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This document outlines the tasks for the Interiors team for the Winter Spring 2021 term.

Term Goals

Project

Goal

OG Date

Date (March)

Priority

Catamaran Cover

Complete manufacturing

2 3 months

End of FebruaryMay

3 months

End of MaySep

Status
colourRed
titleHigh

Seats

Complete manufacturing (plan https://docs.google.com/document/d/1t6-ZhpMnQ-8Mp0LCcsmOvhaA2A8u8Zm8mg8Jn0yAIVg/edit# )

  • testing to confirm design

  • start seat pan manufacturing

  • weld brackets to the chassis

2 months
End of April

2 Months

F21

Status
colourRed
titleHigh

Doors

Complete FULL manufacturing plan (EOT W21)

  • Hinges and Latch need access to A-Plane

  • Latch & Hinges components (2w)

  • Molds & Composites

    • Need manufacturing plan

    • Manufacturing time

** Any Structures changes to hinges need to be communicated

2 months
End of February

Manufacturing Time: 2 months

Commitment for Manufacturing Completion: Mid-F21

Status
colourRed
titleHigh

Trim

Complete detailed design
Started manufacturing plan

  • Currently figuring out headliner

4 months
Fall Term

Trim Integration: 2 months

Status
colourYellow
titleMedium

Dashboard

Complete detailed design
Started manufacturing plan

4 months
Detailed design & Completed Manufacturing Plan: Mid-S21

Manufacturing: 3 months

Integration: 1-2 months

Status
colourRed
titleHigh

Manufacturing Projects

Note

Will recommend that we email the Scrutineers that review the VDRs to get feedback on our seats and steering wheel, both of which we are designing from scratch. VDR is in progress for seats (~75% ~85% completed).

Project

Task

Time Allocation

Status

Catamaran Cover + Seats

Obtain all materials required for manufacturing the catamaran cover
(MDF, layup consumables)

Finish assembly plan

BOT

Status
colourYellow
titleIn PRogress

All MDF for catamaran cover by mid-march, mdf for seats and doors by EOT

Catamaran Cover

Manufacture Molds

  • Cut and glue MDF

  • Machine molds

  • Sand and prime

2 weeks

Status
titleNot Started

Manufacture Major Battery Box Panels (bottom + side walls + lid)

  • Prep work

  • Make extra for test specimens

3 weeks

Status
titleNot Started

Manufacture Internal Parts
• 3D printing
• Cutting and thermoforming polycarbonate

1 week

Status
colourYellow
titlein progress

Material Testing

  • Deflection test

  • Heat test

  • Adhesive test

1 week

Status
titleNot Started

Dry Run Assembly with Electronics

• Install electronics and battery modules

• Mark part locations

• Test fit catamaran cover into car

→ Will gate electrical

1 week

Status
titleNot Started

  • will require coordination of finished chassis, bottom panel, battery modules

Final Assembly
• Epoxy internal components
• Install electricals

• Permanent mounting of catamaran cover to chassis

2 weeks

Status
titleNot Started

External Finish
• Add fabrics and other cosmetic trim to battery box

Status
titleNice to Have

TBD

Status
titleNot Started

Seats

Seats Mock-up (optional)
• Fabricate and install flat panels in wood to verify seating position, harness pass-thru, visibility, steering wheel and pedal position
• May need to mock-up seatback using flat sheets

1 week

Status
colourGreen
titleDONE

Manufacture Seats Flat Panels using the Glass panel

  • Fabricate all seat pan & seat support flat panels in carbon fibre (either in 1 go or 2 depending on the size of vacuum bag)

  • Bond flat panels to bottom panel/structural elements

2 weeks + 1 week = 3 weeks

Status
titleNot Started

Manufacture seat supports

  • depending on method chosen:

    • 2 built in filets (require small amount of mdf and require producing each seat support separately which is time consuming considering there are 8 of them)

    • 1 built in filet (require producing each seat support separately which is time consuming considering there are 8 of them)

    • 0 built in filets (will be weaker around 1.5-3 times based on research but can manufacture flat pieces 4 supports at a time meaning there will only be 2 rounds of infusion)

2 filets 3 weeks

1 filet 2-3 weeks

0 filets 1 week

Status
titleNot Started

Ballast using using the Glass panel

  • after install of seat pan the measurements and checking to make sure the ballast will hold enough weight/there will enough room

  • begin manufacturing flat panels (glass sheet)

  • install with hinges, lock, and lid

2 weeks

Status
titleNot Started

Brackets and fastener installation

  • order brackets (if VDR approved)

  • order screwsbigheads

  • order fuji/flex locks

  • drill appropriate holes and weld brackets onto chassis

3 weeks

Status
titleNot Started

  • Further purchases are required (brackets approved by EngSoc)

  • fasteners TBD

Manufacture Seatbacks
• Fabricate tooling for non-flat panels (mdf)
• Fabricate non-flat seatback panels
• Install seatbacks into car (as well as seat tabs)

2 weeks + 1 week = 3 weeks

Status
titleNot Started

Finishing Touches
• Fabricate foam padding and cushions and install
• Fabricate and install remaining fabric coverings
• Install harnesses

TBD

Status
titleNot Started

  • These can be done over long term

  • Further purchases are required: fabric

Integration with Subteams/Dependencies

  • Catamaran depends on:

    • Aero-chassis BP integration

    • Battery box modules ready

    • Dynamics assembly (question)

  • Seats depends on:

    • Chassis integration

    • Side panel integration (for rear seats install)

    • Floor panels SHOULD NOT need to be added into the vehicle (so that brackets can be welded)

    • Welding items for chassis (question)

    • B,C-bulkheads Integrated

  • Dashboard depends on:

    • Dynamics

    • Aero-Chassis Integration (A-bulkhead, A-Plane)

    • Interior doors

    • Electrical & Battery Box need to be integrated so we can route wires

      • Depends on Displays & cameras to be ready

Contingency Planning

  • If lockdown happens, manufacturing will be impacted as long as lockdown remains

Design Projects (Trim + Dashboard)

Task

Time Allocation

Status

Finalize Research + Concepting

2 weeks

Status
colourYellow
titleIn PRogress

CAD design

4 weeks

Status
colourYellow
titleIn PRogress

Materials Selection

2 weeks

Status
colourYellow
titleIn PRogress

Supplier Interfacing

Assembly Plan

TBD

Status
titleNot Started

Core Team

Name (Term)

Responsibilities

On-site Capacity

Renzo (Co-op)

• Leading manufacturing of catamaran cover
• Form factoring of dashboard

On-site

Kristen Sheila (Co-opSchool)

• Assisting with manufacturing
• Leading design for displays
• Infotainment liasing w/ Firmware• Leading manufacturing of seats

On-site

Sheila (Co-op))

• Leading manufacturing of seatsAli (School)

•Design and integration of Dash

On-site

Cordelia (Co-opSchool)

• PM for dashboard
• PM for seats

On-site for Spring

Asher (Co-op)

• Leading manufacturing of seats

On-siteRemote

Kimia (Co-opSchool)

• Design of ballast

RemoteOn-site

Lovisa (Co-op)

• PM of trim

Remote

Joy Jens (School)

• Assisting with manufacturing
• Form factoring of doors
(door handle)

On-Site (question)
Dependent on COVID situation

Geoffrey (Co-op)

• Form factoring of trim
• Form factoring of doors
• Assembly plan for doors

Remote

  • Trim

On-site

Joy ()

  • Dashboard

On-site

Onboarding Project

Onboarding Project Instructions

...