Hi guys,
On my studies we need to do a project again. This time we have gotten the task to improve, refine and build a concept created by previous students.
The team
We work together with Industrial Design students and financial students. The total team is comprised of 16 people. 6 Automotive Engineering, 6 design and 5 Financial. The total is lead by one teacher, that gives us tips and tricks, hints and most important, grades.
I am the project leader of the AE team, which proves quite a difficult and stressful challenge.
The first phases
Last years design is like you can see in attachment 1&2.
We got hold of a full 3D-CAD model done by design students (IPO - Industrial Product Design) in a Unigraphix format.
The first phase we went through was that of the analysis and data gathering.
In the analysis process we got the following conclusions:
- Several weak points in the chassis under maximum stress.
- Not enough room in the car for the engine and gearbox
- Donor car inapropriate and too expensive
- Barely in budget
Our own list of demands combined with those of school were the following:
- Fix these points in the chassis (attachment 3)
- Fit inside budget(2500$) and find a proper donor vehicle (take all donor parts needed from that).
- Design a cheap suspension, capable of off-roading.
- Max. speed of 60 km/h (40 m/h)
- Able to carry 1 ton of load !!!
- Change front side to fit drivetrain.
The car should be sold in a few years time in Congo. We have contact with some students there, that provide us with information about the conditions there.
For all this work we have just 8 weeks. In these 8 weeks we will also have to build a scale model (1:5) of the vehicle.
Current status
We are now in the midst of designing a completely new chassis/frame. I cannot show pictures of that, confidential stuff, but it has been almost completely redone. The reason for that is the budget. We took away some beams and pipes, making it a bit weaker at certain points. Also we widened it a bit and moved struts to make the drivetrain fit in it.
Some of my team members are now designing the suspension. The front will be a simple MacPherson strut and back leaf springs. IIRC they got the design finished and are now calculating the KPI, roll centre etcetera etcetera.
The engine guy is right now going across the city, finding prices for donor vehicles. He has made some suggestions yet, like a VW Golf 1, Ford Sierra / Escort and FIAT Panda ()... We'll hear from him soon I guess.
Me personally is working out some of the elctrics for the car. We will keep it very simple, just some lights and the neccesary engine electronics. But still it remains bloody difficult
Friday we will start work on the 1:5 model.
I'll let you guys know more, when we progress further !!!