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LeadMembersReviewersStatus
Shalin Patel, Clarke Vandenhoven (Deactivated)Connor Hawkins (Unlicensed), Hamza Abuabah, kaizen liu

Status
colourYellow
titleIN PROGRESS


Problem

Problem Statement

Build a lightweight and aerodynamically efficient Aerobody

Goals Aerodynamic efficiency will lead to reduced power requirements, this allows us to travel further with the same amount of power. 
Constraints Regulations 

Top surface area of 5m^2 to accomodate array (If curved, then only in 1 plane)

Max dimensions (L x W x H): 5.0m x 2.2m x 1.6m

Criteria 

Coefficient of drag (Cd) < 0.15

Frontal area (A) < 1.5 m2 

Large enough to accommodate 4 people

Requirements

Minimize molds

Minimize cost

Highly durable

Reference materials

Scope


Activity
Must have
  • Research
  • Design
    • Sketches
    • Surface Model
    • Solid Model (Solidworks)
    • Molds
    • Panelization
  • CFD
    • Analysis
    • Verification
  • Detailed design
    • Mounting points
    • Windshield and window cutouts
    • Flanges at connections
    • Wheel Fairings
    • Array Mounting
  • Manufacturing
    • Molds
    • Panels
    • Trimming
    • Finishing
  • Integration
    • Doors
    • Lights
    • Cameras
    • Windshield
    • Windows
  • Mounting to Chassis
  • Sealing all panel gaps
Nice to have
  • Small scale wind tunnel testing
  • (Inset array?)
Not in scope
  • Full scale wind tunnel testing


Milestones and deadlines

Milestone
OwnerDeadline
DateStatusNotes
Concept Sketches
Status
colourGreen
titleDONE

Concept generation

Final Sketch

Status
colourGreen
titleDONE
Converge to a final look
Preliminary Model
Status
colour
Yellow
Green
title
IN PROGRESS
DONE
Surface
Rough model
ready to put into SimScalePreliminary CFD StatuscolourRedtitleNOT STARTEDBuild up an iteration model by running preliminary model through CFDCFD Verification26
to give us an idea of how the car might look (3D model to work out rough space requirements)
CFD Learning
Status
colour
Red
Green
title
NOT STARTEDGet CFD reviewed by
done
Prof.
Sean
Peterson First Meeting
Iteration
Surface Model Complete
28 Oct
Status
colour
Red
Green
title
NOT STARTED
done
Improved model using feedback from Prof. Peterson - Ready to iterate rapidlyIteration Review 104
First surface model + render to show the end goal
Packaging Review
Status
colour
Red
Green
title
NOT STARTED
done
Review
updates to modelIteration Discussion 108 Nov
all system packaging requirements
Aerobody End of Term Review
Status
colour
Red
Green
title
NOT STARTEDPresent findingsCFD Verification09 Nov
done
Aerobody review with Adem and Nathan (Minnesota/Stanford Alums)
End of Term Model
Status
colour
Red
Green
title
NOT STARTEDProf. PetersonCombine Changes 1
done
Model with clean surfaces and "easy" to control
Improved Aesthetic Model
Status
colour
Red
Green
title
NOT STARTEDUpdate model with all changes and put into SimScaleIteration Review 2
done
First look at a realistic aesthetic model and reviewed features that were desirable as a team (Rev 1)
Make Aesthetic Model Aerodynamic
Status
colour
Red
Green
title
NOT STARTEDReview updates to modelIteration Discussion 2
done
Integrate aerodynamic shapes into aesthetic model (Rev 2)
Improved Aesthetic Model
Status
colour
Red
Green
title
NOT STARTEDPresent findingsCombine Changes 2
done
Aesthetic model with better performance than the pure Aero model (Rev 2E)
Mold Design Started
Status
colour
Red
Yellow
title
NOT STARTEDUpdate model with all changes and put into SimScaleIteration Review 3 StatuscolourRedtitleNOT STARTEDReview updates to modelIteration Discussion 3 StatuscolourRedtitleNOT STARTEDPresent findingsCombine Changes 3 StatuscolourRedtitleNOT STARTEDUpdate model with all changes and put into SimScaleIteration Review 4 StatuscolourRedtitleNOT STARTEDReview updates to modelIteration Discussion 4 StatuscolourRedtitleNOT STARTEDPresent findingsCombine Changes 4 StatuscolourRedtitleNOT STARTEDUpdate model with all changes and put into SimScaleIteration Review 5 StatuscolourRedtitleNOT STARTEDReview updates to model*Add milestones in between as determined later*TBDTBDTBDGeometry Lock StatuscolourRedtitleNOT STARTEDMajor Geometry and Shape Lock (Only small changes to exterior if deemed necessary)

Design Journal 

DateJournal EntryNotesStakeholders Involved Concept sketches complete, working towards converging to single final sketchDocumented at the Conceptual Design Page

Final aesthetic locked down

  • Blended hood to windshield angle
  • Large catamaran
  • Cambered airfoil design for underbody
  • Body comes down to cover rear wheels
    • Documented at the Conceptual Design page
    IN PROGRESS

    Figure out how to make molds














    Design Journal 

    DateJournal EntryNotes
     Concept sketches complete, working towards converging to single final sketchDocumented at the Conceptual Design Page

    Final aesthetic locked down

    • Blended hood to windshield angle
    • Large catamaran
    • Cambered airfoil design for underbody
    • Body comes down to cover rear wheels
    • Documented at the Conceptual Design page
    Rough model in CAD
    • Rough geometry modeled in CAD
    • Minimum array space, length, width, and height considered
    • Wheelbase and track roughly defined
    • Need to add space for front wheel sweep and suspension
    Revision 1
    • Added space for front wheel sweep and suspension
    • Modelled the car "pontoons" to be similar to Sunswift Eve
    • Beginning of parametric model

    Revision 2

    • First iteration of TopFoil, Pontoons design with simplified Pontoon design
    Revision 3 + Surface Model Rev 1
    • Oversized volume model with very large amounts of space for everything to go
    • New surface model to show the goal of aesthetics for MS14
    Revision 4
    • Cut down to the bare minimum space required
    • Still a volume model, unusable surfaces for simulating
    Revision 5
    • First revision of slightly clean surfaces and decent blend between Topfoil and Pontoons
    • Trailing edge is now unified and continues from pontoons to Topfoil
    • Two models A,B (variation of windshield inflection point)
    Revision 6
    • Narrowed down to a simpler geometry for the Topfoil and more features to show aesthetic lines
    • Best performing model by end of Fall 2018 
    Revision 7
    • First clean model to easily change Topfoil and pontoon geometries
    • The model doesn't have enough controls to change everything, but has enough to change major shapes and iterate quickly
    • Created with the intersect feature, which is very finicky to use
    Aesthetic Model Revision 1
    • First revision of aesthetic model with all main features included
    • Simple enough to change parametrically
    • Has all rough aero shapes necessary
    Revision 8
    • Most optimal topfoil shape determined through iterations in February and put as Rev. 8
    • Pontoons still need to be optimized
    Revision 8 +
    • Model with better pontoons
    • Included inflection point at the back of the pontoons
    Aesthetic Model Revision 2(E)
    • Aesthetic model that performs better than all aero models
    • Still needs to be improved to fit the suspension
    • Needs more space for people
    • Current drag force: 40N (25N Pressure, 15N Viscous)