2024-11-19 Leads Meeting

 Attendance

Michael Mohn
Philip Bortolotti
Hardhik Sripuram
Gerard Cardenas
Pratyush Patra
Diya Rajon
Lakshay Gupta
Andrew Yin
Pablo Romero
Frank Li
Parthiv Shah
Noah Hickman
Harshit Dalmia
Jason Heston
Aidan Hodgin
Advait Joshi
Matthew Murzaku
Kaden Nguyen
Kenta Yoshizaki
Devansh
Ravi
Oscar
Cesar
Kadhir
Kayla

General Updates

  • General Meeting at 7:30 this Thursday in ECJ 1.202. React for Cabo Bob’s

  • Facilities updates

  • Buy Solar Merch before midnight.

    • Laser Cutter has been removed from the ETC Garage. This gives us a much larger working footprint. Solar could try to negotiate for some of that space for frame welding purposes

    • Walt cleared out the flammable cabinet in the engine room

  • Would people be interested in a pre-thanksgiving or pre-winter break movie night/karaoke? Philip will send a message out tomorrow gauging member interest.

    • nobofy give a fuck

  • Daybreak

    • Driveday updates: the car drove. It then broke because of blown fuses in the controls system. Buy more fuses (Michael already did it). Could be the precharge. Diya was going to work on it during thanksgiving break, but doesn’t know what is causing the issue. No HV involved. Advait will go up the same time, after 5 pm.

    • Gerard and Cesar will grind out dynamics over break. Before winter break want to do empirical testing to see how much load shocks need to bottom out.

 Goals

  • Get updates from leads


Operations

  • Any tire updates?

  • Old president of UT SVT who wants to come visit. Are they goated? Feather guy

Chief Engineer


 System Updates

Controls:

Updates

  • Motor Controller STILL isn’t working (no more CAN Issues tho)

    • Parthiv can say more abt this

    • Don’t think this is from Controls side, need to verify.

  • Three more members know how to use profinity/set up + debug

  • Maddie and Krish - Layout in progress

  • Lucy - Lighting schematic draft reviewed

  • Oscar - Leader Dash, SendTriitum

  • Mika - Addressing Parthiv’s ideas on dashboard, addressing pedals board accel sensor

Week Plan

  • meeting with Eliana Thursday to look at brakeline for board

  • I intend to stay on campus throughout break to catch up on whatever work is behind (after 5 PM everyday): pedals board, MC fix if possible, ordering, finalizing with dash etc.

Upcoming Deadlines

Pedal needs to have first draft completed EOW.

BPS:

Updates

  •  Boards are developing

  • Michael tested his watchdog on hardware but there’s some weird stuff going on, will be starting RTOS stuff soon

  • Phoenix is testing her RTOS stuff on a Nucleo now

  • Aneri got SPI running on Nucleo and is working on it over break

  • Clark is pretty close to starting layout and I think he can get it done pretty quickly

  • Abby is also pretty close to starting but she needs to address comments on the schematic

  • Progress on Amperes board is kinda slow, if it conitnues to be slow I’ll starting adding more help

Week Plan

 

Upcoming Deadlines:

  • 11/09/26 - BPS Software Architecture

  •  

 

Power Generation:

Updates

  • Accepted quote for MPPT

  • Tanya and Tong about to send review request

    • Constant current lighting driver schematics

    • Temperature sensor schematics

  • Erika started ADC breakout boards layout

Week Plan

  •  

 

Upcoming Deadlines

  • 12/16/2024 - Order boards

  • 01/19/2024 - Array x Mechanical PDR

 

Data Acquisition:

Updates

  • Weather + Array + Battery + Terrain all integrated. Working on simulating dynamics.

  • RF Receiver schematic complete. Working on layout

  • IMU/RPM board schematic complete. Working on layout.

