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This page is a duplicated of this page: Chassis - Mechanical - Confluence (atlassian.net)

Lead

Members

Reviewers

Status

Shalin Patel

Mabel Song (Deactivated), Michael Zhang (Unlicensed), Former user (Deleted), Shi Jing Yang (Deactivated), Jason He

Matt Suski, Robin Pearce, kevin bui

Status
colourYellow
titleIN PROGRESS


Problem

Problem Statement

Build a lightweight, yet robust chassis that can safely support 4 occupants in normal driving conditions and in the event of a crash as well as provide hard mounting points for all of the systems required in the car

Goals 

Occupant safety is the number one priority in designing this vehicle's chassis so roll over protection and impact protection structures must be incorporated into the design.

To reduce the power consumption of the vehicle, we must also keep the chassis as lightweight as possible.

Constraints Regulations 

Load cases: 5*9.81*Mass of car (N) force applied to vehicle from different angles of attack (to simulate a real crash)

Crush Zone: 150 mm wide crush zone on the side of each occupant.

Impact Energy Absorption: 

Criteria 

Safety factor of 2 for all major parts of the chassis.


Scope


Activity

Must have

  • Research

    • Mounting structural composite floor to metal protection structure

    • Manufacturing of structural floor

    • Space requirements

    • Joining composite to composite

    • Type and thickness of honeycomb core

    • Type and thickness of core for less structural portions

  • Design

    • Metal structure

    • Composite layup plan

    • Mounting solutions for all systems

    • Composite to metal joints

    • Composite ribs

  • FEA

    • Metal structure

    • Composite floor

    • Both together

  • Validation

    • 1:1 prototype for verifying occupant comfort, viewing angles

    • Testing carbon fiber layup parts that we make and validating them against known properties / ANSYS FEA properties

  • Detailed Design

    • Mounting points for all systems

    • Mounting hardware designed

    • Fasteners and joining methods completely defined

    • Clearance and interference validation for each system

    • DFM and DFA verification

    • Drawings

    • Welding Jig for metal structure

  • Manufacturing

    • Metal structure jig

    • Welding

    • Composite layup with honeycomb panels

  • Integration

    • Mount to Aerobody/ structural floor 

    • All systems integration into chassis

Nice to have

Not in scope


Milestones and deadlines

Milestone

Owner

Deadline

Status

Notes

Composites Test Planning 

Former user (Deleted)

Michael Zhang (Unlicensed)

 

Status
colourYellow
titleIN PROGRESS


TBD on Prepreg

Collision Sims Review

Mabel Song (Deactivated)

 

Status
colourGreen
titleCOMPLETE

Everything should be passing but need to get prepreg to confirm

Non-helmeted passengers  will also change seat positions, changes need to be made before completing sims

Door CAD Geometry Update

Jason He

 

Status
colourYellow
titleIN PROGRESS

Jason He To review CAD with Shalin before finalizing

Review Chassis for VR3 Guidlines

Mabel Song (Deactivated)

 

Status
colourGreen
titleCOMPLETE

Mabel Song (Deactivated) to send Robin Pearce questions to send Don 

All mounting points provided (Dynamics) 

kevin bui

 

Status
colourYellow
titleIN PROGRESS

Former user (Deleted) to determine interior compartment features (i.e. on or under the dash) 

Finalize CAD & Send for Review w/ VR3

Mabel Song (Deactivated)

 

Status
colourRed
titleNOT STARTED


Finalize Seats & Seat Mounting

Yuvraj Singh

 

Status
colourRed
titleNOT STARTED


Finalize Welding Jig

Shi Jing Yang (Deactivated)

 

Status
colourRed
titleNOT STARTED



Design Journal 

Date

Journal Entry

Stakeholders Involved

 









Budget

Total:

Date

Description

Cost

 





Reference materials

  • Link 1

  • Link 2

  • Link 3

Page Tree

Page Tree
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About

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Projects on the interiors team are broken into 4 phases:

