MS14 Chassis Structural FEA Project

Driver

@Tommy Tran

Participants

@Catherine Cai

@Min Qian Lu (Deactivated)

@Kimberly Liu (Deactivated)

Project start date

May 3, 2021

Status

HIGH PRIORITY - IN PROGRESS

On this page

Sections of this project

Problem Definition

Between January 2020 to October 2020, there was a major change in vehicle design that involved removing the structural bottom panel from the design. A major premise of MS14 was that we would be able to manufacture a structural bottom panel which would provide us significant weight reduction and maximize occupant space. Major factors that prevented us from having a structural bottom panel included the absence of a sponsor for an autoclave, the aggressive bend angles of the bottom panel that were difficult for honeycomb nomex core to conform to and the general difficulties of performing prepreg carbon fiber manufacturing.

Figure 1. Image of Bottom Panel CAD

Figure 1: Image of the Bottom Panel CAD

What needs to be now completed is a vehicle re-design that does not consist of a structural bottom panel while satisfying all American Solar Challenge Regulations (ASC Regs).

Jason’s Insight: What is important to keep in mind is that if a solar car was hit by an actual vehicle, no one would survive. The ultimate goal of vehicle collision simulations would instead be to survive a rollover.

Related American Solar Challenge Regulations (ASC Regs)

Below are images from ASC 2021 Regs Release A that relate to the structural design of the vehicle. There are possibly even more regulations that can be relevant factors for vehicle design. It is strongly recommended to fully review the latest release of the ASC Regs before beginning any design project. Feel free to add screenshots of additional regulations that may apply.

Criteria

Minimize weight
Minimize labour
Minimize composites manufacturing
Lean towards metal solutions because of:
manufacturability, time, complexity/simplicity, cheaper, faster, easier
Lean away from composite solutions
composite simulation has complexities and unknowns
but having composite panels in simulations generally yields better simulation results
Make solutions as simple as possible; helps in the long run
manufacturing, number of people needed, resource limited, minimize cost, minimize lead times

Constraints

Vehicle weight that we use to design is 720 kg.
Would want to get a more updated quantity of how much the current assembly weighs.
Would need to include at least: Chassis tubes, Dynamics assembly, Battery Box, Seats, and more.
Can work from a baseline how much the Chassis weighs and then see how any further modification creates how much percentage weight change
Should do onsite measurements and inspection of any implementation method before finalization. This is because there are inaccuracies with the welded Chassis assembly.
We will not model the current thin Bottom Panel and put it into simulations in hopes of contributing to structural integrity
We will not manufacture another bottom panel using the current mold

Options for Reinforcement

Housekeeping Reminders

Project Stages

Timeline

Resources