By
BACCALAUREUS INGENERIAE
In
At the
UNIVERSITY OF JOHANNESBURG
October 2012
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Anti-Plagiarism Declaration
I, Jules David de Ponte, hereby declare that this design Report is wholly my own work and has not been submitted anywhere else for academic credit by myself or another person. I understand what plagiarism implies and declare that this mini-dissertation is my own ideas, words, phrases, arguments, graphics, figures, results and organisation except where reference is explicitly made to anothers work. I understand further that any unethical academic behaviour, which includes plagiarism, is seen in a very serious light by the University of Johannesburg and is punishable by disciplinary action. Sign: Date:
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James A. Michener
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Acknowledgements
I would like to thank the following people, without whom, this project would have been unsuccessful. God For the ability, intellect and strength of will to complete this project. My Family For motivating and encouraging me, and also financial support during my degree. N. Janse van Rensburg Whose efforts has made the UJ Solar Team a reality. Also, for providing practical advice on how to best complete this project. The UJ Solar Team I would like to acknowledge the good job that was done during the 2012 Sasol Solar Challenge. May the 2014 race be even better for us. Thanks to the masters students for their advice during the design phase of this project, and to the rest of the undergraduate students who assisted in building and completing Ilanga I.
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Executive Summary
This Report will document the process untaken to design the updated suspension system for the UJ solar car, Ilanga I. The need is identified as a suspension system, which is stronger, lighter, more aerodynamically efficient and more practical than the solution currently employed. In order to facilitate this, the suspension will be constructed from AISI4130 chrome-moly. This material is stronger than the aluminium currently used, but it is also heavier. Therefore, to reduce weight, the system will be optimised as much as possible; any non-essential members have been removed. In order to perform these optimisations, literature on suspension designs was reviewed. This gave valuable insight into the various systems currently in use, as well as what sort of practical design aspects have to be considered. After reviewing the literature, the selection criteria for the concepts could be chosen. This would provide a semi-quantitative answer as to which concept is better; rather than merely a subjective selection. The concepts were generated such that they would fulfil the design requirements. The literature was also used extensively in devising practical solutions. The concepts were evaluated using a pair-wise comparison, and the best concepts were chosen for further development. The selected concepts were double wishbone suspension, with a pushrod and rocker. The conventional steering swivel was chosen, instead of a bicycle fork arrangement. With the selected concept in mind, the design calculations were performed. The design process was an iterative one, where various geometries were altered. After the geometry was altered, a performance simulation was conducted. The geometry was changed slightly and re-evaluated. The best solution from multiple iterations was carried forward for further development. The Performance Simulation in Section 8 shows the final performance simulations. The strength of materials calculations was performed to validate the design. A finite element analysis was conducted on one of the components; this was done, in a large part, to illustrate the concept of finite element analysis. A review on material properties was conducted in Section 9, and the most appropriate material was selected; AISI4130. The manufacturing involved laser cutting of certain components, welding and assembly. Plates were cut for the steering swivels, pushrod rocker arms, and parts of the suspension box. The suspension box consists of plates and tubes; these were welded together, as were the suspension control arms. The unit was assembled, and bolted onto the chassis. While the suspension was being designed, other members of the Solar Team were optimising the chassis. The new chassis, dubbed Ilanga I-I, would be used in the South African Solar Challenge. After assembly, the car was tested. Driver feedback was positive, with the drivers stating that the handling was good.
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Table of Contents
Anti-Plagiarism Declaration ................................................................................................................... 2 Acknowledgements ................................................................................................................................. 4 Executive Summary ................................................................................................................................ 5 Table of Contents .................................................................................................................................... 6 List of Figures ......................................................................................................................................... 9 List of Tables ........................................................................................................................................ 11 Definition of Terms............................................................................................................................... 12 1. 2. 3. Introduction ................................................................................................................................... 13 Needs Identification ...................................................................................................................... 15 Operating Environment, Functional Analysis and Mission Analysis ........................................... 16 3.1 3.2 Operating Environment and Functional Analysis ................................................................. 16 Mission Analysis ................................................................................................................... 17 Sponsors ........................................................................................................................ 17 Technical Obligations ................................................................................................... 18
3.2.1 3.2.2 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11
Contextual Background................................................................................................................. 19 Introduction ........................................................................................................................... 19 Types of Suspension Systems ............................................................................................... 19 Castor Angle ......................................................................................................................... 21 Scrub Radius and Steering Angle Inclination ....................................................................... 22 Camber .................................................................................................................................. 22 Springs and Dampers ............................................................................................................ 23 Ackermann Angle ................................................................................................................. 25 Centre of Gravity, Roll Centre and Roll Axis ....................................................................... 26 Toe Settings .......................................................................................................................... 27 Bump Steer............................................................................................................................ 27 Legal, Health and Patent and Other Considerations ............................................................. 28 Legal ............................................................................................................................. 28 Health and Safety .......................................................................................................... 28 Patents ........................................................................................................................... 29 Social, Environmental and Other Considerations ......................................................... 30 Conclusion .................................................................................................................... 31
Product Design Specification ........................................................................................................ 32 Selection Criteria .......................................................................................................................... 33 6.1 6.2 Criteria Governing the Steering Swivel Arm ........................................................................ 34 Criteria Governing the Suspension System........................................................................... 35
7.
7.1 7.1.2
Design considerations ........................................................................................................... 36 Existing Bodywork ....................................................................................................... 36 Existing Suspension Geometry and Front Wheels ........................................................ 36 Existing Steering Rack .................................................................................................. 36 Front Fork Arrangement ............................................................................................... 38 Steering Swivel Arm ..................................................................................................... 39 Pushrod Suspension with Rocker Arm ......................................................................... 41 Pushrod Suspension without Rocker Arm .................................................................... 42 MacPherson Strut .......................................................................................................... 43 Using the Lower control Arm as a Rocker.................................................................... 44 Alternative Design Concepts ................................................................................................ 37
7.1.1 7.1.3 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.3 8. 8.1
Conclusion ............................................................................................................................ 46 Performance Simulations ...................................................................................................... 48 Change in Track Length vs. Suspension Travel............................................................ 49 Change in Camber due to Steering Input ...................................................................... 50 Ackermann Steering Geometry ..................................................................................... 50 Control Arm and Pushrod Force Calculations .............................................................. 51 Pushrod Rocker Stress Calculations.............................................................................. 54 Axel Bending Stress Calculations ................................................................................. 56 Control Arm Pivots Force Calculations ........................................................................ 57
Performance Simulations and Design Calculations ...................................................................... 47 8.1.1 8.1.2 8.1.3 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.3
Conclusion ............................................................................................................................ 57 Material Science.................................................................................................................... 58 Metals............................................................................................................................ 58 AISI 4130 Chrome-Moly .............................................................................................. 61 6063-T6 Aluminium ..................................................................................................... 62 Material Properties ................................................................................................................ 60
9.
Material Selection ......................................................................................................................... 58 9.1 9.2 9.1.1 9.2.1 9.2.2 9.3 9.4
Side-by-Side Comparison ..................................................................................................... 62 Calculations........................................................................................................................... 63 Control Arm and Pushrod Material Calculations .......................................................... 63 Pushrod Rocker Material Selection............................................................................... 64 Suspension Box Structure ............................................................................................. 64
10.2 10.3 10.4 10.5 11. 11.1 11.2 11.3 11.4 11.5 11.6 12.
Welding ................................................................................................................................. 67 Standard Parts ....................................................................................................................... 68 Manufacturing ....................................................................................................................... 68 Assembly............................................................................................................................... 69 Maintenance .............................................................................................................................. 73 Wheels Bearings and Brakes.............................................................................................. 73 Bushes ................................................................................................................................... 73 Brake Lines ........................................................................................................................... 73 Shock Absorbers ................................................................................................................... 74 Tie Rod Ends......................................................................................................................... 74 Conclusion ............................................................................................................................ 74 Conclusion ................................................................................................................................ 75
Bibliography ......................................................................................................................................... 76
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List of Figures
Figure 1-1 Ilanga I-I, the rendering of the updated UJ solar car [1] .................................................. 14 Figure 3-1 Route for the South African Solar Challenge 2012 [3] .................................................... 16 Figure 4-1 Double Wishbone Assembly [6] ...................................................................................... 20 Figure 4-2 MacPherson Strut Assembly [6] ...................................................................................... 20 Figure 4-3 Pushrod Suspension Assembly [7] ................................................................................... 21 Figure 4-4 Positive Castor Angle and Restoring Moment ................................................................. 21 Figure 4-5 Steering Axis Inclination and Scrub Radius [10] ............................................................. 22 Figure 4-6 Negative vs. Positive Camber .......................................................................................... 23 Figure 4-7 Types of Damping ............................................................................................................ 24 Figure 4-8 Visualisation of the Ackermann Principle........................................................................ 26 Figure 4-9 Roll Centre [18]................................................................................................................ 27 Figure 6-1 Fourth Design Concept..................................................................................................... 33 Figure 8-1 Suspension Geometry....................................................................................................... 49 Figure 8-2 Suspension Travel vs. Track Length Change ................................................................... 49 Figure 8-3 Steering Input vs. Camber Change ................................................................................... 50 Figure 8-4 Ackermann Steering, wheels Straight .............................................................................. 51 Figure 8-5 Ackermann Steering, Wheels Steered .............................................................................. 51 Figure 8-6 Upper Control Arm .......................................................................................................... 52 Figure 8-7 Lower Control Arm .......................................................................................................... 53 Figure 8-8 Suspension geometry with Pushrod ................................................................................. 54 Figure 8-9 Pushrod/Rocker/Shock Absorber assembly ..................................................................... 55 Figure 8-10 Load bearing sections (a), stresses experienced by the components (b) ........................ 56 Figure 8-11 Axel acting as a cantilever ............................................................................................. 56 Figure 9-1 Microscopic Image of Low Carbon Steel Grains [27] ..................................................... 59 Figure 9-2 Microscopic Image of High Carbon Steel Grains ............................................................ 59 Figure 10-1 Final Suspension System ................................................................................................ 65 Figure 10-2 CAD Model of the Steering Swivel ............................................................................... 66 Figure 10-3 Lower control Arm Alignment Jig ................................................................................. 67 Figure 10-4 Lower Control Arm Pivot Bracket ................................................................................. 67 Figure 10-5 Rocker Arm, Right and Left Steering Swivels, taped up, ready to be sent to the welder .............................................................................................................................................................. 68 Figure 10-6 Pushrod Rockers and brackets after being welded ......................................................... 69 Figure 10-7 Steering Swivel after being welded ................................................................................ 69 Figure 10-8 Steering Swivel and Brake Calliper with the wheel attached......................................... 70 Figure 10-9 Full Assembly before being bolted onto the Chassis ..................................................... 71 Figure 10-10 Full Assembly Bolted onto the Chassis ........................................................................ 71 Page | 9
Figure 10-11 Front Right Corner of the Car, Fully Assembled and Operational ............................... 72 Figure 10-12 Ilanga I-I, with the updated suspension, and members of UJ Solar, ready to participate in the Solar Challenge ........................................................................................................................... 72
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List of Tables
Table 4-1 Environmental Data of 25CrMo4 ...................................................................................... 30 Table 6-1 Selection Criteria for the Steering Swivel Arm ................................................................. 34 Table 6-2 Selection Criteria for the Suspension System .................................................................... 35 Table 7-1 Ease of Design and Manufacture ....................................................................................... 40 Table 7-2 Ability to set up the car for a desired handling characteristic ........................................... 40 Table 7-3 Compliance of the design within existing parameters ....................................................... 40 Table 7-4 Ease of incorporating the rest of the suspension system with the steering swivel arm ..... 40 Table 7-5 Aerodynamic Efficiency .................................................................................................... 45 Table 7-6 Incorporation of design within existing parameters .......................................................... 45 Table 7-7 Design uses available resources or equipment .................................................................. 45 Table 7-8 Design provides the opportunity to tune the suspension if desired ................................... 45 Table 7-9 Weight ............................................................................................................................... 46 Table 8-1 Suspension Parameters ...................................................................................................... 48 Table 9-1 - AISI 4130 Steel, normalized at 870C (1600F) Properties [29] ....................................... 61 Table 9-2 - 6063-T6 Properties [30] ..................................................................................................... 62 Table 9-3 - Side-by-Side Comparison between AISI 4130 and 6063-T6 ............................................. 62 Table 10-1 Selection of Standard Parts .............................................................................................. 68
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Definition of Terms
Throughout this Report, there will be several terms which may be unfamiliar to the reader. Some of these will be defined here:
Term Centre of Gravity CVT: Constantly Variable Transmission FIA: Federation Internationale de lAutomobile Ilanga I, I-I, II Pair-wise Comparison PDS: Product Design Specification
Definition Point at which all of the mass/forces of the car is said to act. An alternate means of transmitting power from a motor to the driving wheels. A pulley system where the diameters of the pulley are varied to change the gear ratios. The governing authority for the South African Solar Challenge 2012 Ilanga is the isiZulu word for sun. Ilanga I and Ilanga II are two solar powered cars being design and built by the University of Johannesburg. Ilanga I-I is the updated version of Ilanga I. A method used to evaluate the worth of the design selection criteria as well as the design alternatives. The design specifications to which the design must measure up. In the pushrod suspension design, the rocker is a pivot point which transmits the up-and-down motion of the wheel to the shock absorber. Using the principle of leverage, the force acting on the shock can be increased or decreased. Point around which body roll will occur during cornering. An alternative fuel race around South Africa, governed by the FIA.
