2024-10-07 Mechanical Meeting

Announcements

• Congrats on making it through SRR!

• Are we still taking the frame out this Saturday?

  • Coordinate with Electrical to see if we can do this 2nd half of workday (there are 9 people on composites)

  • After workday: we will have to gather some people (6 available atm)

• Machine shop training

  • We only have 15 slots for this training (in 2ish weeks)

  • Dynamics planning on training machine shop week 6

• NEW REGS

ClickUp for Daybreak

• Tag tasks with Daybreak on ClickUp

• Daybreak tasks should be as granular as possible

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What is something you struggled with this week? What is something you are proud of this week?

• Finishing SRR early enough for practice

• We got our SRR done for actual presentation day and got good feedback

• Members seemed to enjoy workday

• Harshit’s keyboard works

• wasnt confident in how the meeting went and how to do member accountability

• workday was really good, felt like all the members were engaged and having a good time(matthew wanted to kill himself tho)

• Workday was good, but a few members were missing : (

• SRR was good, constructive and valid criticism/pointing out oversights we had
  
  

• Good workday, all new members were there and started working on Solidworks. Also started sims for battery module.

SRR Key Takeaways/Next Steps

• Overall

  • Ideas for reviewing drawings and structure for estimating weights

  • Get reasoning for 3 wheel by PDR

• Suspension

  • Not being scared of aluminum welding and using that as a way to push ourselves

  • Quantify with just reasoning our parameters like 60-40 or FOS

• Steering

  • Look further into gearbox design as the issues we were maybe afraid of aren’t as big of a thing

  • Look into tunability

• Unsprung

  • Figure out brake disks

  • Tolerancing of bearings

Overall

• we need to define how we are going to do reference points on the mold, and confirm that the knowledge is transferred

Aerodynamics

• We need to solidify the plan for splitting up work and creating different parts of the shell(nose, tail, how to we avoid it messing up the overall geometrey)

• Talk about roll cage in an intersystem meeting, because thats the next big thing that defines what we do

Composites

• Figure out design of windshield with respect to the polycarb and what materials we should use

• LOTS of wesley notes, not worth putting all in this spot since its lot of smaller specific notes

• resin infusion is a risk and will cost a lot of money (vacuum)

• consider having aeroshell PDR at the same time as dynamics and frame CDR

• Be more thoughtful/less arbitrary with goals (i.e. goals were good, but have them bounded better, and be able to directly measure/compare them in the future

• Really really review composites plan to ensure we can make good progress while reaching our key frame goals

• Be more thoughtful in ergo design, think more about possible situations/applications (minimize oversight)

• Difference between making a part that would be cool, and making a part that is practical and effective (i.e. carbon fiber steering wheel vs fiber glass steering wheel)

• Rethink whether we really need so much of cooling, vibration dampening, etc

• Have a good testing and simulation plan - know the basics.

• Do composite testing but only test for your expected loading/impacts. Wastes time

• Add FOS to only few parts and then design other parts to handle extreme cases

• Shield all HV cables - probably a source of most EMF interference

• properly fuse all battery connections

• Match mechanical loading of rest of the car in terms of FOS/what we can see during transport

• Base cooling off of RMS current

Workday Review

• Overall

  • Jacob’s solids Lecture

• Suspension

  • Walked through suspension parts

  • Assigned members new member project of design their own suspension and vsusp

• Steering

  • New members caded basic ackermann model and design considerations for upper and lower steering

  • Showed how 6 bar linkage works to achieve ackermann and new members caded it

• Unsprung

  • Walked through unsprung components and potential designs

  • Gave research tasks

Aerodynamics

• more solidworks training

• got them going on looking at a bunch of cars and thinking about design

• taught how to import an airfoil

Composites

• solids lecture!

• spent more time doin researching

• had meetin w array and dynamics to discuss scope of projects/testing (for array cooling and push rods respectively)

• Should have materials ordered for mold prep and for push rod testing ordered

Both

• vibes were really good in both teams, feels like people are enjoying being there

• Ergo got directly distributed projects to get started on (new members → ergo jig) (old members → daybreak re-designs)

• Frame learned about weldments, used weldments, then performed FEA on a structure in SolidWorks. Also, got them up to speed on FEA theory and gave then a little walkthrough/rundown of ANSYS
  
  

• New members started solidworks project

• Enclosure design almost done

• Started working on an equation for calculating the heat dissipation of a single cell

• Battery internal PCBS done (need to add a few components but major design complete)

Next Workday Plan

• Overall:

  • Play SRR for ppl that weren’t at SRR

• Suspension:

  • Basic suspension overview again - SIMPLIFIED

    Go over notes of the video together

    Go over questions

    Go over the starter project - 1 hour to work on it

    Explain it step by step and show my model

    Go over assignments with DAYBREAK

    Explain in detail the different geom and design changes for it

    Control arm

    Bearing selection

    Extender fix

    I walk through esther master model - if i can finish it

    Clickup?

• Steering:

  • Calculate physical geometry for Ackerman for 6 bar

    Daybreak tasks (still needs to understand more)

• Unsprung

  • Mockup designing (architecture pros and cons)

    Brackets (mounting with wishbones and steering)

    Hubs

    Axle/Spindle

    Upright

    Research

    Figuring out deliverables today

    Sumi: bearings

    Sohan: brakes

    Jonathan: tires

Aerodynamics

• Introduce members to surface modeling

• continue work on the aerodynamic profile slides

Composites

• continue researching projects

• if we can remove frame we’ll start working on fixing the inside of the shell

• Assign frame members direct tasks

  • Get started on reference model of frame, possibly start making an oc prototype

  • Begin frame jig design brainstorming

• Continue ergo tasks

  • Finalize ergo jig plans/design

  • Continue pedal box redesigning

  • Continue steering wheel research

• Start giving real tasks to new members

  • Acetone bath rig

  • Vibration testing

  • Water ingress barriers

  • New cooling system for daybreak

• Start eplan training if we have licenses

• Hopefully battery is done by then so we can start manufacturing plan and more detailed timeline + start ordering materials

• Make general layout for dashboard buttons to give to controls

Daybreak Progress?

Finished SRR and now can begin CADing the new control arms

nope, waitin to remove frame

nah

^

Module sims, heat calc and heat pipe research progress

Questions subsystems want to ask:

• Ergo: if we get a driver dimension form together, can every channel blast it out so we can have driver data : D

• Notes: Need driver height (torso height) and weight,

What do you need from me this week?

• No lectures planned for workday

  • if lecture is planned, let know by Wed

• Getting new members on Confluence, Bild, and ClickUp

• Getting members on confluence. Members should sign in once and then Michael can add them to the space

• Set a date for confirming hardpoint location

  • dependent on internal vs. external suspension decision