Week Plan

  • Give thanks to the people that have given us so much

Upcoming Deadlines

Nov 23, 2024 - RF Board Layout

Nov 23, 2024 - IMU/RPM Board Layout

 

Power Systems:

Updates

  • Power board layout complete. Waiting on review. Reviews will be addresed prior to thanksgiving break and ordered by the same deadline.

  • Contactor driver and dataacq env board ordered.

  • eFuse testboard ready for review. Will be ordered alongside power board

  • Good progress on env board software (reading humidity and temp values on terminal).

  • Active precharge board undergoing a slight change (changing power delivery from LDO to buck). Finished and awaiting review.

  • Power monitoring board sch reviewed. Layout will start soon.

  • Encountered some issues when trying to spotweld on sigmaclad. Reached out to Kevin Yu (electric) with observations and questions. Havent recieved a response just yet.

Week Plan

  • Continue battery manufacturing (spotwelding) testing

  • review active precharge and eFuse testboard.

  • We also try out hand at the challenges placed before us. But we do it better.

 

Upcoming Deadlines

Nov 9, 2024 - Power Board Layout
Nov 24, 2024 - Order Power Board
Nov 24, 2024 - Order eFuse testboard
Nov 24, 2024 - ESP32 Batt Char board sch
Nov 24, 2024 - Power Mon board layout
Nov 24, 2024 - Active Precharge layout

Electromechanical:

Updates

  • Started on Eplan

  • spot welding problems, going up sometime this week to hopefully get test module built

  • battery box locks finished with fea completed as well

Week Plan

design review for final cooling parts before we come back

complete mppt and motor controller cooling

 

Upcoming Deadlines

Dec 4 - MPPT and MoCo Enclosures

 

Body:

Updates

  • Frame 1st iteration had to be redone

  • Jig Design plan and Welding order started

  • Pedal Jig used, pedal ratio was tested and confirmed for daybreak pedal box redesign

  • Steering Wheel layup setup tested, CFC viable for steering wheel construction, needs some refinement

Week Plan

  • Go over welding theory to help with jigging/welding plan

  • Re-finish 1st frame iteration, start ansys sims

  • Decide pedal box placement/bounding box

  • Continue work on Daybreak pedal box redesign

 

Upcoming Deadlines

Nov 16, 2024 - Roll cage position/dimensions set
Nov 16, 2024 - Driver Model finalized

Dynamics:

Updates

  • General:

    • Manufactured inserts for composite testing

  • Unsprung:

    • Decided brakes

    • CAD for rear a-arm structure

    • Sohan began learning manufacturing with me and Gerard

  • Suspension:

    • Talked with fergo to better understand bounding boxes and HDPTS need to be changed

    • All members got Ansys installed

    • Carter is doing finding the loads related to bell cranks

    • Oliver and La’akea began learning manufacturing with me and Gerard

  • Steering:

    • Found lower steering rack geometry

 

Week Plan

  • Unsprung:

    • More mockup designs for both front and rear

    • Break button dimensions and forces on the rotor when we lock up

  • Suspension:

    • First iteration rear reference sketch

    • Load conditions for suspension focusing on bell cranks

    • Oliver and La’akea testing pushrods

    • Test with dummy suspension

  • Steering:

    • Reviewing lower steering rack geometry

    • Members work on designs for upper steering, figuring out how gearbox will work

 

Upcoming Deadlines

Nov 16, 2024 - Brake calipers and rotor size decided (Arav got us this data) - Unsprung
Nov 16, 2024 - Upper steering architecture selected (is in talks with ergo and suspension)- Steering
Nov 16, 2024 - Bump steer design optimization - Steering
Nov 16, 2024 - Version 1 of Upright design in CAD - Unsprung
Nov 16, 2024 - Finalize brakes and rotor config (Arav got us this data) - Unsprung
Nov 23, 2024 - Caliper and motor mount for Swingarm - Unsprung + Suspension
Nov 23, 2024 - Decide bearings - Unspung
Nov 16, 2024 - Version 1 of Hub design in CAD - Unsprung
Nov 16, 2024 - Suspension Geometry Finalized - Suspension