Pushrod Rocker Roll Centre SASC 2012: South African Solar Challenge 2012 UJ
University of Johannesburg.
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1. Introduction
The University of Johannesburg (UJ) has endeavoured to partake in the South African Solar Challenge 2012. This is a race of over 5 100 km around South Africa and is open to universities from around the world. The entrants are required to design, build and race a solar powered vehicle through harsh environments, such as the Karoo and as well as through the Drakensburg Mountain range. The University entered the competition in 2010 with a petrol-electric hybrid vehicle, which came first in its class. In 2011, UJ built 3 alternative fuel vehicles; the effort was filmed and broadcast under the name Fuel Duel on the Mindset Learn Channel. Of the three cars to be designed, one was a solar car. The car was called Ilanga, which is the Zulu word for Sun. The upper side of the body is covered with solar cells, which collects electromagnetic radiation from the sun, and uses it to charge batteries. This energy is used to power the motor and drive the vehicle. The University has since undertaken a project to build a second car, Ilanga II. Both Ilanga I and Ilanga II are expected to be race-worthy in time for the South African Solar Challenge which starts in mid-September 2012, and runs for two weeks. Ilanga I was built by [then] final year students, in 2011, which have now graduated and are doing their Masters degree; they are now designing the flagship Ilanga II solar car. Currently, the task of ensuring Ilanga I is race worthy has fallen to a group of final year students from both mechanical and electrical engineering. This group will work closely with the Masters students in ensuring that all design tasks are completed to the required specifications. Additionally, the Masters students will assist the final year students in terms of offering advice. Ilanga I has already been built, and at the time of writing, has a rolling chassis. There are however, a few key concerns with the vehicle in its current state. The front suspension which was designed did not conform to the requirements. Therefore, the front suspension has to be redesigned; this is the scope of this text. The other concerns include the rear suspension, which also has to be redesigned, allowing for the correct placement of the constantly variable transmission (CVT). The steering column must be redesigned to be collapsible during an impact, while the steering rack must be modified such that it will accommodate the changes to the front suspension. Other research and design areas remain, but are not relevant to the scope of this text. This Report will serve as the Design Report for the suspension reconfiguration/optimisation. The subsequent sections will cover the project request in detail. Further, an in depth Literature Review will be conducted to familiarise the reader with all the relevant concepts and terminology involved in suspension design. The Design Description will cover topics such as the operating environment of the finished product, legal, social and patent considerations, and the financial side of the project. Thereafter, the concept generation will be presented where, based off of established design criteria, the most effective design will be selected. Performance simulations of the selected design will follow, giving a baseline, from which actual real world results may be determined. The manufacturing processes necessary to complete the design will follow. This section will provide details and instructions to ensure that the finished product meets an acceptable standard. Finally, some conclusions of the design process will be made, summing up the experience, and the final product.
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Figure 1-1 Ilanga I-I, the rendering of the updated UJ solar car [1]
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2. Needs Identification
The design request is as follows: Redesign/reconfiguration of the front suspension, braking system and nose section of Ilanga I within existing design parameters. Also, considerations must be made for quick tyre change under race conditions. All design considerations must be made to FIA specifications. The suspension governs how a car behaves during cornering, and over bumpy roads. It is arguably one of the most important aspects of the design to do correctly; thus the need to optimise the current suspension system. The design request was provided by the Masters students who designed and built Ilanga I. The design request can be further dissected to glean more detail: 1. Optimise/Reconfiguration of the front suspension: The current solution is a type of double wishbone and pushrod assembly, though not the conventional sort. This solution has the pushrod on the upper control arm, instead of the lower one. This uses more space, which requires more extensive modifications to the body of the car. Furthermore, the current wheel track is too wide for the body. Bicycle wheels were used, which do not have the required strength to support the weight of the chassis, batteries, bodywork and driver. These, therefore have to be changed. Brakes: The current braking system uses a disc brake from a bicycle. The problem is that the brake discs cannot sustain braking for extended periods. These will have to be upgraded to a hydraulic braking system from a motorcycle. The new brakes have already been designated. A steering swivel arm has to be designed to accommodate these new brakes, i.e. callipers and discs. Nose Section: The nose section of the vehicle has to be designed to conform to the FIA Crash Test Regulations. The current nose section is adequate, in terms of strength; however, it is built in, and is an integral part of the current front suspension which will be redone. The nose section presents an interesting research project; it can be simulated using Finite Element Analysis. Existing Design Parameters: The body of Ilanga I has been designed and built. There is very little, if any, room for modifications to the body. Therefore, all designs must be made to fit the bodywork.
2.
3.
4.
These specifications have been determined based on consultations with the Masters students and during meetings. The minutes of the meetings have been added in Appendix A. The minutes cover topics pertaining to how each of The Team members is faring with their respective tasks. Most of the detail in the above request was given by Warren Hurter, one of the Masters students. He has set out very specific guidelines as to how the design should be done, and some product design specifications (PDS). The PDS is deferred to a later section.
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Figure 3-1 Route for the South African Solar Challenge 2012 [3]
A conservative estimate of the length of the course is 5 100km. This route takes the competitors through some harsh environments. The stint through the desert Upington to Springbok is perhaps the most severe for the driver and the car. The elevation changes are also substantial; from the Highveld, down to reef altitude and over a mountain range. The front suspension will have to be designed in such a way as to limit the possibility of dirt and grime interfering with the moving components. The materials must also be corrosion resistant, as a fair deal of the race is along the coast, which has a humid atmosphere. Another consideration is the Page | 16
condition of the South African roads. Experience has shown that especially in the smaller towns along the route, the roads are often poorly maintained, with many potholes. The National Roads are in better condition though. Nevertheless, the suspension must be of such a nature that if the driver were to drive over a pothole, the shock would be absorbed, with little ill effects on the car, equipment or driver. The route along the National Roads has been set out by the FIA in [2], however, the route through the urban areas has not. Due to the fact that almost all of the race will be conducted on the Nation Roads, the suspension will be set up for the best straight line ability; cornering performance is not critical. The following functions that the suspension must accomplish can be summarised thus: Straight line performance: The vehicle will be travelling in a straight line for most of the journey. Therefore, the suspension must be set up in a way to ensure the car is easy to steer in a straight line for long distances, i.e. with minimal driver input. This way, the drive can drive for a longer stint without fatiguing, saving time on driver changes throughout the race. Resistance to dirt: Dirt is the bane to many mechanical components. Since the vehicle will be traversing through harsh environments, it must be able to cope. The wheel fairings will provide some protection against dirt and dust. Nevertheless, the suspension must have a fair tolerance for dirt. This can be achieved by ensuring that the tolerances on the moving components are such that if dirt is trapped in the system, it will not end up damaging it. Furthermore, allowance should be given to facilitate easy cleaning of the system. Performance over bumps/during cornering: The shock absorbers for Ilanga I have already been specified. They are gas filled units with only 5cm of travel, and are generally fairly stiff. However, the units stiffness can be adjusted, thus optimal performance over bumpy terrain can be accounted for. Another consideration is that the more stiffly sprung the shock absorbers are, the less body roll will be present during cornering. An optimisation must then be reached between cornering performance and acceptable ride quality. Corrosion Resistance: The suspension will be manufactured from either AISI 4130 chrome moly or 6063-T6 aluminium alloy. Both of these are corrosion resistance. The fasteners must also be corrosion resistant, to ensure they do not rust together, making them difficult undo. Fatigue Life: Fatigue may turn out to be a problem, especially if an aluminium alloy is used. The race is over a long distance, and the interior of the car is expected to be hot, in the region of 50 C, due to the hot motor and motor controller, and limited ventilation. The fatigue life of aluminium is dependent on temperature, and the suspension will be subjected to cyclic loading. Therefore, the material selection must take these factors into account.
