Nothing Special   »   [go: up one dir, main page]
Scribd Logo
Upload

Welcome to Scribd!

  • 511 views

    Rouelle PPT

    Uploaded by

    A Van Di
    This document provides design tips and mistakes to avoid for formula student race cars. It highlights common errors seen in suspension design such as rod ends in bending, links not going through chassis nodes, and unnecessary compliances. Other areas discussed include keeping parts compact and lightweight, efficient cooling system design, and minimizing tubing and nodes in the chassis frame. The overall message is to make each part as light, stiff, simple and cheap to manufacture as possible while avoiding extra compliances.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Rouelle PPT

    Uploaded by

    A Van Di
    511 views36 pages
    This document provides design tips and mistakes to avoid for formula student race cars. It highlights common errors seen in suspension design such as rod ends in bending, links not going through chassis nodes, and unnecessary compliances. Other areas discussed include keeping parts compact and lightweight, efficient cooling system design, and minimizing tubing and nodes in the chassis frame. The overall message is to make each part as light, stiff, simple and cheap to manufacture as possible while avoiding extra compliances.

    Original Description:

    Apa itu team

    Original Title

    RouellePPT

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    This document provides design tips and mistakes to avoid for formula student race cars. It highlights common errors seen in suspension design such as rod ends in bending, links not going through chassis nodes, and unnecessary compliances. Other areas discussed include keeping parts compact and lightweight, efficient cooling system design, and minimizing tubing and nodes in the chassis frame. The overall message is to make each part as light, stiff, simple and cheap to manufacture as possible while avoiding extra compliances.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    511 views36 pages

    Rouelle PPT

    Uploaded by

    A Van Di
    This document provides design tips and mistakes to avoid for formula student race cars. It highlights common errors seen in suspension design such as rod ends in bending, links not going through chassis nodes, and unnecessary compliances. Other areas discussed include keeping parts compact and lightweight, efficient cooling system design, and minimizing tubing and nodes in the chassis frame. The overall message is to make each part as light, stiff, simple and cheap to manufacture as possible while avoiding extra compliances.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 36
    At a glance
    Powered by AI
    The document discusses common mistakes in formula student race car design and principles to improve design such as reducing compliances, using lightweight materials, and ensuring linkages pass through rigid points.

    Some common mistakes discussed are rod ends subjected to bending forces, suspension linkages not passing through rigid chassis points, and unnecessary long suspension elements.

    Design principles that can help avoid unnecessary compliances discussed are ensuring linkages pass through rigid chassis points, keeping distances between linkages short, and designing suspension points before the chassis frame.

    Formula Student Design and Manufacturing

    Do and Dont

    Illustrated with pictures mostly taken at Student Formula Japan 2016 and 2015

    Claude Rouelle

    What makes me qualified to speak about race car design.


    I made the same mistakes

    1979 Master Thesis

    What makes me qualified to speak about race car design.


    I made many mistakes

    Race Car Engineering 1980 to 1997

    What makes me qualified to speak about race car design.


    And I had a few success

    What makes me qualified to speak about race car design.


    Created OptimumG in 1997
    Located in Denver, CO, USA
    Multicultural and multidisciplinary staff
    Training

    Simulation

    Consulting

    Design Judge Formula Student competitions for over 15 years


    Australia, