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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

IN 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)

 

IN PROGRESS


TBD on Prepreg

Collision Sims Review

Mabel Song (Deactivated)

 

COMPLETE

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

 

IN PROGRESS

Jason He To review CAD with Shalin before finalizing

Review Chassis for VR3 Guidlines

Mabel Song (Deactivated)

 

COMPLETE

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

All mounting points provided (Dynamics) 

kevin bui

 

IN 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)

 

NOT STARTED


Finalize Seats & Seat Mounting

Yuvraj Singh

 

NOT STARTED


Finalize Welding Jig

Shi Jing Yang (Deactivated)

 

NOT STARTED



Design Journal 

Date

Journal Entry

Stakeholders Involved

 









Budget

Total:

Date

Description

Cost

 





Reference materials

  • Link 1

  • Link 2

  • Link 3

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

May2020 Jun Jul Aug Sep Oct Nov Dec Jan2021 Feb Mar Apr May Jun Jul Today Design Kick-off Manufacturing Kick-off Testing Kick-off ASC 2021 Project Complete!
Project

Planning Phase

Design Phase

Manufacturing & Assembly Phase

Testing & Validation Phase

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

May2020 Jun Jul Aug Sep Oct Nov Dec Today Mfr./Supplier Kick-off DFMA Kick-off Detailed Design Kick-off
Design
Form-factor
Mtrl/Mfr/Assem
Test/Validation

Concept Design

Detailed Design

Mfr./Assem. Design

Research

Sketching

Part Design

CAD

Architecture

DFMA Updates

Materials/Manufacture/Assemby Research

Mfr. Selection

Material Selection

DFMA

Supplier Interfacing

Tooling Design

Risk Identification

Proof-of-Concept Testing

Pre-Mfr. Validation

Mfr. & Assem. Testing

Phase 3 - Manufacturing/Assembly

Phase 4 - Validation and Testing

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