3.2.1 Sponsors
The project is sponsored by some leading corporations in the industry. Some of which include [4]: Eskom Arrow Altech ProductONE Altium Technopol Milled and Shaped Profiles MTN
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These sponsors have sponsored the labs where the cars are being built, design software, technical assistance and money. Their logos will be displayed on the body of the solar cat and the support vehicles during the race, as well as being displayed on national television. Therefore, the university has an obligation to them to do well, and showcase their brands in a professional manner. The following contractual obligations and agreements are between UJ and the Technology Innovation Agency, although much of these obligations remain the same with the other sponsors. The contract states some general terms and gives definitions thereof. The contract states commencement and duration of the agreement, in this case, the agreement ends on the 31 st day of December 2012. The monies and/or resources provided will be used to design and build Ilanga I for participation in the south African Solar Challenge 2012. UJ agrees to display the trademarks of the sponsors in a manner which is mutually acceptable for both parties. UJ also agrees to inform the sponsor of any upcoming promotional event in which the cat or Team is showcased. UJ is also to inform the media/broadcasting organisations about the sponsors involvement, and at all times, where applicable, display the sponsors trademark by means of branding and/or team gear agreed upon by both parties. In addition to the issues of displaying the sponsors trademarks where applicable, the contract protects both parties, wherever possible, with regards to intellectual property (IP) rights and privacy. Any IP belonging to a party before the agreement was entered into would remain the property of that party. Any IP created during the design and construction of the solar car, using the sponsors money, would be the property of UJ. UJ will have full possession of the solar car. Any information which one party discloses to another, which is not in the public domain, will remain private. Furthermore, the contract delves into the details of breach of contract, termination, warranties and indemnities. The main focus of the sponsors who enter into an agreement with UJ is that of advertising and branding. The contracts are fairly straight-forward and do not bog the reader down in legal jargon.
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4. Contextual Background
4.1 Introduction
When designing a suspension and steering system, there are various aspects one needs to consider in order to ensure its efficacy. Firstly, one has to consider the type of vehicle and the environment in which it will be used. With this information, the appropriate performance objectives can be set. With this overarching theme in mind, specifics of the design can be finalised. Some of these specific details are: Type of suspension system, i.e. independent, wishbone, etc. General suspension geometry, such as castor angle, steering axis inclination and scrub radius. Calculating the forces acting upon the suspension, both in cornering as well and over bumps and static loading. Calculating what spring rates are required. Determining what sort of damping system is required. Determining the necessity of torsion bars. Optimising the system to have the best performance during cornering, in terms of Ackermann and camber angles. Selecting wheels and tyres which will meet the space requirements of a solar car. Designing the uprights which will accommodate the wheels and tyres, allow for the positioning of the braking system and integrate seamlessly with the suspension design. Optimising the design to ensure it meets strength and budget constraints.
This Literature Review will focus on each of the abovementioned points. Using this information, the design of the suspension system can be carried out. In each subsection of the Literature Review, the relevant literature will be discussed. Following this will be a paragraph describing how the information is pertinent to the UJ solar car, Ilanga I. NOTE: The information outlined in this Literature Review is, for the most part, an introduction to the abovementioned concepts. It merely gives a broad description of the various aspects and nomenclature encountered in suspension design. The more detailed calculations will be presented and referenced in the Design Calculations section.
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The other popular choice of suspension design is the MacPherson strut assembly. In this configuration, there is a lower wishbone, with a telescopic strut, anchored at the top via a flexible mounting. The lower end of the strut is mounted via a transverse-link. This system helps the vehicle follow irregularities in the road, and is mechanically simpler. It does not cause a substantial change in camber when cornering [5].
Another type of suspension design is the pushrod system. This type is used in most modern racing cars. This is also the type used on the current iteration of the UJ Solar Car. Pushrod suspension follows the same principles as those of the double wishbone. However, instead of the damper and coil spring, a pushrod is used. It is connected to the damper and wishbone by means of a mechanical linkage, called a rocker arm. This is favoured in open wheel racers because it is more aerodynamically efficient. It is also slightly more complex. It is questionable whether this type of suspension is strictly necessary in a solar car. If the suspension is closed off to the environment then the aerodynamic gains for open wheel cars will be nullified.
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When the front wheel steers the vehicle, it would naturally want to pivot around the wheels central axis. However, the wheel actually pivots around the steering axis, which is slightly offset from the wheels central axis. Therefore, when the wheel turns to steer the car, it scrubs along the ground. The SAI reduces the scrub radius. The SAI also causes the car to lift slightly as the steering wheel is turned. Therefore, the mass of the car is used to restore the front wheels to a straight ahead position, increasing stability [10]. This type of self-centring steering is advantageous compared to the castor angle, as this configuration provides the same benefits without the drawbacks. The front suspension can either have zero scrub radius, positive of negative scrub radius. When the SAI line intersects the contact patch, the car will have zero scrub radius. This is also called centre point steering. This situation causes the steering to lack feel, and feel unstable during cornering [11]. When the SAI line and the normal to the contact patch intersect below the road surface, a positive scrub radius is present. If the SAI line and the normal to the contact patch intersect above the road surface, negative scrub radius results. Positive scrub radius provides more steering feel, but also increases the steering effort required. Negative scrub radius decreases steering feel, but in the case of a tyre blow out, less force will act on the steering wheel, thereby ensuring the vehicle is safer [11]. Ilanga I will have a negative scrub radius for the following reasons. Firstly, steering feel is less important when navigating straight roads. Second, in the event of a blowout, the car must still be controllable, both to ensure the safety of the driver, and to preserve the car.
4.5 Camber
Camber is viewed front the front of the vehicle, and it is the angle at which the tyre tilts. When the top of the tyre is tilted away from the car, the camber is positive. When the top of the tyre is tilted towards the car, the camber is negative. In Figure 4-5 above, the camber is positive. A positive camber serves to shorten the scrub radius. Additionally, it also serves to offset vehicle loading. In terms of stability, a negative camber may be desired. This is easy to visualise; when the car turns a corner, the weight is transferred to the outside wheel, which will tend to stand up, i.e. become more perpendicular to the ground [10]. Thus, the more perpendicular the tyre is, the greater the contact patch on the ground, and the higher the cornering forces will be. The camber for the solar car will be slightly negative. This will provide some lateral stability during cornering, with little expense to directional stability. A negative camber angle of 1 will be used for Ilanga I. Page | 22
k = Spring Stiffness d = Diameter of the wire D = Diameter of the coil spring N = Number of turns of the spring
The number of turns depends on the end condition of the spring. The end condition refers to the whether the spring is cut, ground, or has a closed end. When the spring has a closed end, those coils in the end are not active, and therefore do not behave as the rest of the coils would [12]. It is instructive to elaborate on how different spring rates would affect balance of the car. Increasing the spring rate of the front springs will increase responsiveness. It will also, however, decrease grip on bumpy surfaces and increase tyre wear. Decreasing stiffness will increase grip on bumpy surfaces, reduces tyre wear, but also reduce responsiveness. One can only reach the best compromise when the route of the SASC has to be known. This includes both the type and quality of road surfaces, as well as whether there will be many corners or not. Elementary mechanics tells us that a mass attached to s spring will oscillate back and forth if the spring is displaced from its equilibrium point. In the real world, this oscillation will not continue indefinitely, since there is always friction. The oscillation is said to be damped. There are three types of damping available to engineers when designing a damping system; they are: over damped, under damped and critically damped.
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(4.2)
Where: m = Mass attached to the spring k = Spring constant, i.e. stiffness b = Damping Coefficient x = Direction of motion t = Time
(4.3)
Where: = b/m = damping factor, multiplied by two = k/m = Natural Frequency squared
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If: ; the system is said to be over damped. The roots to the characteristic equation of (4.2) are real and distinct [14].
If: ; the system is critically damped. The roots of the characteristic equation of (4.2) are real and equal. Therefore, the solution to (4.2) in this case is [14]:
(4.4)
If: ; the system is under damped. The roots are complex and distinct. Manipulating the equation using Eulers Equation yields the following solution for (4.2) [14]:
(4.5)
The mass of the car still has to be determined before any real calculation of the spring rate or damping coefficient can be completed. Driver preference as well as the road conditions and route layout will all play a part in determining the required damping. The ultimate goal of this vehicle is for stability. As in open wheel racing, little thought is given to driver comfort when designing suspension. The car must be stable, balanced and drivable; it is assumed that the driver will be fit enough to endure a stint of approximately two hours behind the wheel.
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4.11.1 Legal
There are several legal responsibilities that the University has to fulfil while undertaking this project. The first, and probably most important, is the responsibility towards the sponsors. The second legal issue revolves around the Universitys participation in the SASC 2012. This includes meeti ng all the requirements set out by the FIA, obtaining the correct temporary licence for the vehicle and obeying all of the roads regulations while competing. A third issue is centred on the manufacturing of components. Should a part require specialised welding, such as aluminium or stainless steel, then qualified and certified personnel should be sought to do the job. This section will take a brief look at some of the specifics regarding these issues. The sponsors of The Team are providing support primarily by means of monetary contributions. Others are providing services free of charge. There are two issues of importance concerning the sponsors; the sponsors each have their own contractual obligations, and the event will be televised. The contractual obligations have to be fulfilled. This may include displaying the sponsors logos and trademarks at all public events, or being barred from using competitors products. The event is also being televised, putting UJ and the sponsors on show for the rest of the country. The Team thus has to maintain professional conduct at all times in front of the cameras, and display the relevant sponsors signage when and where required. Each entrant into the SASC 2012 will have to pay the entry fee, and ensure that their vehicle is registered with the relevant authorities [2]. There are regulations concerning how the race is run. More specifically, the regulations detail how many support cars the entrant requires, the running order of the support vehicles, the following distances and overtaking protocols. Although these are not technically legal issues (in terms of national law), they have been set out by the FIA, and must be observe to ensure the safety of the entrants. Additionally, not observing the regulations will result in penalties and/or exclusion from the event. Certified welders are required by law for certain tasks. For example, a welder must undergo continuous training and re-evaluation if he to weld a pressure vessel. There are certain materials that are very difficult to weld and hence require a specialised and certified welder to complete the task. This includes aluminium and stainless steel welders. Certified welders will guarantee a standard of work that a non-certified welder will. Further, if the certified welders work does not meet a certain standard, then the customer can rightfully demand that the work be redone at the welders own expense.
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As mentioned previously, driver fatigue is a concern, so the following courses of action are necessary (These are stated in the PDS). Driver inputs into the steering wheel to keep the car going straight must be kept a minimum to reduce the risk of driver fatigue. According to the regulations [20], adequate ventilation must be ensured inside the cockpit. The scrutineers require a simulation of the airflow within the drivers compartment. This simulation is to be done using software such as StarCCM+. Other regulations include ensuring that all sharp edges within the driver compartment must be cover up, or filed smooth. This extends to the presence of sharp edges anywhere on the vehicle. All wires must be properly insulated to avoid the risk of the driver being shocked. All electrical components must comply with the IEEE standards. Where the vehicle operates with a voltage higher than 32V, warning labels must be fixed to the cars, and it must be demonstrated that it is impossible for the driver to touch a live wire. The scrutineers also require a drawing of the power circuits and electrical equipment with specifications. The vehicle must be fitted with lights and indicators which must be visible from 30m in daylight. Importantly, all entrants must have rear brake lights fitted. All vehicles must have a horn, hooter or some audible warning device fitted. In the event of a front end collision, the solar array must be deflected away from the driver compartment. It is required to show the scrutineers a simulation of this. The vehicle will be fitted with a collapsible steering column; the column will use a shear pin which will shear off under a certain loading condition, i.e. a high load experienced during a collision. The seat must be approved by the FIA, along with a five point harness. Ilanga I will use a six point harness. There is a maximum time limit that the driver has to exit the vehicle. From a driving position, with all safety equipment in place and with the safety harness attached, the driver should be able to exit the vehicle in 7 seconds or less. The driver compartment should be able to be opened both from inside and outside the vehicle. The handles on the outside of the vehicle must be painted red, orange or yellow; a colour which is clearly distinguishable from the rest of the bodywork. Furthermore, a person unfamiliar to the vehicle should be able to open the driver compartment should he need assistance. The brakes must be able to achieve a deceleration of 5.8m/s2. The front steering swivel arms will have to be designed such that they accommodate the callipers and brake discs. The swivel arms and the suspension control arms should be able to withstand the forces imposed on them due to braking. This is a critical aspect of the design, as the braking forces are severe. The brake discs will also have to be of an appropriate specification. If they are too thin, the will warp under the braking loads. As mentioned, ventilation to the driver is very important. Ilanga I has two slots for ventilation in the front, with several placed where the air can exit, out the back. Nevertheless, the cockpit is expected to reach upwards of 50C, due to the hot motor and motor controller. This is in addition to the fact that the driver is required to wear a fire-retardant overall, gloves and helmet. Therefore, a drinks bottle will have to be added into the car to keep the driver hydrated. The maximum stint a driver can expect to manage is 45 minutes.
4.11.3 Patents
Many patents have been approved with regards to front suspension design of automobiles. These patents include the use of active systems, that is, suspension the firms- or softens up depending on the road and/or other conditions. Other patents investigate designs for specific conditions, such as offroad, or suspension for snow vehicles. Yet others examine various methods of stabilisation. This section will investigate some of these patents. Reviewing patents can stimulate thought and help improve ones own design. The invention patented by R.H. Kress in [21] aims to optimise ride height characteristics of heavy vehicles, both laden and unladen. Kress mentions that a design that optimises ride height of a fully loaded truck may not be the correct design for an unloaded truck. Thus the characteristics of the suspension may be a compromise between the two extremes. The invention aims to optimise the suspension characteristics by providing a system where the vehicle load is supported by a compressible fluid. The pressure of this fluid is largely controlled by the driver.
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More recently, active suspension systems have become increasingly popular. The Williams FW14 Formula One car incorporated active suspension, which took Nigel Mansell to World Championship title in 1992. In [22], R.I. Davis patented an electrically powered active suspension for a vehicle. The purpose of the invention was more sophisticated than the one presented in [21], which merely optimised ride height. R.I. Davis invention sought to maintain the ideal relationship between the suspension control arms and the chassis in real time, by the use of electric motors. The types of motors employed to power this active suspension may either be permanent magnets, synchronous, variable reluctance or an induction motor. The motor can either be linear or rotary. It is clear that Davis sought a general, all-encompassing solution. Although it is instructive to know about these more advanced types of suspension systems, their existence bears little influence on the current task. The suspension to be used on Ilanga I will be a passive system, with no possibility of active ride height control and the like. These systems are expensive and require a lot of time to develop. They will also add significantly to the weight of the vehicle, with little redeeming value. A final comment about patents; while doing the review, it was found that a lawyer in Australia, John Keogh patented what he called a circular transportation facilitation device; more commonly referred to as the wheel [23]. Apparently, Keogh wanted to test new patent system introduced in Australia.
Quantity Eco Indicator 95 EPS Ex(in)/Ex(out) GER Raw Materials Input Solid Eco Indicator 99
Environmental Remarks: Environmental data for the production of 1 kg crude steel from SPIN. Transport is added. The coal comes for 65% from Canada, 23% Australia, 12% from the EEC. Iron ore comes for 37% from Brasil, 21% Australia, 31% Europe and the remaining 11% from elsewhere. Page | 30
Lime is imported from Belgium. Metallic alloy elements are assumed to be added in the required percetages. The production and emission data are for 1989 [25]. The social implications of this project are fantastic. The Team itself consists of members from every background; white, black, Asian, English, Afrikaans. Therefore, The Team is exposed to different cultures and ethnicities which instil the values of tolerance and acceptance. The Team is also exposed to a realistic working environment, while completing their degree. This serves to prepare The Team for the challenges encountered outside of University. Thus the members will emerge better prepared than their colleagues. UJ strives to produce top quality engineers, and this project serves to accomplish just that. Better engineers mean better possibilities for those engineers themselves, as well as the communities in which they work. Furthermore, the research into alternative energy vehicles will have an impact on society in the future. Solar energy in one of its various guises may provide cheap, clean energy, thus even impoverished communities will benefit. The environmental and social implications of this project make it worth pursuing by themselves. Care must be taken when selecting solar panels. Although they produce no emissions, solar panels production can in some cases, be environmentally unfriendly [26]. The irony is that solar panels require electricity to manufacture, and thus, during their construction, solar panels indirectly lead to greenhouse gas emissions. However, the University of Johannesburgs Physics Department has developed a new solar cell technology. Professor Vivian Alberts has created a thin-film solar cell [27]. The cells are cheaper, easier to make and more efficient than conventional photo-voltaic cells. According to the Universitys website, these panels can produce 60kW of power for only R650 [28]. This is precisely the point of projects such as the UJ solar car. Research into various fields will ultimately lead to technological improvements for society. The manufacturing of batteries is another cause for environmental concern. According to a study conducted by Notter, D.A., ET. Al. [29], the impact on the environment due to personal mobility is predominantly caused by the operation phase, and not the manufacturing phase. So while the production of batteries may not be environmentally friendly, the clean operation of the vehicle mitigates this fact. With time and more research, the production of these batteries may become cleaner.
4.11.5 Conclusion
The legal and health considerations are to be kept in mind as the project progresses. It is a good idea to refer back to the literature regularly to find out if there is something more one could do to increase safety, or to ensure one does not wander into the realm of infringing on patents, and inadvertently copying others work. The future environmental impact the project presents cannot be stated with a high degree of certainty. Many companies and universities are looking to develop alternative energy, and solar energy is just one of the possibilities. UJ itself is exploring two other avenues, namely hydrogen fuel cells and turbo-electric power. Although it is impossible to know what the future holds, it is certain that the research into these projects can only have a positive effect.
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6. Selection Criteria
Different design concepts will be generated to ensure most possibilities are considered. The quality of each concept will be measured based upon selection criteria. The pair-wise selection method will be used. A brief description of the pair-wise method of selection follows. A certain number of criteria are selected; these must be pertinent to the goal of the project. These criteria can be: speed, accuracy, corrosion resistance and the like. Essentially, any performance characteristic of the product can be chosen. Once a list of criteria has been determined, the importance, or weight of each criterion can be evaluated. An matrix is set up with each criterion plotted along a single row and column (Assuming n criteria). Each criterion is compared against every other criterion. When two criteria are compared against each other, the criterion with the higher priority is assigned a value of 1, and the lower priority criterion is assigned a value of 0. If the priority of the two cannot be distinguished, they are each awarded a value of 0.5 each. This way, the most important criteria are determined, and they are assigned the most weight. After the criteria have been selected, the alternative design options can be compared. An m matrix is set up, for each criterion (Assuming m alternative designs). The design concepts are plotted along a single row and column. The designs are compared against one another in a similar fashion as mentioned above in terms of a particular criterion. This is done for each criterion. The alternative design which has obtained the highest score for a particular criterion is multiplied with the weight of the criterion. Thus, one design solution may have fared the best in one particular comparison, but that criterion may not have the highest priority. This way, the alternatives are compared on a level playing field, and the design solution that fared the best, in the most important comparisons will end up being the design that is chosen. In the case where a criterion fails to score a point during the criteria evaluation process, it will be assigned a value of 1. All other criteria have an additional point added to them. This is important when evaluating the design alternatives. This is so that, if a criterion does fail to score a point, it does not mean that it is completely unimportant; it simply means that it has a lower priority than the other criteria against which it is being compared. The pair-wise comparison method was chose to select the design criteria for the following reasons: It is a powerful method to determine qualitatively, when the conditions the design alternative must adhere to. It also provides a way to quantify which selection criteria have priority, over their counterparts. The design alternatives can be compared using this method as well. Thus, the pair-wise selection method is useful in determining both the selection criteria, as well as the best design alternative. There are two distinct aspects of the suspension design that can be identified. The first is the design of the steering swivel arm, and the second is the type of suspension system used. Based on consulting with W. Hurter, there are two possible solutions for the steering swivel arm fork design and a conventional steering swivel. There are four possibilities for the suspension system itself MacPherson Strut, Pushrod suspension with rocker arm, and pushrod suspension without rocker arm. A fourth concept was devised later on; it entails incorporating a sort of rocker onto the lower control arm. This idea is displayed in Figure 6-1. As the control arm is displaced due to bumps or cornering, the shock absorber is also displaced. More detail on these can be found in Section 7. PIVOT POINT CONTROL ARM SHOCK ABSORBER
Figure 6-1 Fourth Design Concept
Each one of these two design aspects has their own set of design criteria; for example the steering swivel arm is housed inside the wheel fairing. Therefore it does not have to be aerodynamically Page | 33
efficient, but is must be compact. The suspension system is licked by the airstream, and thus must by aerodynamically efficient. The criteria for these two design aspects are present below with a brief description. The criteria have an abbreviated form in brackets. These abbreviations will be used in the selection criteria tables.
HC 1 X 0 0 2
The two most important criteria are Compliance of the design within existing parameters and Ease of incorporating the rest of the suspension system with the steering swivel arm. This is a logical conclusion, because, if the system is to work at all, it must be enclosed by the wheel fairings and it must be able to be incorporated into the rest of the design. The criterion Ability to set up the car for a desired handling characteristic was third in priority, because, which ever design is chosen, that design will be done in a way as to ensure the desired handling characteristics are achieved. The final criterion Ease of design and manufacture failed to score a point in the process, but it is still awarded a point, merely to prevent it from having a value of zero. This criterion is not unimportant; it simply has a lower priority than the other criteria. It is still a valid design concern which should be considered.
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6.2
The criteria governing the suspension system itself will now be considered. These are different from those presented in the previous section, as there are different factors to consider. Once again, these criteria have an abbreviation used in Table 6-2. The criteria are: Aerodynamic Efficiency (AE): The design must present the least possible resistance to the air as possible. The bodywork was designed with a heavy focus based on aerodynamics, and it would be nonsensical to not consider this aspect in the design. It is worth noting that the control arms and/or other linkages will be in the airstream, and will be subject to aerodynamic drag. Incorporation of design within existing parameters (Incorp): The design will have to accommodate the existing bodywork. The nose section of the vehicle to which the front suspension is bolted will be redesigned, but the prospects of changing the design substantially are low. Thus any changes that need to be made to the bodywork and/or chassis should be kept to a minimum. This is also to save costs. Design uses available resources or equipment (Avail): The first Ilanga I design team has sourced components which are to be used in the reconfiguration of the suspension. These include the shock absorbers, wheels and brakes. The new design must incorporate these new parts in order to keep costs down. Design provides the opportunity to tune the suspension if desired (Tune): The design should allow some aspect of flexibility. It would be detrimental to design a system which cannot be set up to achieve the desired handling characteristics. Weight (W): Different solutions will differ in terms of mass. Weight savings are important, especially in this type of vehicle. Everything else being equal, the weight of the system will be the deciding factor.
