

3 Gs Vertical

PRV


29/38

AET

Analysis

PRV


30/38

PRV


31/38

SAA


32/38

Ex. Working Drawing

SAA


33/38

Routing Sheet

COMPANY NAME: PSU Racing Part Name: Rear Passenger Hub

Date: 11/17/2006 Size of Run: 1 Unit

Oper. # Description Operatio Material Time Feed/ Speeds5 Rapid Prototype RPT Poly 24hr NA

Create RPT part

10 Create Flask Ram Green Sand .5hr NA

Ram part i flask

Add gating system

Remove patterns

Place on pouring line

15 Pour Part Casting 356 Al Alloy 2hr NA

Pour 356 Al Alloy

in flask

Allow to cool

Break out part

20 Solution Treatment Heat treat 356 Al Alloy 24hr NA

Heat treat part in

furnace

Quench

Age part in furnace

25 Machine Holes Mill 356 Al Alloy 1hr ?

Machine bearing

surface

Machine ball jointclearance MD/AT


34/38

Final Assembly

SAA


35/38

SAA


36/38

MD


37/38

Conclusions

In conclusion, our vehicle design is simple yet effective.Through F.E.A, destructive testing, and research it isdetermined this design meets or exceeds all criteria setforth by the S.A.E. and PSU Racing. The goals ofmanufacturing a product that is easy to manufacture,reliable, and cost effective were met. By meeting thegoals set forth, a vehicle that is marketable to theaverage weekend racer was produced. We appreciate

the time taken by the advisory committee to review thisreport.


38/38

Questions?

07formulasaeweb

Documents