Preliminary Design Review Guidelines

Preliminary Design Review Guidelines

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.

    • This allows advisors to have physical context for the choices we are making

  • 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:

  • At the end of PDR, why you chose the design and how you will implement it/proceed with it should be defined

    • General manufacturing process/steps selected

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

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

Battery Layout Finalized

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

Dynamics

Body

Electromechanical

Aeroshell

Suspension

Architecture selection
Decision matrix?
Packaging
Weight
Goal
Material Selection
Telemetry/Data Acquisition
Sensors
Mounting
Manufacturing

Frame

Frame
Frame Jig
Approach
Features
Layout
Hardpoint Jig
Approach
Features
Layout
Packaging Layout
Where other systems and assemblies will go
Node map
Tube Geometry/Sizes
Purpose of tubes/sections
Weight
Goal
Optimization/savings
Material Selection
Tube material
Filler material
Torsional Rigidity
Simulation
Validation
Timeline

Battery

Battery layout
Components

Aerodynamics

Design philosophy/process
Architecture selection
Decision matrix?
Shell configuration (canopy, top/middle, bottom, aero covers)
Cl and Cd goals
CFD analysis
Setup
Results

Unsprung

Architecture selection
Decision matrix?
Component design
Component Selection
Bearing selection
Caliper selection
Brake rotor selection
Brake button selection
Wheel selection
Tire selection
Packaging
Assembly
Weight
Goal
Material Selection
Brake rotor
Upright
Hub/Axle
Telemetry/Data Acquisition
Sensors
Mounting
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
Goal
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