Avail 1 1 X 1 1 4
Tune 0 0 0 X 0 0.5
W 0 0 0 0 X 0.5
The criterion Design uses available resources or equipment was ranked the most important. The equipment available must be used in the design, and there is no way around this. The two criteria Aerodynamic Efficiency and Incorporation of design within existing parameters were tied for second. The bodywork can be modified to a small extent; therefore incorporating the new design into the existing bodywork can be achieved. Aerodynamic efficiency is an important goal in this project. The lower the wind resistance, the less power the batteries will have to provide to drive the car. Finally, Design provides the opportunity to tune the suspension if desired was ranked with the lowest priority, along with Weight These two conditions are still important, but in terms of completing the design within budget, they assume a lower priority. In this case, no criterion scored a value of zero, unlike the situation in Table 6-1.
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available lengths of the control arms, relative to one another, and it also influences the steering axis inclination. The steering rack was designed as an off-centre system, although this will be changed to a central system.
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From the above, it can be seen that the front fork may be a viable solution. If it were to be used, it is recommended that a high quality, off-the-shelf product is used. This will reduce the amount of design work and manufacturing involved, which will likely save money. The front fork will also have the necessary mounts for the brake callipers. The downside to using an existing fork would be that the fork more than likely will not conform to the space constraints of the bodywork. 7.2.1.2 Advantages With this solution, it would be easy to change the front wheel is race conditions. The wheel fairings would not have to be altered to change wheels. The car could simply be raised to the required height, and the front wheel could be removed. It is a simple solution in terms of attaching the wheel and brake to the fork. The axle in this case will act as a simply supported beam with two supports, and one load in the middle. This is a stronger solution than the conventional swivel arm, where the axle is subjected to bending, such as that found on a cantilever.
7.2.1.3 Disadvantages It is a complex solution in terms of attaching the fork to the chassis. A front fork requires more space than a conventional steering swivel arm. With the already strict space constraints, this may prove to be a real challenge. In order to replace a wheel quickly under race conditions, the ole wheel must be removed, the hot brake disc taken off and bolted to the new wheel, which can then be put back in place.
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The conventional steering swivel arm provides the designer with more flexibility than the fork arrangement. In this arrangement, the axle will act as a cantilever, which implies that the axle material must be very strong and hard; does not deform to an appreciable degree under the applied loads. 7.2.2.2 Advantages Provides flexibility to the designer; offers more choice pertaining to the best solutions for the rest of the suspension system. It takes up less space than a fork arrangement. This solution will enable quicker tyre changes than the fork arrangement during race conditions. This also satisfies the design request. It will use less material than a fork, which will make it lighter.
7.2.2.3 Disadvantages The bodywork will have to be modified to facilitate a wheel change during the race. Potentially more difficult to design, particularly with respect to the mechanism that locates the wheel to the brake. Material selection is more critical, especially for the front axle.
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Table 7-2 Ability to set up the car for a desired handling characteristic
Table 7-4 Ease of incorporating the rest of the suspension system with the steering swivel arm
Conventional Steering Swivel Conventional Steering Swivel Front Fork Arrangement Totals: Conventional Steering Swivel = 4 Front Fork Arrangement = 0 X 0
The conventional steering swivel wins the pair-wise comparison outright. The front fork arrangement was considered only as it was a suggestion made by the Masters students.
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7.2.3.2 Advantages The system presents less frontal area to the on-coming airstream. The rocker arm provides some additional scope for tuning the suspension, i.e. alter the forces acting of the shock absorber. It is easy to determine the location of the roll centre and other pertinent points based on the geometry. Once the geometry has been determined, designing the system will be fairly straight forward.
7.2.3.3 Disadvantages The rocker may add weight to the system, as it needs to be mounted using a bearing. The shock absorbers are physically small, which is less conducive to being used as part of a pushrod assembly.
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7.2.4.2 Advantages The system presents less frontal area to the on-coming airstream. The lack of a rocker saves on weight. It is easy to determine the location of the roll centre and other pertinent parameters based on the geometry. Once the geometry has been determined, designing the system will be fairly straight forward. Since the shock absorbers are small, they will be fairly simple to incorporate into the design.
7.2.4.3 Disadvantages The lack of a rocker limits the scope for performance optimisation, i.e. cannot alter the forces acting on the shock absorber.
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7.2.5.3 Disadvantages The shock absorber is small, and is not conducive to this design. The shock absorber would be in the airstream, causing substantial drag. The car was not designed around this type of suspension system, which implies that trying to design a MacPherson strut assembly would be more effort than what its worth.
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7.2.6.2 Advantages Very simple design. Saves on weight, due to less components in general. Reduces drag, due to less components being present in the airstream. This solution presents the design with the added flexibility due to the presence of a rocker.
7.2.6.3 Disadvantages Since this is a new design, it is untested and unfamiliar. The force acting on the shock absorber may be large due to the small moment arm of the rocker.
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Pushrod w/ rocker Pushrod w/ rocker Pushrod w/o rocker MacPherson Rocker on A-Arm Totals X 0.5 1 0 1.5
MacPherson 0 0 X 0 0
Rocker on A-Arm 1 1 1 X 3
Pushrod w/ rocker Pushrod w/ rocker Pushrod w/o rocker MacPherson Rocker on A-Arm Totals X 1 1 1 3
MacPherson 0 0 X 0 0
Pushrod w/ rocker Pushrod w/ rocker Pushrod w/o rocker MacPherson Rocker on A-Arm Totals X 0.5 1 0 2.5
MacPherson 0 0 X 0 0
Table 7-8 Design provides the opportunity to tune the suspension if desired
Pushrod w/ rocker Pushrod w/ rocker Pushrod w/o rocker MacPherson Rocker on A-Arm Totals X 0.5 1 0.5 2
MacPherson 0 0 X 0 0
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Pushrod w/ rocker Pushrod w/ rocker Pushrod w/o rocker MacPherson Rocker on A-Arm Totals X 0 0 0 0
MacPherson 1 1 X 0 2
Rocker on A-Arm 1 1 1 X 3
Now, to determine the most feasible design alternative, the totals in each comparison must be multiplied with the corresponding weight for that criterion. Thus Pushrod w/ rocker = 1.5(1.5) + 3(1.5) + 2.5(4) + 2(0.5) + 0(0.5) = 17.75 Pushrod w/o rocker = 1.5(1.5) + 2(1.5) + 2(4) + 2(0.5) + 1(0.5) = 14.75 MacPherson = 0(1.5) + 0(1.5) + 0(4) + 0(0.5) + 2(0.5) = 1 Rocker on A-Arm = 3(1.5) + 1.5(1.5) + 1.5(4) + 2(0.5) + 3(0.5) = 15.25
7.3 Conclusion
From the preceding sections, the following conclusions can be drawn: The conventional steering swivel arm was far and away the superior concept. The front fork arrangement was considered on the advice of the Masters Students. Although it may be a reasonable concept to employ, based on the current design constraints, it is not feasible. The pushrod with the rocker is the concept that will be developed. The added weight of the rocker assembly will be mitigated by the fact that it has the highest likelihood of working correctly. The pushrod without the rocker offers the designer limited flexibility in terms of the forces acting on the shock absorber. The forces acting on the shock absorber may be too great for the shock, and may end up damaging it. The same is true for the control arm which incorporates the rocker. The MacPherson Strut was considered for the sake of completeness, but was never really a viable design option.
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After conducting the pair-wise comparison in Section 7, the components chosen for the design are the conventional steering swivel arm and the pushrod suspension with rocker. The design software used was SolidWorks Academic Edition 2011-2012. The first order of business was to reverse engineer the steering rack. As was mentioned in Section 4.10, the steering rack dimensions must be known in order to account for bump steer in the design. Some simple suspension geometry was drawn as a starting point. The steering rack was inserted into the model, and its height above the reference plane (ground plane) was adjusted such that its tie rod ends centres intersected the line joining upper and lower control arm pivot points. After this, the wheels were inserted into the model and planes were created to define the wheels final positions. Based on the Literature Review and consulting with the senior students, the geometry was refined. Some mock steering swivel arms were modelled based on the suspension geometry. Its position was defined, in the process, defining the scrub radius. With this in place, the turning circle was determined next. The wheel was steered to the left/right and stopped just before intersecting the body work. The track length was adjusted so that the inner wheel could turn through a smaller arc than the outer one. Once the maximum steering angles were found (by implication, the turning circle), the Ackermann angles were determined. The above design process was an iterative one. Various parameters were tested, and the most promising values were brought to light. These values are tabulated below:
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Parameter Steering Axis Inclination Castor Angle Camber Angle Toe In Angle Lower Control Arm Angle Upper Control Arm Angle Scrub Radius Length between upper and lower control arm pivots Steering rack Length Lower Control Arm Length Upper Control Arm Length Turning Circle Radius
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-30
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y = -0.1387x + 88.81
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Steering Rack
Figure 8-5 above shows the wheels steered to the left. Again, it is difficult to see, but at full lock, the inner wheel is steered approximately 4 more than the outer wheel. This is also a convenient, as the steering rack is mounted onto the same mounting structure as the shock absorbers; all of the components (pushrods, shock absorbers, steering rack) therefore line up, thus mitigating the need for additional mounting structures.
(8.1) Where: F = Longitudinal force acting on the suspension m = Mass of the car a = Required braking acceleration
The regulations stipulate that the required braking force is 5.8m/s^2 [20]. The mass of the car is (including driver and batteries) 250kg. Thus applying NII:
This force will have to be withstood by four control arms, so the actual force acting on each of the control arms is 362.5N. Assuming a factor of safety of 3, the force acting on each member is approximately 1 100N (conservatively rounding up). The control arms are of an A-Arm configuration.
The control arms were a compromise between attaining the best geometry of the A-Arm to ensure the lowest possible forces act on the members, and ensuring that they fit inside the bodywork. Figure 8-6 shows the values for angles Alpha and Beta. A simply truss analysis was carried out to determine the loading condition on these control arm members. The following two equations were derived: (8.2)
(8.3) Where F is the load due to braking. With the known angles, and using equations 8.2 and 8.3, the forces acting on the control arm members are: 1214N on the member acting in tension, and 1064N on the member acting in compression. Page | 52
The results yielded 1737N on the compression member, and 1917N on the tension member. The cross member seen in Figure 8-7 has been added for extra rigidity of the control arm, as the lower control arm is considerably longer than the upper one.
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A similar truss analysis for the suspension geometry itself (including pushrods) will yield the forces present on the structure due to the mass of the vehicle. The car (including driver, etc.) weighs 250kg. Approximately 126kg acts on the front wheels, thus, 63kg on each wheel. The forces present due to this loading condition where found after deriving the following two equations and solving simultaneously: (8.4)
(8.5)
Thus, the forces present are 950N in compression on the pushrod, and 600N on the lower control arm. This is due to a force of 630N acting on the steering swivel arm. The upper control arm carries very little load; so little in fact, it can be neglected.
absorber side to the pushrod side. The geometry of the rock has been designed in such a way that the pushrod acts perpendicularly to the rocker, which in turn acts perpendicularly to the shock absorber. This is the case when the car is standing stationary, and the suspension has not travelled. As the suspension travels up or down, the angle between the pushrod and rocker, and between the rocker and shock absorber changes slightly, but this change is on the order of 2 degrees, which has very little effect on the suspension system itself.