  1. Planning Phase

  2. Design Phase

  3. Manufacturing & Assembly Phase

  4. Testing and Validation Phase

Note: All dates shown are for illustrative purposes only. Actual timelines should be referenced from Interiors Timeline

Roadmap Planner
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source%7B%22title%22%3A%22Roadmap%20Planner%22%2C%22timeline%22%3A%7B%22startDate%22%3A%222020-05-26%2000%3A00%3A00%22%2C%22endDate%22%3A%222021-07-01%2000%3A00%3A00%22%2C%22displayOption%22%3A%22MONTH%22%7D%2C%22lanes%22%3A%5B%7B%22title%22%3A%22Project%22%2C%22color%22%3A%7B%22lane%22%3A%22%23f6c342%22%2C%22bar%22%3A%22%23fadb8e%22%2C%22text%22%3A%22%23594300%22%2C%22count%22%3A1%7D%2C%22bars%22%3A%5B%7B%22title%22%3A%22Planning%20Phase%22%2C%22description%22%3A%22This%20is%20the%20first%20bar.%22%2C%22startDate%22%3A%222020-05-14%2012%3A07%3A07%22%2C%22duration%22%3A1.188118811881188%2C%22rowIndex%22%3A0%2C%22id%22%3A%222bdc7f6d-527d-4810-9cde-2e8564ff0b20%22%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22title%22%3A%22Design%20Phase%22%2C%22description%22%3A%22This%20is%20the%20second%20bar.%22%2C%22startDate%22%3A%222020-06-21%2019%3A00%3A35%22%2C%22duration%22%3A3.1485148514851486%2C%22rowIndex%22%3A0%2C%22id%22%3A%22b169281c-b546-46cc-93db-004361ad4989%22%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-10-01%2000%3A00%3A00%22%2C%22id%22%3A%22c7b62a3b-46f8-41ed-8d85-01b18b882a4a%22%2C%22title%22%3A%22Manufacturing%20%26%20Assembly%20Phase%22%2C%22description%22%3A%22%22%2C%22duration%22%3A2.9702970297029703%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222021-01-13%2014%3A01%3A11%22%2C%22id%22%3A%22bb1c533f-5205-4e36-934d-69b4b2b25f19%22%2C%22title%22%3A%22Testing%20%26%20Validation%20Phase%22%2C%22description%22%3A%22%22%2C%22duration%22%3A4.584158415841584%2C%22pageLink%22%3A%7B%7D%7D%5D%7D%5D%2C%22markers%22%3A%5B%7B%22title%22%3A%22Today%22%2C%22markerDate%22%3A%222020-05-14%2019%3A29%3A06%22%7D%2C%7B%22markerDate%22%3A%222020-06-20%2007%3A21%3A58%22%2C%22title%22%3A%22Design%20Kick-off%22%7D%2C%7B%22markerDate%22%3A%222020-09-25%2022%3A48%3A42%22%2C%22title%22%3A%22Manufacturing%20Kick-off%22%7D%2C%7B%22markerDate%22%3A%222021-01-01%2000%3A00%3A00%22%2C%22title%22%3A%22Testing%20Kick-off%22%7D%2C%7B%22markerDate%22%3A%222021-07-06%2019%3A57%3A37%22%2C%22title%22%3A%22ASC%202021%22%7D%2C%7B%22markerDate%22%3A%222021-05-31%2016%3A38%3A01%22%2C%22title%22%3A%22Project%20Complete!%22%7D%5D%7D
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Phase 1 - Planning Phase

  • Project Planning Document

    • Team formation

      • Project DRI

      • Interdependencies

      • Stakeholders

    • Problem Breakdown

      • Needs statement

      • Major goals

      • Requirements/Regulations

  • Project Planning Review and Design Kick-off

Phase 2 - Design Phase

Note: All dates shown are for illustrative purposes only. Actual timelines should be referenced from Interiors Timeline

