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Meet the Team
Enrique DeLeon Manjula Hodekar Keith Hernandez
Mechanical LeadPublic Relations
Design LeadLogistics
Team LeadProject Management
2
Instructor:Dr. Raresh PascaliUH Professor
Alumni Advisor:Sean VanVactorUH MET Graduate
Undergraduate Colleague:Joshua ContrerasUH Industrial Design
Faculty Advisor:Marcus GaminoUH Instructor
Objective
Deliverables
History & Events
Major Components
Project Management
Comments & Questions
Outline
3
To design and build a vehicle that meets the rules and regulations of the 2017 Baja SAE competition and participate in the competition that will take place in Pittsburg, Kansas on May 25-28, 2017
Objective
5
• Register for the 2017 Baja Competition in Pittsburg, Kansas by the November 14, 2016 deadline
• Have a Baja vehicle that is mechanically complete with a functioning suspension assembled by December 2016
• Manufacture carbon fiber uprights for the suspension
• Achieve a vehicle weight under 400 lbs.
• Pass the Baja SAE inspection for the competition
• Achieve a top speed of 30 mph on a flat surface
• Design a vehicle that can achieve a flat jump of 7 ft.
• Implement instrumentation that is capable of data acquisition
Deliverables
6
• Baja SAE History
• First competition – 1976
• University of South Carolina
• Under the direction of Dr. John F. Stevens
• Number of teams in first competition – 10
• Average number of students per team – 9
• Number of teams in 2016 – 100
• Baja SAE International
• South America, Africa, Asia
• Popular countries – Brazil, South Africa, India
8
History
9
Dynamic Events• Acceleration
• Vehicle has two attempts during this event and is tested on a flat surface for 100 ft.
• Land Maneuverability
• Vehicle attempts to go through bumps, sand, rocks, logs etc.
• Hill Climb/Rock Climb
• Vehicle should reach destination point without stopping
• Traction Event
• Vehicle attempts to climb an incline surface or pull an object on a flat surface
• Endurance
• Vehicle attempts to operate continuously for a total of 4 hours
10
Static Events• Design Event
• Teams are graded on design analysis, testing, development, and manufacturability
• Cost Event
• Teams must provide supporting documents to verify the cost calculations for proposed model and the actual cost of the particular prototype model
• Sales Presentation
• Objective of the presentation is to convince a hypothetical company to purchase the team’s Baja SAE vehicle design and put it into production
• Note: there are about 4000 units manufactured every year
11
Dynamic 700 Points
Acceleration 75
Land Maneuverability 75
Hill Climb/Rock Climb 75
Suspension & Traction 75
Endurance Race 400
Static 300 Points
Design 150
Cost 100
Presentation 50
https://www.facebook.com/michiganbajaracing/photos
https://www.facebook.com/Michiganbajaracing/photos
Main Events Scoring
12
2016 2015 2014
University Univ. of Michigan Cornell University Cornell University
Team Michigan Baja Racing Big Red Racing Big Red Racing
Dynamic 696.40/700 683.35/700 672.87/700
Static 311.03/300 293.70/300 257.16/300
Overall score 1007.43/1000 977.05/1000 930.03/1000
https://www.facebook.com/michiganbajaracing/photos
Winning Teams
13
Winning Strategy
• Continuous vehicle improvement from previous competition
• University/college funded vehicle
• Vehicle weight – less than 400 lbs.
• Ultra high molecular weight polyethylene material for the body
• Light weight hammock seat
• Composite material for the flooring
• Maximum points in static event
• Speed & RPM sensors
• LCD display systems
• Driver communication systemsmotorsportjunction.com
Frame - Design
15
Function
• Series of tubes connected together to form a coherent structure
• Provides a rigid connection between the front and rear suspension
• Creates structural support for other necessary systems
• Provides protection for the driver
Frame - Design
16
• In order to meet our deliverable by December 2016 we will use the frame that was designed and fabricated by the Baja Brigade senior design team
• The team will reconsider the material and design in the second semester and modify it accordingly
• Advantages of spaceframe design
• Inherent structural properties
• Easier to fabricate
• Easier to modify
Frame - Fabrication
17
• Original frame was only tack welded
• Completed welding on frame members
• Arc Welder - E6013 Welding Electrodes
• Prepared frame to apply primer paint coat
Frame – Possible Material Reselection
18
http://www.clienttest.spryox.com/quality_forge/imag
es/steel_images2.jpg http://p.globalsources.com/IMAGES/PDT/B1135131129
/Seamless-mechanical-tubing.jpg
http://www.aedmotorsport.com/images/uploads/products/
aluminum-tubes.jpg
MaterialDensity
(lbs./in3)Tensile Strength
(psi)Modulus of Elasticity
(ksi)Workability
(1 low-10 high)
AISI 1018 Steel 0.284 63,800 29,000 7
AISI 4130 Chromoly 0.283 97,200 29,700 7
6061 Aluminum 0.0975 45,000 10,000 4
Frame – Design Requirements
19
• Load Restrictions
• Weight: Minimum requirement to carry a driver weighing 250 lbs.
• Height: Minimum requirement to fit a driver that is 75 in. tall
• Vehicle Dimension Restrictions
• Width: Max of 64 in. at the widest point
• Length: Max of 108 in.
Suspension - Basics
20
• Camber
The angle of the wheel relative to the road
• Caster
The angular displacement of the steering axis from the vertical axis of the wheel
• Toe
The symmetric angle that a wheel makes with the longitudinal axis of the vehicle
Suspension - Linkage
21
• Double Wishbone
• Equal A-arm Setup
• Unequal A-arm Setup
• Multilink
• Trailing Arm
Transmission
22
• Automatic Transmission (CVT)
• Good for acceleration
• Fit for all terrains
• More complex and heavier
• More challenging to tune
• Manual Transmission
• Lightweight
• Cheaper than a CVT transmission
• Torque and speed are restricted on gear shifting
ATVRiders.com
Engine
23
• All teams in the competition have to use the same engine
• Briggs & Stratton Model 19
• Horsepower: 10 HP
• Engine displacement: 305 cc
• Bore: 3.12 in
• Stroke: 2.438 in
• Compression ratio: 8.0 to 1
25
The highest costs for the entire project
includes the suspension, registration fees
and the travel expenses for the 2017 Baja
SAE competition in Kansas
Component: Cost:
Chassis $1,000
Suspension* $2,000
Steering $650
Engine $250
Drivetrain $1,000
Brakes $400
Tires and rims $900
Seat $60
Safety equipment $300
Instrumentation/electrical $350
Registration fees* $1,250
Travel & lodging* $1,500
Total: $9,660
Contingency 20%: $1,932
Total with contingency: $11,592
BudgetMitigation:
• Suspension - Use available donated parts
• Registration Fees – Make fundraising a
weekly focus throughout the semester
• Travel & Lodging - Use our own
vehicle/trailer to reduce the cost of travel
and check routinely for deals on lodging
28
Baja Vehicle
Research
Rules/safety
requirements
Major
components
Materials
Cost analysis
Design 1
Frame design
Suspension
design
Design analysis
Fabrication 1
Frame
fabrication
Suspension
fabrication
Design 2
Braking
Steering
Powertrain
Instrumentation
Fabrication 2
Braking
Steering
Powertrain
Instrumentation
Testing
Mechanical
Electrical
Instrumentation
Completed
In progress
Not started
29
Risk Matrix
5
4 3
1 2 3 4 5
1
2
Severity
12
34
5P
rob
abili
ty
Mitigation
1 Funding Continue talking to potential sponsors and use donated parts
2 Manufacturing Recruit industry help
3 Fabrication Recruit experienced welder
4 Time Management Hold weekly meetings and track time sheets
5 Meeting SAE requirements Consult with previous teams and review rulebook
Risk