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  • Has every system decided on their sub-system leads?

    • Aeroshell

      • Aero lead: Aidan

      • Composites: Advait

    • Fergo

      • Frame: Josh

      • Ergo: Kenta

    • Dynamics

      • Steering: Evan

      • Suspension: Kayla

      • Unsprung: Sami

    • Emech

      • Cooling: Kaden

      • Wire Harnessing: Kailash

      • Enclosures: John

  • What are our thoughts on implementing a skeleton model this cycle?

    • Maybe there isn’t a choice, previous methods were not sustainable

      • there are good resources to teach people how to do it

      • Need to determine what characteristics and geometry - spend time outside of meetings to determine these things

      • Dynamics and fergo are the most applicable systems - aeroshell might not really need one/emech can reference the fergo one

    • Should we divert that energy into other ways to improve design of the systems

      • consider using the time instead to learn how to make things lighter, how to use ansys, how to better utilize simulations

    • Skeleton model will make the changes described above easier to implement

      • model will give members one singular model to reference to design parts from - makes it easy to review/catch mistakes, makes it easy for members to know what references they need to follow

    • Set a deadline for the skeleton sketch for when the new members are introduced. If not done by then, revert to previous methods (in context/part-level design)

Recruiting (Time: 10 mins)

...

System

Category

Number to Recruit

Aeroshell

Total

5 (whether or not members return)

Design

3

Manufacturing/Composites

2

Fergo/Structures

Total

3

Frame

2

Ergo

1 (+1 maybe +2)

Dynamics

Total

12 (maybe 9)

Steering

4

Suspension

4

Unsprung Mass

4

Emech

Total

6

Enclosures

2

Cooling

2

Wire Harnessing

2

Onboarding (Time: 30 mins)

...

Notes

General Ideas/Thoughts

  • I know we are pivoting away from lecture based learning, but should we have at least one lecture on CAD best practices for example? Or are we removing lectures entirely

  • Length of onboarding process: around 3-4 weeks to allow ample time to form solid foundation

  • Should we have people learn on their own? Since there isn’t enough time for one-on-one tutoring, is shadowing returning members while doing design work a good idea?

  • Assigning documentation and external resources?

  • Starter projects from Daybreak?

  • Philip’s two stage starter project idea?

  • Yes, one lecture would be good for introduction - maybe save the lecture for a little after members join so they get a feel for the software first

    • structure: put together an article detailing tips and best practices for reference

  • There shouldn’t be a moment where members are idle just observing - repeating work won’t be productive

    • instead, pair members together where the new member is working on the part and the returning member will be there for advice or explanation (not explain how to do it, but guide them to do it)

  • Systems can propose what ideas on what people can work on (since not all projects could apply to Daybreak)

Aeroshell

Strategy:

Composites: mostly hands on learning, actually do composites work.

Aerodynamics: teach solidworks over the span of a few weeks, then give people Daybreak parts to work on/other personal projects.

Curriculum:

Composites: 1x2 foot molds that are similar to bottom shell, do the entire mold prep to layup process so members know what to do.

Aerodynamics: work along soldiworks lectures, branch into let members make random things into solidworks and running solidoworks compeitions.

Potential starter projects:

Aero

  • For CAD, personal projects to increase motivation

  • Solidworks competition - give everyone something to CAD and see who has the best

  • Jump into next car if can’t find other projects to do

  • Work on prototypes for latch and hinging mechanism

Composites:

  • Hands on small scale work (described beside)

Fergo/Structures

Strategy:

Trial by fire (with help as needed)

Dive straight into making a simple part following ASC and VR3 guidelines, experimenting and asking questions as you go along

Curriculum:

  • Some sort of introductory slides on the systems and what we will utilize in each system

  • 2-3 weeks of designing a simple part start to finish, potentially 3d printing the parts at the end

  • Intro to basic solids, reinforced with FEA (e.g., beam in pure bending problem and compare results w/ FEA)

  • Developing best practices

    • 2D 3D sketches and weldments - using these to create a simple frame structure

    • simple FSAE structure to follow VR3

    • Ansys and FEA skills - simple cantilever beam problem and having them calculate stress/analyze results

    • Physical/empirical testing with popsicle sticks maybe?

Dynamics

Strategy: 2 weeks of independent study throughout the week and discussions and applications on workdays.

Curriculum:

  • Discussions with Jacob about content from classes like Solids

  • Each subsystem looks into different things

    • Suspension - Double wishbone vs Trailing arm

    • Steering - 3-wheel steering vs 4-wheel Ackermann

    • Unsprung - First other teams unsprung components like hubs and uprights. The purpose of those and then generative design and Ansys

Starter projects:

  • redesign wishbone (need to do it anyway - good holistic learning example)

Electromechanical

Strategy:
Since we work with every system on the car, we want to get them in front of the car, show them everything we do, how it works, shortcomings, etc.