Roadmap Planner
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source%7B%22title%22%3A%22Roadmap%20Planner%22%2C%22timeline%22%3A%7B%22startDate%22%3A%222020-05-26%2000%3A00%3A00%22%2C%22endDate%22%3A%222020-12-30%2000%3A00%3A00%22%2C%22displayOption%22%3A%22MONTH%22%7D%2C%22lanes%22%3A%5B%7B%22title%22%3A%22Design%22%2C%22color%22%3A%7B%22lane%22%3A%22%23d04437%22%2C%22bar%22%3A%22%23dc7369%22%2C%22text%22%3A%22%23ffffff%22%2C%22count%22%3A1%7D%2C%22bars%22%3A%5B%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-05-01%2000%3A00%3A00%22%2C%22id%22%3A%22a92fddd6-8271-4486-b1e4-2fe8f982a040%22%2C%22title%22%3A%22Concept%20Design%22%2C%22description%22%3A%22%22%2C%22duration%22%3A2.99009900990099%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-08-01%2000%3A00%3A00%22%2C%22id%22%3A%22888b7540-9215-4c95-b331-de908d74b210%22%2C%22title%22%3A%22Detailed%20Design%22%2C%22description%22%3A%22%22%2C%22duration%22%3A3.00990099009901%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-11-01%2013%3A15%3A26%22%2C%22id%22%3A%220355521e-90f4-4436-8791-185d4752998d%22%2C%22title%22%3A%22Mfr.%2FAssem.%20Design%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.99009900990099%2C%22pageLink%22%3A%7B%7D%7D%5D%7D%2C%7B%22title%22%3A%22Form-factor%22%2C%22color%22%3A%7B%22lane%22%3A%22%23f6c342%22%2C%22bar%22%3A%22%23fadb8e%22%2C%22text%22%3A%22%23594300%22%2C%22count%22%3A1%7D%2C%22bars%22%3A%5B%7B%22title%22%3A%22Research%22%2C%22description%22%3A%22This%20is%20the%20first%20bar.%22%2C%22startDate%22%3A%222020-05-01%2000%3A00%3A00%22%2C%22duration%22%3A1%2C%22rowIndex%22%3A0%2C%22id%22%3A%2274e2dd36-4620-4d0d-8e2a-fdd08bb4048f%22%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22title%22%3A%22Sketching%22%2C%22description%22%3A%22This%20is%20the%20second%20bar.%22%2C%22startDate%22%3A%222020-06-02%2004%3A30%3A53%22%2C%22duration%22%3A0.9405940594059405%2C%22rowIndex%22%3A0%2C%22id%22%3A%2277370f5d-9fc9-49b3-9135-0ce312da1734%22%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-09-01%2000%3A00%3A00%22%2C%22id%22%3A%2226a492bf-fd61-4419-97fe-ae9d4e54e293%22%2C%22title%22%3A%22Part%20Design%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.99009900990099%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-07-01%2014%3A43%3A57%22%2C%22id%22%3A%22ad98f66b-8f45-4a0b-a4de-607f34bc5ace%22%2C%22title%22%3A%22CAD%22%2C%22description%22%3A%22%22%2C%22duration%22%3A0.9504950495049505%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-08-01%2014%3A43%3A57%22%2C%22id%22%3A%22e71e4fef-5f55-4a68-b6a4-20a552463eb4%22%2C%22title%22%3A%22Architecture%22%2C%22description%22%3A%22%22%2C%22duration%22%3A0.9603960396039604%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-11-01%2013%3A15%3A26%22%2C%22id%22%3A%224b739877-2da4-49ca-88f6-067043bd7510%22%2C%22title%22%3A%22DFMA%20Updates%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.9405940594059405%2C%22pageLink%22%3A%7B%7D%7D%5D%7D%2C%7B%22title%22%3A%22Mtrl%2FMfr%2FAssem%22%2C%22color%22%3A%7B%22lane%22%3A%22%233b7fc4%22%2C%22bar%22%3A%22%236c9fd3%22%2C%22text%22%3A%22%23ffffff%22%2C%22count%22%3A1%7D%2C%22bars%22%3A%5B%7B%22title%22%3A%22Materials%2FManufacture%2FAssemby%20Research%22%2C%22description%22%3A%22This%20is%20the%20third%20bar.