Figure 8-9 Pushrod/Rocker/Shock Absorber assembly The centre line shows the lines of action of the respective forces.
As a larger amount of force is acting on the rockers, a finite element analysis of the rockers was conducted to ensure they will operate as desired. Refer to Appendix C for the full finite element analysis report of this component. The following two images show were the load is carried by this component, and what the stress on this component is.
(a)
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(b) Figure 8-10 Load bearing sections (a), stresses experienced by the components (b)
The images in Figure 8-10 shows that the load is carried by the two sides, thus justifying the large hole in the middle of the plate. The maximum stress on the plate is approximately 60MPa, which is well within the yield strength for this material, AISI4130.
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The length of the axel supporting this load is 97mm. Using the bending moment equation yields: (8.6) Where: Thus: M = 0.097630 = 61Nm y = 0.006m I = d4/64 = (0.0124)/64 = 1.017910-9m4
This stress is fairly significant, thus, an appropriate material must be used. 8.2.4 Control Arm Pivots Force Calculations
The control arm pivots are subjected to some large forces, especially the lower control arms. From the calculation from equations 8.4 and 8.5, it is seen that the force acting on the lower control arm is approximately 600N. This is acting on the A-Arm, which is essentially a truss. The maximum force acting on the members is 860N (found from simple truss analysis). The bolt holding the control arm also acts as its pivot. The force acts on the bolt in double shear. Once again, the bending moment applies a greater stress than the shear stress. Grade 8.8 bolts have been selected for the suspension. If M12 bolts are used, the bending stress on them would be:
The yield strength of the bolts is 660MPa [12], thus, the bolts will be strong enough.
8.3 Conclusion
The results obtained in this section will show their true worth when it comes to selecting the appropriate materials. When selecting the materials, a minimum safety factor of 8 will be aimed for. This high safety factor includes the different load cases the design will be subjected to during operation.
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9. Material Selection
The preceding section on the design calculations provides a tangible sense of the loads each of the components will experience. Using this information, the materials for these components can be selected. There are some additional material selection criteria to consider, which include cost and ease of manufacture. This section will deal firstly with the most suitable materials to use for the design, in terms of strength; thereafter, the other considerations will be taken into account. After all the available information has been analysed, the material will be selected. Before delving into the material selection, it would be appropriate to conduct a brief review of material science to provide a startingoff point for the later selection. Most of the literature surveyed with regards to material selection comes from [25]. This source demonstrates material selection for the design. That is, it demonstrates that the design can be conducted, and the material will be selected to suit the design, and not designing the product to suit a particular material. The present design was conducted with the same philosophy as outlined in [25]. Ilanga I was built using 6063-T6 aluminium, thus this material will be under consideration for the design. The other alternative is to use AISI4130 chrome-moly. This steel is used for aircraft, and is approximately three times stronger than the aluminium (ultimate tensile strength); it is also three times heavier. The most appropriate material will be selected from these two front runners.
9.1.1 Metals
Metals generally have a high modulus of elasticity, that is, they are generally stiff. Unless alloyed with some agent, pure metals will deform quite easily, meaning that they have a low yield strength. The yield strength can be increased by alloying, or by heat treating. Despite this, under standard conditions (not extremely low temperatures), the material will remain ductile, thus alloying to yield a certain amount before failing/fracturing. The resistance the material has to fracturing in called toughness. Metals will generally corrode if not protected, either by some surface treatment, of by the introduction of some alloying agent [25]. Metals have many properties that are appealing to an engineer. A wide range of treatments can be conducted on them to increase strength, corrosion resistance, electrical conductivity and the like. A full review of the mechanical properties of metals is beyond the scope of this review, so only some pertinent aspects will be discussed. 9.1.1.1 Grain Structure Metals are cast when they are in the liquid phase. As the metal begins to cool, the molecules of the metal start forming bonds with each other. This yields a grain of an almost perfect crystal. This happens at different locations within the cast at the same time. Eventually, the metal will contain hundreds of these crystals within it. The lattice structure of these crystals has a different orientation from one grain to the next. The yield strength of a material is based largely of the size, shape and orientation of these grains [26]. The grain itself has a very high yield strength, but the weakness of the material lies in the grain boundaries. A crack will propagate along grain boundaries much faster than it would propagate through the grain itself.
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Alloying was mentioned earlier. What some alloying agents, like magnesium, do is promote grain refinement [26]. What this means is that the grains in the metal become much smaller, increasing the amount of grain boundaries. It seems counter-intuitive that this would make the metal stronger, but it does. With smaller grains, the number of grain boundaries increase, thus increasing the number of discontinuities, which would hinder crack propagation [26].
Figure 9-1 above shows the microscopic grain structure. This image shows a low carbon steel. High carbons steels have a grain structure as shown in Figure 9-2. The dark areas are graphite flakes imbedded in the metal.
9.1.1.2 Strain Hardening Metals can be strain hardened. This means that if a metal undergoes strain, or a deformation, it will become harder and stronger [25,26]. The reason for this is that the grains within the metal become deformed. Thus, the grain boundaries will once again contain discontinuities and impede crack propagation. The amount a metal will strengthen is depended upon a quantity known as strain Page | 59
hardening index. Thus, a material can be processed (cold rolled) to increase strength. For a more indepth study of this topic, refer to either one of the following references [12,25,26]. 9.1.1.3 Alloying Alloying is a key concept in material science. It offers the designer some properties that he otherwise would not have had. The steel, AISI4130 has the following constituents: 0.5-0.95% Chromium, 0.120.2% Molybdenum [28]. The Chromium serves to increase corrosion and oxidation resistance, it increases hardenability, increases high temperature strength, and can combine with carbon to form hard, wear resistant micro-structures [28]. Molybdenum promotes grain refinement, and improves high temperature strength [28]. Steels can be combined with many other alloying agents, such as silicon, vanadium, nickel and others to produce these and other characteristics. Aluminium can be alloyed in much that same way. 9.1.1.4 Conclusion The preceding paragraphs provide a very cursory view of metals. For further information, the reader may consult references [25,26,28]. The purpose of the above sections is to demonstrate the range of possibilities, and material properties available when choosing a material. The focus was given to metals, as a metal will be used to construct the components; at this stage however, it is uncertain as to which metal will be chosen. The following sections will present a list of material properties and selection criteria. After which, calculations will be made and the most appropriate material will be selected.
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AISI 4130 Steel, normalized at 870C (1600F) Physical Properties Density Mechanical Properties Hardness, Brinell Hardness, Knoop Hardness, Rockwell B Hardness, Rockwell C Tensile Strength, Ultimate Tensile Strength, Yield Elongation at Break Reduction of Area Modulus of Elasticity Bulk Modulus Poissons Ratio Izod Impact Machinability Shear Modulus Metric 7.85 g/cc Metric 197 219 92 13.0 670 MPa 435 MPa 25.5 % 60.0 % 205 GPa 140 GPa 0.290 87.0 J 70 % 80.0 GPa English 0.284 lb/in English 197 219 92 13.0 97200 psi 63100 psi 25.5 % 60.0 % 29700 ksi 20300 ksiT 0.290 64.2 ft-lb 70 % 11600 ksi in 50 mm Comments
Comments
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Aluminum 6063-T6 Physical Properties Density Mechanical Properties Hardness, Brinell Hardness, Knoop Hardness, Vickers Tensile Strength, Ultimate Modulus of Elasticity Ultimate Bearing Strength Bearing Yield Strength Poissons Ratio FatigueStrength Machinability Shear Modulus Shear Strength Metric 2.70 g/cc Metric 73 96 83 241 MPa English 0.0975 lb/in English 73 96 83 35000psi Comments
@# of Cycles 5.00e+8
Table 9-3 above shows that the steel is nearly three times as dense as the aluminium, while offering only twice the strength. If the weight-to-strength ratio was the only consideration, aluminium would be the preferred material. Since this ratio is not the only factor, we have to investigate what sort of loads each respective material can handle. The following two sections were recommended for each respective material: AISI 4130: 19.051.25mm 6063-T6: 31.763.18mm
The following sub-section will use the values obtained in Section 8 to determine the stresses acting on these members.
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The AISI 4130 is also far easier to weld than the aluminium. This is according to the welder. The welders personal preference, and area of expertise is welding AISI 4130 structures, whic h adds another tick for the steel alloy.
9.4 Calculations
Using (9.1) Where: A = Cross-sectional Area. D = Outer diameter of the tube. d = Inner diameter of the tube. AISI 4130: 6.96410-5 m2 6063-T6: 2.85510-4 m2
This means that the area of the steel section is 24% of that of the aluminium section. Thus, for unit length, the respective masses of the sections are calculated using: (9.2) Where: m = Mass per unit length. = Material density. = Volume per unit length. AISI 4130: 0.5467kg/m 6063-T6: 0.7709kg/m
These values agree with the values given by SolidWorks. So, despite the aluminium having the lower density, because a smaller section of AISI4130 is being used, the steel alloy is actually lighter.
The stress these forces would impart on the structural members are calculated using: (9.3) Where: -
The stresses on the upper control arms members are thus: = 17.43MPa - Tension = 15.28MPa - Compression Page | 63
The forces acting on the lower control arm members are shown in Figure 8-7 and Figure 8-6. The two forces present on the arm are: 1 917N - Tension 1 737N Compression AISI 4130: o Where F = 1 917N, = 27.5MPa - Tension o Where F = 1 737, = 24.9MPa - Compression 6063-T6 o Where F = 1 917N, = 6.6MPa - Tension o Where F = 1 737N, = 6MPa - Compression
Thus, the stresses induced on the members are very small, and the factors of safety are very high, about 16 for the steel, and 36 for the aluminium. Thus, based on strength, it does not matter which of these two materials are used. Therefore, the lighter of the two will be chosen, the steel.
9.5 Conclusion
The material chosen for all the components is AISI 4130 chrome-moly. There are several reasons for this: The sections are lighter than the aluminium sections currently in use. The steel offers high strength, affording more than acceptable safety factors. The welder prefers to work with AISI 4130, thus ensuring high quality workmanship. The new car, Ilanga I-I will use this material for its chassis. Thus, the material will be ordered in bulk by the University. Therefore, for economic reasons, it would be beneficial to use this material for the present design. So for the reasons of strength, weight, economics and time, it will be beneficial to use the AISI 4130.