CAD - Do a mini lecture showing all the features but have them try to design some simple parts but have them fix some issues, or at least attempt it. Go over these designs, talk about DFM.

TIW training on printers and laser cutting


Curriculum:

  • List of stuff on the current car we work on + how it works and why we need it, how electrical stuff interfaces with mechanical stuff

  • All 3 subteams will need to learn SW

  • Wire Harnessing will probably have to be a lecture based at first for the new software since it is very proprietary and a bit hard to use. Next part will be hands on working with wires and quality control. Starter projects to solidify EPLAN versatility

  • Cooling - basics of heat transfer + maybe look into people interested in learning ansys and getting them started, Starter projects (CAD)

  • Enclosures - Composites, strength to weight ratios for different configurations of composites, major focus on DFM

  • At the beginning, sit them in front of the car so they can ask questions and learn about the components

  • designing new parts to circumvent certain issues we faced on last car

    • make sure they are designing for manufacturability

  • Start training on printers

Timeline (Time: 50 mins)

Purpose: develop a rough idea of a timeline for your system, including major goals, their dependencies, and when you want to accomplish them by

  • Determine high level stages

  • First work backwards in creating the timeline then going forwards to adjust timing

Aeroshell

  • Milestone: Deadline

  • Ex.: Aeroshell mold sent out: 12/10/24

    Major Goals

    Dependencies

    Rough Timeline

    Demold top shell

    Design shell

    Fergo, what does the frame look like

    Dynamics, how much space will wheels take/ turning radius etc, exposed suspension

    Array - array size/config

    • Decide what the car will look like(3/4 wheel)

    • Design car in Solidworks: 12/14/24

    • Begin work on one half of car: 1/11/25

    • Finish that half: 5/3/25

    • Begin work on second half: 5/17/24

    • Finish full composite shell: 12/13/25

    • Completely finalized aeroshell: spring break '26

    Demold bottom shell

    Top shell layup complete

    Bottom shell layup complete

    ...

    Milestone: Deadline

    Major Goals

    Dependencies

    Rough Timeline

    Frame welded

    Frame validated and ordered

    • Driver dimensions taken

    • Seats molded

    • Frame Design drafted

    • Ergo Parts (pedal box, steering wheel, ballast box, etc.) drafted

    • Frame ordered

    • Frame welded

    • Ergo integrated onto frame

    Pedal box assembled

    Drivers set in stone, driver model created, pedal design validated and ordered

    Chassis width decided

    Dynamics geometry decided

    Dynamics

    Major Goals

    Dependencies

    Rough Timeline

    Onboarding/Training

    Recruitment

    • Training: 10/12/24

    • Preliminary Designs: 11/9/24

    • Final Designs Ideally: Before we leave for winter break

    • Final Desings Designs FINAL: 2/15/25

    • Manufacturing Begins: 2/22/25

    • Manufacturing Finished: Before start of winter break of 2025

    • Integration starts depending on other systems

    Trackwidth decided

    Volumetric bounding box decided

    Unsprung components assembled

    Suspension components assembled

    ...

    Major Goals

    Dependencies

    Rough Timeline

    Volumetric bounding box decided

    • Milestone: Deadline

    ✅ Action items

    •  

    (New Car)

    Frame/Dynamics - where battery can go, how much space there is

    • Training Finished - 10/12/24

    • Day Break Battery Architecure Finalized - Mid October

    • Day Break Enclosure design finalized (mounting, cooling) - Before Winter break

    • Day Break Battery Manufactured - End of Feb/Early March

    • New Battery Architecture + any new features Finalized - before winter break

    • New Battery Enclosure (with mounting and cooling) designed - End of March

    • New Car battery manufactured - Nov 25

    • New Car Battery/Electrical Testing - Dec 25 - Mar 26

    • New Car Top Level Layout Finalized - Mid October

    New Battery finished/manufacture (New Car)

    Electrical

    Frame

    New Cooling Finished (New Car)

    Frame, Aeroshell, Battery - duct routing, exhaust/inlet placement

    Possibly: Ergo, Dynamics, and Enclosures placements (in case of any interferences)

    High level placement of enclosures/electrical hardware (New Car)

    Electrical
    Frame - locate hardware + sensors on car

    Aeroshell - lights
    Ergo - brake and accel

    Battery Pack Module/Segment interfacing hardware/parts (Day Break)

    Power Systems - new/old cells

    BPS - how modules will be organized into segments

    Battery Box manufactured (Day Break)

    Driver cooling + motor controller design complete

    Controls

    Frame

    Dynamics

    Aeroshell

    ✅ Action items

    •  Have a discussion about how best to encourage people to join solar at trial work day, why didn’t people choose solar in the past, etc