%22%2C%22startDate%22%3A%222020-05-01%2000%3A00%3A00%22%2C%22duration%22%3A3.4455445544554455%2C%22rowIndex%22%3A0%2C%22id%22%3A%22ea2423bd-5db7-45c4-b329-644c728e4460%22%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-09-26%2005%3A56%3A26%22%2C%22id%22%3A%225a966c95-f55d-4eba-b076-bf80e757f923%22%2C%22title%22%3A%22Mfr.%20Selection%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.1287128712871286%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-08-15%2017%3A35%3A02%22%2C%22id%22%3A%225d924776-6045-42fc-91be-9318edf4b475%22%2C%22title%22%3A%22Material%20Selection%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.3267326732673268%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-11-01%2006%3A07%3A43%22%2C%22id%22%3A%225c41cade-29f3-4ea9-b74e-c121eecb7c78%22%2C%22title%22%3A%22DFMA%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A2%2C%22startDate%22%3A%222020-11-01%2000%3A00%3A00%22%2C%22id%22%3A%227a0012af-9dea-423c-989a-b1bbfd9f1c31%22%2C%22title%22%3A%22Supplier%20Interfacing%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.99009900990099%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A1%2C%22startDate%22%3A%222020-11-17%2021%3A20%3A11%22%2C%22id%22%3A%22a3a7f688-8dc6-498e-926c-f9777061da44%22%2C%22title%22%3A%22Tooling%20Design%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.1485148514851484%2C%22pageLink%22%3A%7B%7D%7D%5D%7D%2C%7B%22title%22%3A%22Test%2FValidation%22%2C%22color%22%3A%7B%22lane%22%3A%22%238eb021%22%2C%22bar%22%3A%22%23aac459%22%2C%22text%22%3A%22%23ffffff%22%2C%22count%22%3A1%7D%2C%22bars%22%3A%5B%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-05-01%2007%3A21%3A58%22%2C%22id%22%3A%2206f28ba2-40ab-48e9-b584-41224eb11a49%22%2C%22title%22%3A%22Risk%20Identification%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.4356435643564356%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-06-14%2015%3A55%3A14%22%2C%22id%22%3A%2285cb9358-7dad-4ca7-b38a-9005df64c737%22%2C%22title%22%3A%22Proof-of-Concept%20Testing%22%2C%22description%22%3A%22%22%2C%22duration%22%3A3.099009900990099%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-09-17%2015%3A12%3A28%22%2C%22id%22%3A%225a439287-40fe-4cb2-9808-708be7c6a54b%22%2C%22title%22%3A%22Pre-Mfr.%20Validation%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.4158415841584158%2C%22pageLink%22%3A%7B%7D%7D%2C%7B%22rowIndex%22%3A0%2C%22startDate%22%3A%222020-11-01%2013%3A15%3A26%22%2C%22id%22%3A%2270128ee4-96bf-433c-bdd6-ab54b107de19%22%2C%22title%22%3A%22Mfr.%20%26%20Assem.%20Testing%22%2C%22description%22%3A%22%22%2C%22duration%22%3A1.6336633663366336%2C%22pageLink%22%3A%7B%7D%7D%5D%7D%5D%2C%22markers%22%3A%5B%7B%22title%22%3A%22Today%22%2C%22markerDate%22%3A%222020-05-15%2002%3A51%3A05%22%7D%2C%7B%22markerDate%22%3A%222020-12-31%2016%3A38%3A01%22%2C%22title%22%3A%22Mfr.%2FSupplier%20Kick-off%22%7D%2C%7B%22markerDate%22%3A%222020-11-01%2013%3A15%3A26%22%2C%22title%22%3A%22DFMA%20Kick-off%22%7D%2C%7B%22markerDate%22%3A%222020-07-31%2016%3A38%3A01%22%2C%22title%22%3A%22Detailed%20Design%20Kick-off%22%7D%5D%7D
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Phase 3 - Manufacturing/Assembly

Phase 4 - Validation and Testing