Concept Design through Optimization and Simulation at the Hydro2Motion Team

Johann Lohr & Bastian Henneke www.hydro2motion.de

Hochschule München www.hm.edu

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Introduction H2M

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Problem

• Until now the team has been focused on getting the car to finish the race distance.

• This season we won 5th place at Shell Eco Marathon Rotterdam and 2nd place at Educ Eco near Toulouse. Driving a distance of around 200km.

• In order to be able to win those competition we have to redesign our whole car concentrating on aerodynamics and weight.

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Frame requirements

• Space for driver, fuel cell, tires, batteries, etc.

• Driver overview as good as possible

• Low center of gravity

• Meeting all competition regulations

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Frame concept

• 5 cm roll bar clearance over head

• Steering angle of at least 12°

• No aerodynamic aspects

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Load steps

• Most demanding load cases and constrains

• Roll bar test with 800 N

• Driver getting in and out

• Braking, steering and accelerations

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Optimization result

• Starting designing the new frame

• Position of the beams because of the force flows

• Available design space and joints

• Aerodynamic development next to the space frame development

Steering

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Knee Lever

• Aluminium

• drilled and milled

• Weight: 99,7 g

• Displacement: 0,0004 mm

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Version 1 PA12

• PA12

• SLS by eos

• Weight: 19,2 g

• Displacement: 0,1 mm

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As good as possible?

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Version 2 PA12

• PA12

• SLS by eos

• Weight: 16,5 g

• Displacement: 0,09 mm

Result

• Reduction of mass 83%

• Total increase of displacement over the whole system less than 10%

• Better integration of functions

• Design of part more beautiful

• But biggest archievment through change of material instead of optimization

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Thank You!

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www.hydro2motion.de info@hydro2motion.de