Overall Goal:
To demonstrate that the preliminary design follows all system requirements and is feasible within resource, time, and manufacturing constraints
To establish a foundation for moving forward with detailed design and prove that the design is ready to proceed
By this time, all architectures are final. This review will discuss the architectures and design options that were considered and explain why the final architecture was chosen over the other options
Preliminary CAD should exist. We should have a general understanding of how each part of the car will look.
System bounding boxes must be fixed after this point
Major system-design critical OEM components should be selected and validated
Validation:
Approach should be validated with proper hand-calcs and FEA
A discussion of how you found your inputs will be required to convince the audience that your analysis is correct
Explain why you used this methodology
Implementation Plan:
Between PDR and CDR, all that should change is the optimization of designs. Weight savings, improving intra-system interfaces and repairability, more in-depth planning for manufacturing
System Deliverables:
Dynamics | Body | Electromechanical | Aeroshell |
|---|
Suspension - Suspension Type Selected
- Hardpoints Finalized
- Shock Selected
- Shock-Pot Mounting
- Motion Ratio, Spring Rate determined
| Frame - Bounding Boxes Finalized
- Roll Cage Finalized
- Passing Frame Sim
- Preliminary Tab Placements
| Battery | Aerodynamics - Top Shell Finalized
- Initial Shell to Frame
- Shell-to-Shell Options
- Preliminary CFD Results
- Pitot Tube Mounting
|
Unsprung - Brake Calipers Selected
- Wheel Bearing Selected
- IMU, Hall Effect Mounting
| Enclosures - Enclosure Mounting Locations
- Number of Enclosures Fixed
- Waterproofing Plan
|
Steering - Rack Selected
- Ackerman Geometry Finalized
- Upper Steering Linkage Power Transmission Chosen
- Pot Mounting
| Ergo - Preliminary Pedal Box
- Driver Position Fixed
- Preliminary Brake Routing Diagram
- Steering Wheel Design
- Ballast Location
| Cooling - Cooling Strategy Selected
- Rough Routing Scheme
- Battery Thermal Testing Results
| Composites - Research Results (short presentation)
- Mold Reference Scheme Selected
- Manufacturing Plan
|
Wire Harnessing - Preliminary Wiring Diagram
|
Presentation Content
Dynamics | Body | Electromechanical | Aeroshell |
|---|
Suspension - Architecture selection
- Packaging
- Weight
- Material Selection
- Telemetry/Data Acquisition
- Manufacturing
| Frame - Frame
- Frame Jig
- Hardpoint Jig
- Packaging Layout
- Where other systems and assemblies will go
- Node map
- Tube Geometry/Sizes
- Purpose of tubes/sections
- Weight
- Material Selection
- Tube material
- Filler material
- Torsional Rigidity
- Timeline
| Battery | Aerodynamics - Design philosophy/process
- Architecture selection
- Decision matrix?
- Shell configuration (canopy, top/middle, bottom, aero covers)
- Cl and Cd goals
- CFD analysis
|
Unsprung - Architecture selection
- Component design
- Component Selection
- Bearing selection
- Caliper selection
- Brake rotor selection
- Brake button selection
- Wheel selection
- Tire selection
- Packaging
- Weight
- Material Selection
- Brake rotor
- Upright
- Hub/Axle
- Telemetry/Data Acquisition
- Manufacturing
| Enclosures - Enclosure Mounting Locations
- Material selection
- Manufacturing plan
- Waterproofing Plan
|
Steering - Architecture selection
- Decision matrix?
- Steering transmission
- Upper and lower
- Packaging
- Component selection
- Rack selection
- Bearing selection
- U-joint/bevel gear selection
- Ackermann and bump steer
- Weight
- Manufacturing
| Ergo - Driver Positioning
- Steering Wheel
- Material selection
- Positioning
- Seat and Headrest
- Material selection
- Positioning
- Pedal Box
- Mounting
- Material selection
- Geometry
- Timeline
| Cooling - Cooling Strategy Selected
- Type of cooling system
- Layout/packaging
- Rough Routing Scheme
- Material/component selection
- Battery Thermal Testing Results
| Composites - Material selection
- For each section of the shell
- For any hinging mechanism/fastening mechanism
- Epoxy, mold release, etc.
- Manufacturing plan
- Mold
- Layups
- Mold release
- Etc.
|
Wire Harnessing - Preliminary wiring diagram
|