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The system consists of the following components: Suspension box: This bolts to the rest of the chassis. All other suspension components attach to the suspension box. It consists of the front and rear plates, and an internal structure of tubes to bear the loads. The front and rear plates have holes to accommodate the pivot points for the upper and lower control arms. It has a central cross bar to which the rockers and shock absorbers mount. The front and rear plates have a series of holes cut out to save on weight; the pattern of the holes was chosen such as to not compromise the plates load bearing capabilities. Control Arms: The upper and lower control arms attach to the steering swivel arms. The pushrod comes up from the lower control arm towards the rocker. The lower control arm is subject to more force than the upper one, and it is longer as well. Therefore, it has a strengthening brace partway along its length. Steering Swivels: These members are pivoted by ball joints at the top and bottom, to allow them to steer, and to allow range of motion in the vertical direction. The brake callipers mount to the steering swivels. Therefore, they should be strong enough to withstand the torque imparted on them under braking. They also support the load from the axels.
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Figure 8-10 demonstrates this. FEM analysis was done on these components to ensure their safety. Figure 10-2 below shows the steering swivel; here you can see the holes to reduce weight.
Sheets of the appropriate thickness AISI 4130 were ordered. The flat plates were arranged using Creo (another design package) to fit on these sheets, with minimal wastage. These layups have been added as an appendix. These parts were all designed using SolidWorks. Once designed, they can be saved in a certain file format, which the laser cutting machine can read. Thus, intricate shapes can be cut, and working drawings for these parts are not strictly necessary. Nevertheless for the sake of completeness working drawings of the assembled components are given.
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10.2 Welding
As mentioned, the plates to be welded can be pre-assembled and then given to the welder. The tubes to be welded are also fairly straight forward. Alignment jigs were designed and built. These jigs serve to position the tubes correctly, so the welder can simply weld them.
Figure 10-3 shows one of these jigs. A jig was made for the upper and lower control arms, as well as a structural section of the suspension box itself. The suspension box itself is also fairly easy to weld. The plates which were laser cut (such as the control arm pivot brackets) all have a flat surface, which can be made level using a spirit level. These flat surfaces can be measured and made level using a spirit level.
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All welds are to be 3mm filet welds. Since the material is inherently corrosion resistant, it will not need to be painted. Painting also adds weight, which is undesirable. All of the components are easy to manufacture, with the possible exception of some of the internal suspension box members. These will have to be cut to a specific profile in order to fit. Apart from that, this will be an easy project for an experienced artisan.
Part Name CBR125RW8 2008 Graphite Black CBR125W8 Brake Master Cylinder (including braking lines) CBR125W8 Brake Caliper DT Swiss M210 Shock Absorber IKO POS 12A[5] Tie rod ends Hex Bolt, M12 50 long Hex Bolt, M10 50 long Hex Bolt, M12 30 long Hex Nut, M14 Hex Nut, M12 Hex Nylock Nuts, M12 Hex Nut, M10 Washers, M14 Washers, M12 Washers, M10 Steering Rack (unknown make and model)
Quantity 2 2 2 2 8 20 20 20 10 20 20 20 80 120 80 1
10.4 Manufacturing
Some images of the components in various stages of production will now be shown.
Figure 10-5 Rocker Arm, Right and Left Steering Swivels, taped up, ready to be sent to the welder
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Figure 10-5 shows the parts which returned from the laser cutters, General Profiling. The plates were assembled and taped together, ready to be sent to the welder. At the time these pictures were taken, certain plates had not yet arrived, which delayed production of these parts by a few days.
10.5 Assembly
Assembly of the components is arguably the easiest phase of the project. The suspension box will be attached to the chassis by means of seven bolts. The suspension control arms will be attached Page | 69
(pivoted) by two bolts, with a bush. The steering swivel arms, suspension pushrods and steering arms will all have tie rod ends screwed into inserts (designed by another team member). The steering rack will be held on by four bolts, and it will be attached to the steering column by means of a universal joint.
Figure 10-8 Steering Swivel and Brake Calliper with the wheel attached
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Figure 10-9 Full Assembly before being bolted onto the Chassis
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Figure 10-11 Front Right Corner of the Car, Fully Assembled and Operational
Figure 10-12 Ilanga I-I, with the updated suspension, and members of UJ Solar, ready to participate in the Solar Challenge
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11. Maintenance
Maintenance of the system should be fairly straightforward. The South African Solar Challenge is a long race however, so although it may be straightforward, it should not be overlooked. Several components should be inspected on a regular basis (each evening after the days running during the race), and cleaning and/or replacing necessary components should take place. This includes the bearings, bushes, brake lines and shock absorbers. This section will take a brief look at each of these components.
11.2 Bushes
As with bearings, bushes are meant to reduce rotational friction and support loads. The bushes used in the present design are used to support the control arms and the pushrod rocker. The bushes must also be kept clean, although this is not as big a concern as with the bearings in the wheels. The main concern with the bushes is that they might deform due to a load in a particular direction. The material used for the bushes is vesconite, for the control arms, and aluminium, for the pushrod rocker. Should these bushes become deformed, the easiest solution would be to replace them. Thus, at least three spares of each bush should be manufactured.
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d. Top up the master cylinder. Do not let the master cylinder run too, otherwise, air will enter the system, and the process would have to be restarted. e. Repeat steps b. to d. until no more air come out of the system. Repeat for the other wheels.
11.6 Conclusion
The system was designed to be low maintenance from the start. The concepts selected were the one which presented the lowest possibility of the adverse effects of dirt and grime. The scale of maintenance can required can only be assessed in earnest, once the system is operational. The information provided in this section serves as a guideline; recommending the best solutions to possible problems that may arise. If the system is used sensibly, there should be no problems in terms of maintenance.
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12. Conclusion
This Report detailed the process of designing and manufacturing the updated front suspension of the UJ Solar Car, Ilanga I. The task started out by identifying the need which was to be fulfilled. The need was to optimise the front suspension of Ilanga I, such that it would be able to cope with the rigors of the South African Solar Challenge. The operating environment was identified; the environment consists of desert, coast lines, potholed roads and dirt. The system has to cope with all of these conditions. The mission analysis was conducted. The Team has an obligation towards the sponsors and technical obligations in order to participate in the race. The obligations towards the sponsors include upholding their good reputation, and displaying their logos at all public events. The technical obligations consisted of safety concerns, by and large, as well as practical aspects, such as, ensuring the car can make a full U-turn in 16 meters. A study of the available literature concerning suspension designs was conducted. This gave a valuable insight into all of the technicalities of designing suspensions. The importance of properly designed suspension geometry was discovered. The literature study also helped in formulating the product design specification. It also ensured that seemingly obscure concepts were kept in mind while the design was undertaken. The product design specifications were established. All the technical aspects of the design had to conform to the specifications set out in Section 5. The main concern was safety, and the second one was weight. The steering axis inclination was set to 10 degrees and the camber and toe were set to 1 degree negative and toe in, respectively. These angles, as well as the geometry of the control arms, were calculated so, such that the car would be safe to drive. The current geometry ensures the car is still controllable after a tyre blowout, while still affording the driver good feedback, and cornering ability. Selection criteria were formulated in order to compare concepts against one another. Two sets of criteria were established. One to determine what type of design should be used for the control arms, and what type of design should be used for the steering swivels. With this being completed, the design concepts were considered. Two concepts were generated for the steering swivels, and four were generated for the control arms. After conducting the pair-wise comparison, the concepts selected were the conventional steering swivel arm, and the double wishbone suspension, with a pushrod. These were selected based on the selection criteria, as well as the practical aspects of implementing the designs within the constraints set out in Section 7.1. Performance simulations were run to develop and optimise the design. The design process was an iterative one. A certain parameter for a particular component was selected, and that components behaviour was evaluated, with respect to the rest of the design. The parameter was changed and reevaluated. This process was follow when design the suspension geometry, the steering geometry, the shape of the steering swivels and the shapes of the upper and lower control arms. The performance simulations gave the first representative indication of the loads and forces acting on the system. With this in mind, the materials were selected. The choice of materials was limited, based on available resources. AISI 4130, chrome-moly was selected to construct the suspension. The manufacturing and maintenance of the system used up the most time, but they were the easier aspects of this project. The manufacturing section of the Report contained many pictures of the various components as they had been laser cut, welded and assembled. All of the components fit together very intuitively; the manufacturing aspect was simply. The maintenance aspect is equally simple. One should merely inspect the design regularly (every night after a the days race), to check for leaks in the break lines, air leaks in the tyres, and ensure the shock absorbers are still functioning.
