Immortus EVX Solar Carfront suspension mount

Josh PattersonJai CornesSteve TaylorAnthony Campana

Introduction Our design statement

“Design and build the front suspension mount of the Immortus EVX solar car. “

Introduction Our design statement

“Design and build the front suspension mount of the Immortus EVX solar car. “ What is Immortus and what makes it different?

Grid independent electric vehicle

Introduction Our design statement

“Design and build the front suspension mount of the Immortus EVX solar car. “ What is Immortus and what makes it different?

Grid independent electric vehicle Limitations and considerations

Mass: less mass equals greater overall efficiency Space:

Enclosed wheel well Passenger/driver comfort

Performance: Immortus is a performance car, and must be design as such Existing suspension design: We must design a mount for an existing suspension

system

Introduction Our design statement

“Design and build the front suspension mount of the Immortus EVX solar car. “ What is Immortus and what makes it different?

Grid independent electric vehicle Limitations and considerations

Mass: less mass equals greater overall efficiency Space:

Enclosed wheel well Passenger/driver comfort

Performance: Immortus is a performance car, and must be design as such Existing suspension design: We must design a mount for an existing suspension

system Specific challenges

Getting the required strength while keeping weight down Acquiring useful materials knowledge.

Focus Areas Material Selection

Titanium

Focus Areas Material Selection

Titanium Carbon Fibre

Focus Areas Material Selection

Titanium Carbon Fibre Aluminium (galvanic corrosion)

Focus Areas Material Selection

Titanium Carbon Fibre Aluminium (galvanic corrosion)

Manufacturing Techniques Carbon Fibre Rod (Stock)

Focus Areas Material Selection

Titanium Carbon Fibre Aluminium (galvanic corrosion)

Manufacturing Techniques Carbon Fibre Rod (Stock) Carbon Fibre Moulding (Custom)

Focus Areas Material Selection

Titanium Carbon Fibre Aluminium (galvanic corrosion)

Manufacturing Techniques Carbon Fibre Rod (Stock) Carbon Fibre Moulding (Custom) 3D Titanium Sintering

Focus Areas Material Selection

Titanium Carbon Fibre Aluminium (galvanic corrosion)

Manufacturing Techniques Carbon Fibre Rod (Stock) Carbon Fibre Moulding (Custom) 3D Titanium Sintering

Mechanical Design FBD Initial Design

Titanium buttress Carbon fibre buttress Carbon fibre truss (space frame)

FEA

Existing Knowledge Base Existing information sources

SAE prior research Technical papers and product guides 3rd Party research papers

Existing Knowledge Base Existing information sources

SAE prior research Technical papers and product guides 3rd Party research papers

Conventional wisdom Race car suspension design

Double Wishbone (Double A Arm) Laterally mounted suspension Space frames

Existing Knowledge Base Existing information sources

SAE prior research Technical papers and product guides 3rd Party research papers

Conventional wisdom Race car suspension design

Double Wishbone (Double A Arm) Laterally mounted suspension Space frames

Conventional materials used in modern performance vehicles

Carbon Fibre Titanium Aluminium Steel

Y e i ld . T e n s (Mp a ) S tr e n g th to W e ig h t Y o u n g s Mo d u l u s (G p a )

880.

0

113.

8

414.

0

72.4

600.

0

70.0

Property ComparisonTitanium Alloy (Ti-6Al-4V) Aerospace Aluminum (Al-Cu4-SiMg)CFRP (120deg Epoxy Cure)

Our Design Journey Initial mind map

Existing Chassis Model

Our Design Journey

Iteration 1: Titanium ButtressPros Cons

Relatively simple design

Too much material used

Meets strength requirements

Too heavy

Chassis Mounting Issues

Our Design Journey

Iteration 2: Carbon Fibre ButtressPros Cons

Very light Too much material usedUnconventional Shape will be costly to manufacture in CF

Too much deflection

Chassis Mounting Issues

Our Design Journey

Iteration 3: Carbon Fibre Truss

Pros Cons

Extremely Light Too much deflection under compression

Uses off the shelf CF tube

Occupant interference

Plenty of design literatureChassis mounting issues reduced

Our Design Journey

Iteration 4: Titanium truss with carbon fibre core ( or wrap).Pros Cons

Extremely Light Little to no conventional wisdom

Meets initial design load requirements

Unconventional design may lead to unforeseen issues

Minimises titanium usageChassis mounting issues reduced

Current DesignTubular Titanium Truss with CF Core

Innovative design synergising existing modern materials and design techniques Conventional wisdom did not seem to meet our requirements Modern manufacturing techniques require new design paradigm.

Additive vs subtractive manufacturing

Must investigate behaviour of composite members Literature does exist for individual elements Must combine elements in conventional wisdom

Incremental improvement: Pre or post tensioning members

Potential new type of high performance design element

References1. Carbon fibre sheet: https://www.acpsales.com/images/C/DL%20-%20Flex-08.jpg [viewed: 30/03/2016]2. Carbon fibre tube: https://www.acpsales.com/images/C/Roll-Wrapped-Tubes.jpg [viewed: 30/03/2016]3. Titanium mesh ball:https://i.materialise.com/blog/wp-content/uploads/2012/10/Titanium-ex03.jpg [viewed: 30/03/2016]Galvanic corrosion bike frame: http://i1023.photobucket.com/albums/af358/masterquang/Giant%20Cadex%20980c/IMG_4040_zps97dac39c.jpg [viewed: 30/03/2016]Carbon fibre truss node:http://www.teleskop-express.de/shop/Bilder/shop/ts-ritchey-chretien/rc-truss-tubus-1000.jpg [viewed: 30/03/2016]Sintered titanium light sabre handle thing:http://s3files.core77.com/blog/images/2013/10/4cDesign-QBR-6-Prepolish-Full.jpg [viewed: 30/03/2016]Double wishbone suspension:http://www.motor-car.co.uk/images/Suspension/sping/multi-link-suspension.jpg [viewed: 30/03/2016]

Questions