immortus evx solar car modified for slideshare upload_chassis slide
TRANSCRIPT
Immortus EVX Solar Carfront suspension mount
Josh PattersonJai CornesSteve TaylorAnthony 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
Y e i ld . T e n s (Mp a ) S tr e n g th to W e ig h t Y o u n g s Mo d u l u s (G p a )
880.
0
113.
8
414.
0
72.4
600.
0
70.0
Property ComparisonTitanium Alloy (Ti-6Al-4V) Aerospace Aluminum (Al-Cu4-SiMg)CFRP (120deg Epoxy Cure)
Our Design Journey Initial mind map
Existing Chassis Model
Our Design Journey
Iteration 1: Titanium ButtressPros Cons
Relatively simple design
Too much material used
Meets strength requirements
Too heavy
Chassis Mounting Issues
Our Design Journey
Iteration 2: Carbon Fibre ButtressPros Cons
Very light Too much material usedUnconventional 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 design literatureChassis mounting issues reduced
Our Design Journey
Iteration 4: Titanium truss with carbon fibre core ( or wrap).Pros Cons
Extremely Light Little to no conventional wisdom
Meets initial design load requirements
Unconventional design may lead to unforeseen issues
Minimises titanium usageChassis 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