2024-11-11 Mechanical Meeting

\uD83D\uDDD3 Date

11 Nov 2024

\uD83D\uDC65 Participants

Gerard Cardenas

\uD83E\uDD45 Goals

Weekly progress check
PDR Progress Check

\uD83D\uDDE3 Discussion topics

Item

Notes

Announcements

There are two workdays left until the end of the semester
- Remember that PDR is January 18, the first Saturday right after we return from winter break
- Preliminary Design Review Guidelines
Please follow the Bild naming convention
- if your members are working on the same part and have competing designs, those should not go on Bild. Only parts that are selected to go through the iteration process should be on Bild
- Hardware components, numbering system

Highlights

PDR Progress Check

Dynamics

Body

Electromechanical

Aeroshell

Suspension

Suspension Type Selected
Hardpoints Finalized - end of week (11/16)
Shock Selected
Shock-Pot Mounting
Motion Ratio, Spring Rate determined

Frame

Bounding Boxes Finalized

End of week (11/16)

Roll Cage Finalized

End of week (11/16)

Passing Frame Sim

end of idfk

Preliminary Tab Placements

tbd

Battery

Battery Layout Finalized

Aerodynamics

Top Shell Finalized - pretty close to the date they were supposed to be done

Have architectures figured out by Thanksgiving break

Initial Shell to Frame - haven’t started discussing yet

Frame tabs

Shell-to-Shell Options
Preliminary CFD Results
Pitot Tube Mounting

Unsprung

Brake Calipers Selected
Hub and upright prelim design - end of this week
Wheel Bearing Selected - by Thanksgiving break
IMU, Hall Effect Mounting

Enclosures - dependent on electrical (still working on fixes) - 75% chance to have by pdr

Enclosure Mounting Locations
Number of Enclosures Fixed
Waterproofing Plan

Steering

Rack Selected
Ackerman Geometry Finalized
Upper Steering Linkage Power Transmission Chosen
Pot Mounting

Ergo

Preliminary Pedal Box - will start after member is trained

tbd

Driver Position Fixed

end of week (11/16)

Preliminary Brake Routing Diagram

tbd

Steering Wheel Design

end of semester

Ballast Location

tbd

Cooling - sending mock to officials this week

Cooling Strategy Selected
Rough Routing Scheme
Battery Thermal Testing Results

Composites

Research Results (short presentation) - starting testing soon

for cf pushrod testing - need to make inserts (Kayla and Advait on Thurs)

Mold Reference Scheme Selected
Manufacturing Plan

Wire Harnessing

Preliminary Wiring Diagram

	Dynamics:	Aeroshell:	Body:	Emech:
Updates/Blockers	Please update me on the progress you’ve made the past week. Do you have any blockers? YOU MOVE OUT OF THE WAY
Updates/Blockers
Workday Review	Unsprung ran sims on axle diameters, tried out SKF Sim Quick Pro for bearing and trailing arm geometry began development Suspension researched adams kinematics software, Kayla worked on refining her sketch to find non-hdpts defined values, trailing arm geometry began development Steering worked on bump steer research + created a 3D sketch for Ackermann because I had anti for some reason + found the C factor of the old steering rack on the car + found issues with steering placement relative to the bounding box that we have + found a steering geometry that should work for new gen	Aerodynamics: Matthew taught ppl ansys, 1 person was able to fully run a sim over the course of workday Composites: Battery box layup, worked on resin infusion research and test fixtures for composite panels	drivers sized → driver model can be finalized this week first frame iteration finished → simming to begin initial composite research finished → sandwich panel design and mount design next steering wheel designs (daybreak and nextgen started)	critical hardware back in car and harnessed mock cooling intake to send to regs
Next Workday Plan - please break tasks down into sub-tasks	Sim all the CADs that have been made throughout the week for Unsprung Steering will create CAD for the bumpsteer effects that they have been researching throughout the week Suspension begin simming the control arms and pushrods. Finialize HDPTs	Composites Battery box, first frame panel test subject, maybe machining test fixtures (not sure on this yet, depends on materials), design molds for wire cutter Aerodynamics Everyone have a sim done of the parts that they have made by next workday Getting into the flow of make variation, sim variation its really just CAD the shell until January 18th, so it may be repetitive, any tips on how to fix that?	start simulating frame → get initial data for first iteration create initial design ideas for frame jig continue working on steering wheel designs finish up daybreak pedal box changes (test pedal jig, finish design) start work on next gen seat	manufacture mock module characterize a few battery cells and bin have all battery box panel cutouts finished and dxfs created for waterjet only layups will be a blocker then
Daybreak Progress?	Created a preliminary design (CAD model) of the radial tubular intermediate steering shaft constraint	no shell rn so nothing, may just do prep over thanksgiving break? idk yet tho Ideas are there for canopy hinge and shell to shell, need to cook	nah	made intake mock before finalizing to get checked by steve and dan car can drive theoretically need to pump tires
Questions people want to ask:
What do you need from me this week?

Tabled discussions:

Being able to remove the master cylinders from Daybreak to test pedal box - talk to controls during leads meeting tomorrow
Keeping the sim/iterate process less repetitive for aeroshell
Coming up with a plan to accurately apply loads for suspension FEA

✅ Action items

⤴ Decisions

Meeting Notes:

Two real workdays left before Thanksgiving Break
Concern about part-level design and progress thus far to thanksgiving break
PDR is Jan 18, the first Saturday after we return from winter break
We only have a limited amount of time until the break, it’s come to the point where we will probably have to do work over the break
Naming convention is a real concern right now the longer we wait to fix it the harder it will be to fix. Leads and sub leads must take initiative on this
Advait Joshi needs to clutch up on Statics
System updates:
- Unsprung, in talks with calipers, bearings need to be set, haven’t looked too far into sensors. Might not have caliper selection determined by this week, still needs validation in order to make a selection. Preliminary design of hub+ spindle design by the end of this week. Projected date of selection is to have it done by the end of Thanksgiving break.
- Steering ackerman geometry and sterring linkage hasn’t been selected. Steering geometry update: they have a position but they need to test it for bump steer, needs to validate with better values, needs to utilize/refine Jacob’s code. Came up with an issue with where the rack bounding box will be placed relative to ergo and front axle
- Roll cage needs to be finalized by end of week (11/16)
- PDR - CADs need to be made, general geometry is made,critical mounting points need to be fixed (belly pan tabs, etc)
- Ergo next-gen pedal box design needs to start
- Shell to frame may need to have by PDR
- Shell to shell interface may also need to have by PDR
- Geometry issues with the shell with simming the current shell
Workday Review
- Dynamics
  - Manas and Johnnathen on trailing arm geometry
  - Steering 3D sketch of geometry
  - Concern with location of steering rack and ergo bounding box
  - hash out a plan for FEA
- Aerodynamics
  - Teaching Ansys
  - Simming approach
  - goal is for everyone to have a sim done on the parts they have
  - Composites: battery box layups
  - composite test fixtures and resin infusion
- Body
  - Driver model can be finizaled
  - frame first iteration done
  - how to integrate the composite sandwich panels and tubes together
  - Good work on the steering designs for next-gen and daybreak
  - Body
    - test setups need to be setup with current frame iteration
    - comtune work with sgeering wheel design
    - design and testing o pedal jig
    - starting work on nect=gen seat utlizing data from ergo jig