Aeroshell:

Updates

  • Aerodynamics

    • Finished up designs for each members respecitve parts

    • Matthew sims lecture pt 2

      • getting through sims for most parts

  • Composites

    • Battery box layup, metal sheet, resin calculator sheet, test fixture for shear test designed and now its bad

    • Niloo found a company that can may be able to make us a foam mold for bottom shell for mold release testing (working on getting a quote rn)

 

 

Week Plan

  • Aerodynamics

    • Prep sims by meeting, throw em in TACC during meeting

    • hopefully theyve picked what design they want to put on the final car by the end of break

  • Composites

    • advait going to live at pickle over thanksgiving break, finish daybreak prep and battery box layup

    • jaden going to recad test fixture

    • first composite insert bonding test on thursday

    • Do post processing for first fcf test, figure out all changes that need to be made to fix it/ what vars we want to mess around with

 

Upcoming Deadlines

Nov 20, 2024 - aerodynamics members have sims prepped
Dec 3, 2024 - Battery box layups + Kaden's test panel complete
Dec 3, 2024 - Daybreak shell prep complete and ready for shell to frame attachment

 Action items

 Decisions



  1. Array will be having a design review on the same weekend as mechanical PDR Janurary 19th
  2. Saturday - Dynamics, Body ; Sunday - Emech, Aeroshell, Array

 

Notes over Meeting

Saturday Workday Attendance (Optional)

Less than half of leads will be there.

Not many members

  • None for body or composites.

Who’s going to pickle?

Maybe Aero.

Thanksgiving social ideas?

  • Movie night

  • Karaoke?

Ishan brought food.

News

Laser cutter has exited LHR garage (more space)

Walt cleared out flammable cabinet in the garage so now flammable stuff can go there.

Michael was cleaning up controls room and found something he could sell for $6k.

Ops updates

Old president of solar team who wants to visit, but Nathan is gonna deal with that probably.

  • Some feather guy mentioned?

Chief Engr updates

Feedback form sent. Phillip wants to improve so fill it out. Especially if you want to criticize.

Projects:

  • Creating dyna ref sketch with displacements in it.

  • Advait and him met with materials lab prof for testing fissures for composites.

  • If you wanna offload, then you can ask Phillip for help.

Concern: progress on array layout and it’s future.

Daybreak update (possible winter break plans?)

It drives :) It used to drive :(

Some issue surrounding busted fuses.

  • Issue could be precharge (sending too much current through without waiting)

    • Diya will work on this over winter break.

Gerard and dynamics are planning on grinding out stuff over Thanksgiving + Winter break.

  • Before winter break, want to do some empirical testing to see how much load is necessary for the shocks to bottom out.

    • Don’t need anything ordered as of rn.

Master cylinders (for brakes) were put back in, and they were re-bled.

For Array PDR - Are we going in-depth on the design of our PCBs?

  • Probably not

  • Anything that is tied to the mechancial design and layout of array should be brought up at PDR so we can get feedback.

  • Sensor layout and mounting

Exact dates have not been specified as of right now for PDR.

  • Should prob choose a day that electrical can attend, and that most people are available.

    • 2 on Saturday, 3 on Sunday (Jan)

    • Mechanical design reviews will be sometime in Jan 17-19 (friday + weekend)

Aeroshell is currently teaching people how to sim (prob CFD).

ANSYS meeting

  • ANSYS is giving us training licenses for learning hub.

Body updates

  • Welding order + jig finalized before pdr

  • Validated pedal ratio on daybreak pedal box

  • Steering wheel layup to see if we can use “chopped carbon fiber”

    • Apparently we can use it - part was fully assembled and worked.

    • 3D printed mold, used chopped cf on a piece, we may have used too much resin and the 3d printed lines from mold were showing on part.

When is welding training happening?

Combustion + electric doing their welding rn, but can use a diff table when they aren’t doing stuff. Apparently one of the welders' wire is cut so unusable as of now.

 

 

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