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Bibliography
[1] UJ Solar. (2012, September) UJ Solar. [Online]. http://www.ujsolar.co.za/# [2] Federation Internationale de lAutomobile. (2011, May) South African Solar Challenge 2012: Supplementary Regulations, Section 1. Document. [3] Sasol Solar Challenge. (2012, September) Sasol Solar Challenge - South Africa. [Online]. http://www.solarchallenge.org.za/index.php?option=com_wrapper&view=wrapper&Itemid=232 [4] University of Johannesburg - Solar Team. (2012) UJ Solar. [Online]. http://www.ujsolar.co.za/ [5] Automobile Association, AA The Book of the Car, 3rd ed. London, United Kingdom: Drive Publications Limited, 1980. [6] The Car Bibles. http://www.carbibles.com. [Online]. http://www.carbibles.com/suspension_bible.html [7] Word Press. (2010, April) http://scarbsf1.wordpress.com. [Online]. http://scarbsf1.wordpress.com [8] J. Shires. (2008) Wits. [Online]. http://student.wits.ac.za/NR/rdonlyres/AB7FFFEC-CEF6-446FA843-343204FAB0F4/0/SuspensionGeometry.mht [9] D. Burnhill. (2009) rctek. [Online]. http://www.rctek.com/technical/handling/caster_angle_basics.html [10] FamilyCar. (2008) FamilyCar. [Online]. http://www.familycar.com/Alignment.htm [11] Club Protege. (2010, Mar.) Club Protege. [Online]. http://www.clubprotege.com/forum/showthread.php?47204-Effect-of-Wheel-Offset-Change-onScrub-Radius [12] J.K. Nisbett R.G. Budynas, Shigley's Mechanical Engineering Design, 8th ed. New York, United States of America: McGraw Hill, 2008. [13] J.W. Jr. Jewett and R.A. Serway, Physics for Scientists and Engineers with Modern Physics, 7th ed. Belmont, CA, United States: Thomson Brooks/Cole, 2008. [14] D.G. Zill and M.R. Cullen, Differential Equations with Boundary-Value Problems, 7th ed. Belmont, CA, United States of America: Brooks/Cole, 2009. [15] D. Burnhill. (2009) RCTEK. [Online]. http://www.rctek.com/technical/handling/ackerman_steering_principle.html [16] R.N. Jazar, Vehicle Dynamics: Theory and Application, 1st ed. Riverdale, NY, United States of America: Springer, 2008. [17] thecartech. thecartech. [Online]. http://thecartech.com/subjects/auto_eng2/Roll_Center.htm
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[18] wheels-inmotion. [Online]. http://www.wheels-inmotion.co.uk/forum/index.php?showtopic=3337 [19] Longacre Racing Products, Inc. (2011) Longacre Racing Products, Inc. [Online]. http://www.longacreracing.com/articles/art.asp?ARTID=13 [20] Federation Internationale de lAutomobile. (2011) South African Solar Challenge Regulations Section 2. [21] R.H. Kress et. al., "Vehicle Suspension System," 3,232,634, Feb. 01, 1966. [22] R.I. Davis et.al., "Electrically Powered Active Suspension," 5,060,959, Oct. 29, 1991. [23] W. Knight. (2001, July) NewScientist. [Online]. http://www.newscientist.com/article/dn965-wheelpatented-in-australia.html [24] matbase. (2009) matbase. [Online]. http://www.matbase.com/material/ferrous-metals/high-gradesteel/25crmo4/properties [25] M. Ashby, H. Shercliff, and D. Cebon, Materials - engineering, science, processing and design, !st ed. Oxford OX2 8DP, United Kingdom: Butterworth-Heinemann, 2007. [26] W.D. Callister, Materials Science and Engineering - An Introduction, 7th ed. United States of America: John Wiley & Sons, Inc., 2007. [27] S. Eddins. (2012) MathWorks. [Online]. http://www.mathworks.com/company/newsletters/news_notes/win02/watershed.html [28] K.G. Budinski and M.K. Budinski, Engineering MAterials - Properties and Selection, 9th ed. United States of America: Pearson Prentice Hall, 2010. [29] MatWeb. (2012) MatWeb. [Online]. http://www.matweb.com/search/DataSheet.aspx?MatGUID=e1ccebe90cf94502b35c2a4745f63593 [30] MatWeb. (2012) MatWeb. [Online]. http://www.matweb.com/search/DataSheet.aspx?MatGUID=333b3a557aeb49b2b17266558e5d0dc0 [31] R. L. Pierce, "Stabilising Attachment for vehicle front end suspensions," 3,104,117, Sep. 17, 1963. [32] Metallurgy for Dummies. (2011, June) Metallurgy for Dummies. [Online]. http://metallurgyfordummies.com/microstructure-of-metals/
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UJ Solar Team Meeting 2 March 2012 Minutes 1. Add project description on Trello for Ilanga 1 students. To be done before Monday. 2. Electricals to submit project proposal to Electrical Masters. 3. Revise the generalised time table. 4. Group members are to define the auxiliary roles, i.e. finances, logistics, etc. 5. Find a suitable time for smaller team meetings, for undergrads 6. Find a good venue for smaller team meetings, perhaps the engineering corridor. 7. UJ Solar Society E-Mail address to be set up. 8. Speak with faculty heads in connection with UJ Solar Society. 9. Events to promote the UJ Solar Society. Perhaps coupled with the launch of the Prospective Engineers Student Council. 10. Each person to post something about the car each week via Facebook or Twitter, or other social media. 11. The Solar Team should make an effort to attend some of UJs events, like the Varsity Cup. 12. Undergrads to determine deadlines and project plan for Ilanga 1. 13. Go to www.ganttchart.org if you do not have access to Microsoft project. 14. Note that Creo is available from the Masters. They will be able to enable the product keys such that we can use Creo off campus. 15. Altium will likely be available. They want more exposure from UJ Solar first. 16. TomTom meeting on Wednesday, 7 March, 2-3PM. Be there if youre available. Confirm Venue with Mrs Janse van Rensburg 17. E-Mail address for UJ Solar Team team@ujsolar.ac.za 18. JP has some role in sponsorship, TBC. 19. Group Dynamics course, Saturday, 10 March 2012. 20. Results of personality profile to be sent to njvr@uj.ac.za 21. For more info on the solar car project, go to www.ujsolar.ac.za 22. Ilanga 1 is in the Challenge Class, in the FIA regulations. 23. See FIA regulations, and consult with Masters if in any doubt. 24. Speak to Winston? Regarding regulations. 25. Warrick to speak to Masters regarding locking mechanism. 26. Use Mendeley as a PDF database. 27. Create drop box for undergrad group.
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Solar car meeting 9 March minutes Recommended that the electrical undergrads upload their first section of their design reports Ilanga I to be running on 16 March, 16H00 Concerning the meetings, there is no need to work together as this is unproductive. Just meet and catch everyone up. Leave about three months for manufacturing for mechanicals Electricals to use Altium when it becomes available Theran is responsible for understanding and being familiar with the electrical regulations Jules is responsible for understanding and being familiar with the mechanical regulations See F1 dictionary Mechanicals Updates up to 9 March Vincent Has been doing research Jules Modelled mock up suspension geometry. Needs steering rack dimensions Rob Looked at different collapsible steering shafts, shear pin seems to be the desired option. Bafana Chapter 1 of report. Consider off the shelf products for his particular product Geoff Chapter 1. Rese4arch battery management and chip programming Theran Chapter 1. Research into different lights, such as Audi LED lights, etc. Warrick Literature Review Palesa Literature Review. Must look at fibre glass encapsulation, EVA, Solaris Charles Wanted to use KERS (Kinetic Energy Recovery System Regenerative Braking), although car already has it. Look at mounting points for brake callipers, and design new pedal box JP Concept has been generated. Has done CAD drawings Ishmael Must revise chapter 1.
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Solar car meeting 16 March minutes Rear wheel for Ilanga I will now be a HUB motor. JPO should adjust his design Electricals take note, the battery will be changed from 48V-96V bus. This has a particular effect5 on Bafanas work The solar panels need to be rewired to output 60V. Undergrads to post a paragraph on how far they are, and what they still need to do and possible time lines as well. The above should be posted on Trello. Undergrads to set 3 hours aside each week to work on Ilanga i. Work Updates Not much was done as everyone had tests/assignments to complete Palesa Read through Warrens report on encapsulation, and Solaris. Ishmael Must speak to David to gain clarity on what exactly needs to be done. Geoff Will find schematics on motor controllers Rob Has plans laid out. Waiting for the 23rd of March to disassemble the steering rack to draw it up. Theran Reviewed concepts for LEDs and looked at the required specs for the lighting system. Charles Sifting through GrabCAD files. Vincent Will learn how to use/optimise/program the current motor controller from Hayden. Jules Drawn the new nose. Plans are laid out for the suspension. Waiting for the 23rd of March to disassemble the steering rack to draw it up. Ilanga I Bodywork has been bolted to the chassis. The CVT was repaired and placed back on the car. The car can now run. Look at DropBox for the HUB motor drawings. 1st June, likely to be a seminar where the undergrads must present their section of work on the car. If you want to add anything to drop box, search for Jules de Ponte. I believe most of the undergrads have joined DropBox.
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Friday, 30th of March Solar Challenge Meeting Minutes Discussions: 1. Undergrad Concept presentation 2. Sponsorship update from the study-leaders and masters students 3. Budget update Tasks: 4. NB! Undergrads need to generate an updated and detailed project plan in MSP(micro-soft planner) 5. Undergrads need to check if they are available for the race in September ie. No tests, major hand-ins or unmissable classes during those two weeks 6. Undergrads need to form a clear picture of optimizing define Optimizing i.t.o: how what when 7. Undergrads need to attend a Company meeting/information session. It will most likely be on a Saturday. Further details will be given in the near future.
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20 April Minutes 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Mechanicals to E-Mail Jules the Project Plan 17 July is the date for the next mechanicals submission 2May is the date for t eh next electricals submission Presentation of the Solar car project is on the 1st of June Ilanga 1.1 is going to be competing in the challenge class Epsilon Engineering is going to do the moulding of the bodywork for Ilanga 1.1. Warricks design will change as a result of the changed bodywork Ilanga I will race in the SASC 2012. It will be used as a promotional vehicle, training vehicle, etc. Each driver needs 10 hours of experience in the car to race for the SASC 2012. Thus, the car will be run on weekends. The undergrads need to find out if they can race. Therefore, they must e-mail Mrs J. van Rensburg their timetables for next semester. Ilanga 1.1 needs 22-24% efficiency cells. Battery packs have been organised. Undergrads must find out when exams start. Monday, 23 April, the other two heel fairings are to be made. Work that still needs to be completed on Ilanga I: a. Windscreen Epsilon Engineering will likely be able to do this. b. Front Suspension See Jules Progress report. c. Method of attaching the nose must be devised. d. Back wheel faring mould must be delivered. JP must see to this. e. Lights for Ilanga I and Ilanga 1.1 must be finalised. See Thereans Progress report. f. Steering See Robs progress report. g. Swing Arm See JPs Progress report. h. Locking mechanism See Warricks progress report. i. Brakes. For the team meetings, the undergrads are to have PowerPoint Presentations to display progress reports. UJ Solar Society will have a big launch. Geoff is in charge of marketing. Use Google calendar instead of Trello
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25 May Minutes 1. 2. 3. 4. 5. 6. 7. 8. 29/05 Eskom Presentation 30/05 Marketing Day Gauteng Motor Show on 2 and 3 June at Zwartkops. Electricals must work on the encapsulation. Undergrads to send weekly e-mails to masters, especially electricals. Ron to find out about heat treatment and gear cutting. JP to find pipe benders. Based on project plans, the completion dates are 21 august for mechanicals and 11 July for Electricals.
Absentees: Charles
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50
6.281
Steering Input vs. Camber Change Steering Input [degrees] 18.86 16.63 14.38 12.21 10.87 6.27 -1 -3.26 -7.66 -9.95 -14.04 -17.83 Camber [degrees] 91.2 90.95 90.75 90.52 90.38 89.84 89 88.56 87.87 87.48 86.71 85.99
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Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
Description FRONT SUSPENSION SUSPENSION BOX ASSEMBLY SUSPENSION BOX AISI 4130 LONGITUDINAL MEMBERS SQAURE CROSS BAR CROSS TIE 1 INNER V OUTER V CROSS TIE 2-3 LOWER TENSION MEMBER LOWER COMPRESSION MEMBER CONTROL ARM TIE ROD END UPPER TENSION MEMBER UPPER COMPRESSION MEMBER CONTROL ARM PIVOT LOWER A-ARM UPPER A-ARM LEFT LOWER CONTROL ARM RIGHT LOWER CONTROL ARM CONTROL ARM BUSH STEERING SWIVEL RIGHT STEERING SWIVEL LEFT TOP BOTTOM BACK 1 LEVER ARM TOP LEVER ARM BOTTOM LEVER ARM SIDE STEERING TIE ROD END AXEL ROCKER ASSEMBLY PUSHROD ROCKER BUSH SHOCK SHIM ROCKER PLATE 404 ROCKER SIDES PUSHROD MOUNT PUSHROD BRAKCET
Drawing Number OIP4000-A000 OIP4000-100 OIP4000-101 OIP4000-001 OIP4000-002 OIP4000-003 OIP4000-004 OIP4000-005 OIP4000-006 OIP4000-200 OIP4000-201 OIP4000-202 OIP4000-203 OIP4000-204 OIP4000-205 OIP4000-206 OIP4000-207 OIP4000-208 OIP4000-209 OIP4000-210 OIP4000-300 OIP4000-301 OIP4000-302 OIP4000-303 OIP4000-304 OIP4000-308 OIP4000-309 OIP4000-314 OIP4000-315 OIP4000-316 OIP4000-A400 OIP4000-400 OIP4000-401 OIP4000-402 OIP4000-403 OIP4000-404 OIP4000-405 OIP4000-406
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