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

Term Goals

Complete design of Driver Display
Wires for strategy dashboard
Wires for telemetry dashboard

Ensure Infotainment display works FW)

Note: 2 screens is mounted with dashboard and HW integration

4 months

Driver Display Design Commitment: End of April

Hi-Fi Wire Commitment: End of S21

Test Screen before going into the car (pre-Dashboard integration)

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

mockup needs to be done as early as possible for any changes for 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

End of JulyF21

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 researching, sourcing materialsfiguring out headliner

4 months
End of April

Trim Integration: Begin Mid W22

Complete Trim Integration: EOT W22Fall 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
colourYellowRed
titleMedium

Displays

2 months
End of February

Status
colourGreen
titleLow

“easiest”

High

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. Strongly recommend we do this asap so that we don’t run into problems when it’s too lateVDR is in progress for seats (~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
• Machine Molds
• using the Glass panel

  • Fabricate all

seats

  • seat pan flat panels in carbon fibre (

can include ballast box too if also flat panels)
• Bond

  • either in 1 go or 2 depending on the size of vacuum bag)

  • Bond flat panels to bottom panel/structural elements

2 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 + 1 week =

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 bigheads

  • 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
• Fabricate and install headrest
• Ballast box finishing touches (lid, tie-downs)
• 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 integrationBottom

    • Side panel + chassis integrationintegration (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-op)• Assisting with manufacturingSchool)

• Leading design for displays
• Infotainment liasing w/ Firmwaremanufacturing of seats

On-site

Sheila Ali (School)

• Leading manufacturing of seats•Design and integration of Dash

On-site

Cordelia (School)

• PM for dashboard
• PM for seats

RemoteOn-site

Lovisa Asher (Co-op)

• PM Leading manufacturing of trimseats

Remote

Joy Kimia (School)

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

On-Site (question)
Dependent on COVID situationGeoffrey site

Lovisa (Co-op)

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

Remote

Jens (School)

  • Trim

On-site

Joy ()

  • Dashboard

On-site

Onboarding Project

Onboarding Project Instructions

...