2024-10-21 Mechanical Meeting

Announcements

• Leads meeting moved to Thursday at 7pm

• GM tomorrow at 7:30pm in Welch 1.308

  • membership will be discussed during the meeting

• Motor testing was a success - problem we experienced at comp was identified

• Sensors - Philip chose them (please reference the “Mechanical Sensor Suite” spreadsheet on SharePoint

PDR/CDR

PDR: Saturday, January 18, 2025

• Have a mold review internal meeting the day before molds are sent out (in between PDR and CDR)

CDR: Sunday, February 23, 2025

Driver Placement Bias

Cooling Testing Results:

CAD design method

• This will be presented using a lecture format

• The goal of this presentation is to develop consistency in design across the board and ensure that people are implementing best practices while doing CAD

• What topics do people want covered?

  • Naming conventions

  • CAD organization, folders, naming features, reducing no. of features, circular references

  • Basic DFM

    • Manufacturing
      Reference sketch structure

  • Assembly management

    • editing parts in context

    • Defining origins

• Have this lecture in the morning (maybe not at the very start, just to let people trickle in)

• How do we want to approach reference dependencies - do we want to design in context of assemblies

Highlights

Does anybody have any highlights from the week they would like to share?

Blockers

It was brought to my attention that some people are having a difficult time knowing where/how to start since some design/architecture decisions haven’t been made yet. What are y’all having trouble with?

• We should implement the philosophy that designs can be started even without defined constraints. This involves incorporating enough flexibility in your design so that you can modify it once these constraints have been set.

• Finalized hardpoint locations (we can work with a general idea for now) but like also this isn’t exactly ideal

• Finalized hardpoint locations (we can work with a general idea for now)

• Front or rear biased (generally battery box and driver locations)

• Driver measurements

• 26 regs for battery capacity

• battery location (front, back, split?)

Workday Review

Suspension:

• Further progress on new member task of creating their own suspension

Steering:

• Looked into upper steering column and its relation to lower steering column geometry

Unsprung:

• Each member researched further and is starting to develop calcs for their section of research, started CADing practice unsprung parts.

Composites

• started making the array test panels, will finish next weekend

• Did some research as well

Aerodynamics

• Learned surface modeling

• everyone cadded a (very basic) shell except for Matthew who’s shell didn’t work

Frame:

• Talked with suspension for clarification on what rear trailing arm and double wishbone approaches look like for frame

• Also got together an approach for designing around hardpoints and making reference sketches

• Frame Parameters spreadsheet created

Ergo:

• Driver Model outline is finished; will only change slightly based on ergo jig collected data/survey data

• Ergo and pedal jig plans are finalized; just needs to be reviewed before being manufactured

• High level electrical schematic finally exists for daybreak

• Intake and Exhausts for daybreak new battery started (with new enclosure)

• Cooling Calcs for heat disspication - currently looking for thermal mass/amount of lithium inside of cells to get a numerical value. We have it symbolically solved

• Once we know heat generation, we can move onto dissipication efficiency of different solutions

Next Workday Plan

General:

• Go over the reference sketch and get the HDPT-DYN-24 sketch to be a thing

Suspension:

• Check up on member progress on their suspension designs hopefully they are close to being done or are done

Steering:

• Talk to Jacob about lower steering column and geometry

Unsprung:

• Practice CADs for their parts (uprights for Sumi and stuff) should be a thing and can be reviewed. Continue practicing through more designs and getting a feel for unsprung and its relations

Composites

• Finish array test panels, finalize initial tests, order materials, and start some of the work on daybreak

Aerodynamics

• Matthew teaches ansys

• work on surface modelling skills

• Teach basic assembly skills for wheels & wheel covers

Frame:

• Go over general statics/solids intuition as applied to frame building

• Continue determining general roll cage dimensions and creating frame reference sketch

• Create varying designs for front and rear of chassis (new member task)

Ergo:

• Review and then manufacture the pedal jig → Finish measuring drivers

• Continue adapting percy model with survey data and eventually measured data

• Generate a preliminary steering wheel design/manufacturing method

• Continue brake calcs

• Wire Harnessing - Do a more in-depth lecture with final details, signalling, etc for daybreak and come up with possible solutions for placement and topology

• Cooling - complete exhausts and intakes on battery and keep working on finding and calculating values we need and create a “database” of values we are finding

• Try to do waterproofing testing for univ enclosure

• get a design done for vapor smoothing chamber and start ordering parts eod

Daybreak Progress?

• New Suspension Geometry - due Yesterday
• New Wishbone Model - due Yesterday
• Select Spherical Bearings - due two days ago
• Bearing Mounting Scheme - due Yesterday
• Bearing Mounting Design - due Yesterday

• Progress on Refinishing bottom shell?

• Will start on this next week

• Shell to frame ideas?

• Pedal Box redesigning has progressed → Pedal Jig can be manufactured after review and new pedal/master cylinder location can be tested and verified

• When are battery materials getting ordered

• Already being done, only need ASA filament and aluminum stock for waterjetting

Questions people want to ask:

What do you need from me this week?

Timeline Items of Concern

• Hardpoints Finalized
• Shock Selected
• Brake Calipers Selected
• Wheel Bearing Selected

• Top Shell Mold Sent
• Top Shell Demolded
• Canopy Mold Sent
• Canopy Demolded
• Bottom Shell Mold Sent (Assuming we are still planning on getting this in at the start of summer)
•  

• Bounding Boxes Fixed
• Roll Cage Fixed
• Frame Passing Sims
• VR3 Order Sent Out
• Jigging Plan Complete

• Battery Box Panels Waterjet
• Modules Manufactured
• Battery Box Assembled