Immortus EVX Solar Carfront suspension mount

Josh Patterson

Jai Cornes

Steve Taylor

Anthony 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

200.0

147.9

375.0

220.5

0.0

356.3

T I T A N I U M A L L O Y

( T I - 6 A L - 4 V )

A E R O S P A C E

A L U M I N U M ( A L -

C U 4 - S I M G )

C F R P ( 1 2 0 D E G

E P O X Y C U R E )

YEILD STRENGTH VS

DENSITY

Tension Compression

Our Design Journey

Initial mind map

Our Design Journey

Iteration 1: Titanium Buttress

Pros Cons

Relatively simple design Too much material used

Meets strength requirements

Too heavy

Chassis Mounting Issues

Our Design Journey

Iteration 2: Carbon Fibre Buttress

Pros Cons

Very light Too much material used

Unconventional 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 designliterature

Chassis mounting issues reduced

Our Design Journey

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

Pros Cons

Extremely Light Little to noconventional wisdom

Meets initial designload requirements

Unconventional design may lead to unforeseen issues

Minimises titaniumusage

Chassis 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