Winter 2021 Roof and Trunk Prop Onboarding

Owned by Asher L
Feb 20, 2021
4 min read

Overview

The purpose of this document is to serve as a centralized resource for the tasks related to the Roof and Trunk Prop Project Onboarding that occurred in the Winter 2021 Term

 

 

Tasks

Component

Description / Tasks

Component

Description / Tasks

Accessory Trunk Tilt Structure

Responsible for entirety of design process of this component: research, concepting, design, manufacturing and integration

Brackets for: Trunk Prop to Trunk Panel and Roof Prop to Roof Panel

Responsible for research in “Design for Adhesives” - implementing these guidelines into existing or new designs, managing manufacturing and integration of these components

Bracket for Roof Prop to Chassis

Responsible for: concepting, design, manufacturing and integration

 

Accessory Trunk Tilt Structure

As per the 2-14-2021 meeting, it was decided that the trunk panel tilting would be done after it was detached and placed onto an accessory structure that would enable it to tilt.

Functional Requirements

  • Support and hold the detached trunk panel

  • Allow for the trunk panel to be tilted to the side

  • Integrate with the current vehicle architecture

    • i.e. If mounting to the vehicle and / or when stored within the vehicle

Functional Requirements

  • Support and hold the detached trunk panel

  • Allow for the trunk panel to be tilted to the side

  • Integrate with the current vehicle architecture

    • i.e. If mounting to the vehicle and / or when stored within the vehicle

Non-Functional Requirements

  • Be easily manufacturable

  • Preferably in-house, but can also be done by outside suppliers

  • Present low risk and be feasible to implement

  • Be as user friendly as possible

  • Be as lightweight as possible

  • Be as cost-effective as possible

Constraint Requirements

  • Must support the weight of the trunk panel (weight will be given soon)

  • Must fit within volume / space of the car (likely the trunk area) (dimensions will be given soon)

  • At minimum support (given degree of tilt)

    • Note: Accessory tilting structure can either be static (single angle) or variable (multiple angles)

Note:

For storing and/or mounting the accessory trunk tilt structure in the trunk area, the bottom panel (red circled area in picture below) is no longer structural (the core material that was supposed to be within it was not included due to manufacturing constraints)

Thus, it is best to use the chassis tubes that run alongside this area as a mounting point

Next Steps:

  • Begin research and concepting

    • Decide high level items

      • Fixed vs variable angle

      • Placement inside vs outside the car

 

Brackets - Roof/Trunk Prop to Roof/Trunk Panel

These are the brackets that will connect the prop to the panel (functionally similar to the ones highlighted by the red circle in the images below)

Functional Requirements

  • Create a connection between the respective prop and panel

  • Securely attaches to the panel

Functional Requirements

  • Create a connection between the respective prop and panel

  • Securely attaches to the panel

Non-Functional Requirements

  • Be easily manufacturable

    • Preferably in-house, but can also be done by outside suppliers

  • Present low risk and be feasible to implement

  • Be as lightweight as possible

  • Be as cost-effective as possible

Constraint Requirements

 

Next Steps:

 

Brackets - Roof Prop to Chassis

These are the brackets that will connect the roof prop to the chassis (functionally similar to the ones highlighted by the red circle in the image below)

Functional Requirements

  • Create a connection between the prop and the chassis

  • Securely attaches to the chassis

Functional Requirements

  • Create a connection between the prop and the chassis

  • Securely attaches to the chassis

Non-Functional Requirements

  • Be easily manufacturable

    • Preferably in-house, but can also be done by outside suppliers

  • Present low risk and be feasible to implement

  • Be as lightweight as possible

  • Be as cost-effective as possible

Constraint Requirements

  • All sharp edges should be chamfered, filleted and/or planned to have padding placed over

    • As this bracket will be inside the occupant area

  • Must be able to withstand loading conditions - TBD

Note:

The B Panel Bulkhead does not go up all the way to the roof (it ends where the red circled area is in the image below). This may mean that for this bracket / mount that it fastens to the chassis tubes above the red circled area (could have an additional panel fastened to these chassis tubes but this is only one concept)

 

Next Steps:

  • Research and concepting

    • Developing new concepts and / or building upon existing concepts

      • Existing concepts can be found in: Trunk and Roof Props

        • Feasibility Analysis > Roof > Prop Mounting (to Chassis)

 

 

Resources

Relevant CAD Files:

Aerobody Panel Assembly

GrabCAD File Path: MS XIV > Development > Aerobody > Panels > Bulkheads > Aerobody Panels

NOTE: When you download, please click “Download Assembly and Components” (found under “File Options”) - this will allow the assembly to reference the necessary part files when it opens

If it still is suppressing files or if the assembly looks incomplete, you may have to download the entire “Panels” Folder


Inspiration:

University of Minnesota Solar Vehicle Project

 

Solar Team Eindhoven