2024-11-18 Mechanical Meeting

Announcements

• Harshit made a BOM: https://utexas.sharepoint.com/:x:/s/ENGR-LonghornRacing/EeX_HzdixPJJkmWbyRUHIOQBov6_tWhR663ZuV3Sf4sa2g?e=KjyW9t&nav=MTVfezAwMDAwMDAwLTAwMDEtMDAwMC0wMDAwLTAwMDAwMDAwMDAwMH0

  • This will serve as the official standardized BOM for the 24-26 car

• PDR is coming up. Please make sure to document things as they get finalized to save yourself some time later making the presentation.

  • I would recommend leads to start making PDR presentations. Look at the FSAE team’s sharepoints for examples

  • Much less rigidly structured than SSR. Main purpose is to show the solutions you’ve come up with and how you know they fulfill your requirements

  • Devil is in the details

  • Preliminary Design Review Guidelines

• Do y’all want your members to present their own projects at PDR?

  • Case by case basis

    • Dynamics yes

    • Aeroshell - split up slides

    • Emech - depends on how much will be presented

    • Body- yes?

Chief E Help Zone

• Are there any tasks y’all would like my help in solving, or to take off your hands?

  • dynamics reference sketch

Highlights

Blockers/ Conflicts

Do you have any blockers or conflicts that are preventing you from making forward progress/completing certain tasks?

Review of Last Week

General:

• Manufactured inserts for composites testing

Unsprung:

• Decided brakes

• CAD for rear a-arm structure

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

Aerodynamics

• Finished up designs for each members respecitve parts

• Matthew sims lecture pt 2

  • getting through sims for most parts

Composites

• More of battery box layup done

• METAL SHEET SANDED

  • working on sheet 2

• resin calculator sheet completed, made more accurate weight calc for next gen

• initial test fixture for panel shear test designed

• Helped (kinda sorta not really) with ergo’s initial fcf test

• Frame 1st iteration had to be redone (hardpoints changing caused this, that problem is solved now)

• 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 → needs to be refined?

• Started on Eplan

• Progress on daybreak battery cooling intake/exhaust

• Model Module Enclosure for testing design finished

• Panels almost done, thx advait

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

• car moved (does not move anymore)

• mold design research complete, starting work on power distribution enclosure

• battery box locks finished with fea completed as well

• Went to Taco Bell

Plan for this week - please break tasks down into sub-tasks

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

Aerodynamics

• everyone has a design made, and theyre putting them in ANSYS, want to put them all through TACC during the aeroshell meeting

Composites

• BB panel layups, finalize test fixture - double check all calcs etc, do first composite insert bonding test (thursday at 6, show up if you’re free (and interested in this)), also we may have found a company to manufacture small scale foam molds for testing mold release, working on getting a quote now (shoutout to Niloo!!) (also its in san antonio but whatev)

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

• Finish 1st frame iteration

• Decide pedal box placement/bounding box

• Continue work on Daybreak pedal box redesign

• Design reviews for all cooling parts (intake, exhaust, mppt, driver, motor controller)

• Finish exhaust and intake before break

• Continue working on heat gen and heat transfer calcs, maybe reach out to prof Ezekoye for review depending on progress

• Figure out optimal spot welder and bus terminal shape and build module

•  

Thanksgiving Break Assignments

Still deciding

Aerodynamics

• have finalized vague architecture design?

Advait - Finish daybreak stuff + finish battery box panels + finish processing for initial test of first forged carbon fiber test, figure out what to improve in manufacturing/prep process

Continue work on designing/planning ergo projects

Finalize ansys setups for frame sims

• motor controller cooling

• mppt cooling

• Intake/exhaust

Daybreak Progress

You tell me

• Continued progress on shell to shell to shell design

• Advait going to finish surface prepping shell over thanksgiving break

• Pedal ratio validated for pedal box

• Pedal box redesign picked up by Noah (previously Trevor), hopefully done soon

^^^

Questions people have

We want to figure out wheel covers

• interfacing with dynamics components

• need wheel and tire cad

What do you need from me this week?

Need to talk to you sometime about manufacturing of test fixture (both in if its manufacturable, and also logistics of manufacturing)