SAE FORMULA TEAM
Team Members: Nikhil Chhetri, Kevin Crandall, Chris Gibboney,
Daniel Harbour, Ben Holt, Devin Jack, Thomas
Jedlicka, Casey Meigs
Advisor: Dr. Bawab
Outline
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Background
Gantt Chart
Suspension
Frame
Engine
Steering Wheel
Electronics
Brake System
Brake Pedal
Conclusion
Background
• The SAE formula competition is held annually.
• The competition this year is held in Detroit, Michigan.
• Each car is tested in several categories including braking,
sprints, and endurance.
• Rather than modify the previous vehicle, we will design and
fabricate a new one.
• We will be split into several groups, including the frame,
suspension, braking, etc. to accomplish this goal.
• Our goal is to be able to have a working vehicle that will be
able to participate in the 2012 competition in Detroit,
Michigan.
Gantt Chart
Suspension Team
• Previous design: pushrod (rear and front)
• Set Backs:
– Due to a shortened front box, suspension packaging area decreased.
• Current design: pushrod (rear), self mounted pushrod (front).
• After the frame design is completed, we can verify our suspension points and
start to begin the fabrication process the a-arms, tie rods, bell cranks, and
shock mounts.
• Once the frame dimensions are known, we can begin to analyze the kinematics
and the stresses on the a-arm members and adjust the designs accordingly and
fabricate and install the suspension components.
• Suspension Material: 5/8” x 0.065” Chromoly
Suspension Team
Suspension Team
• Stress analysis still needs to be completed once a profile of our
suspension tubing is created for SolidWorks. Blue lines indicate our
centerlines of a-arm members.
Frame
•Complete static analysis
•Perform dynamic
analysis
•Compare analysis with
calculations
•Compare Solidworks
data to Patran data
•Complete fabrication of
frame
Static and Dynamic Analysis
Static
•Rollover
•Torsional rigidity
Dynamic
•Natural frequency
•Front impact
Engine Team
Currently:
• The stock intake and ecu are installed on the
engine
• The electrical system has been rework to fit our
needs
• The necessary parts for the fuel system have
arrived
• The fuel system will be hooked up this week
• The engine will be tested either this week or next
Engine Team
Ahead:
• Once the frame is built the engine will be
installed in the frame
• The engine management system will be finalized
and purchased
• The intake system will be designed, built and
installed
• The exhaust system will be designed, built and
installed
• The final product will be tested and tuned
Steering wheel:
• Aluminum to be used as
steering column.
• Calculated both steering
column U-joints to be
mounted at 145 degrees.
• We might increase the base
plate thickness depending on
our design.
• Steering design focused on
better mobility of steering
wheel.
Electronics Team
• Team has met and discussed grounding points and battery location on the
car.
• Drawing schematics for the battery, alternator, and fuel pump circuits, and
gauging wire.
Future Plan
• Once the engine is operating within stock parameters, mainly assisting the
engine team with modifying the wiring harness and routing the circuits
• Upon completion of the frame design, positioning two master cut-off
switches in accordance FSAE safety regulation
Brakes
Goals
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Absolute reliability
Function at High Speeds
Maximum possible deceleration without locking
Consistent balance with changing temperatures
Assumptions
Total weight of vehicle:
550 lbs
Max. force applied to pedal:
2000 N
Front-Rear Hydraulic Split
Brakes
• Next step:
– Recalculate total mass of
vehicle
– Determine maximum
hydraulic force within
the master cylinder
– Adjust configuration to
maximize efficiency of
braking system
– Determine ideal material
for brake lines
Brake Pedal and Assembly Group
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Function:
Design and assemble a brake pedal system to be used in the SAE Formula Car.
Upon completion of the design, the brake system will be modeled in Patran and a
stress analysis will be performed.
When the stress analysis is complete, the brake system can begin to be fabricated.
Requirements:
The brake pedal must withstand a force of 2000 N. This will be tested in Patran.
The brake pedal must be made from steel or aluminum.
Progress:
We are still in the research phase of the process.
Currently, the brake pedal will be installed on the bottom of the car, rather than
the top, like in most conventional automobiles.
The next slide shows a brake pedal used in race cars that is similar to the design we
are considering.
Brake Pedal Preliminary Design
Conclusion
• For the most part, our project is on schedule,
as was illustrated in the Gantt Chart.
• Future Potential Problems:
Funding
Communication
Inexperience
• So far, we have not ran into any serious
problems that have hindered our progression
and plan to race our vehicle in the 2012
competition.
Questions?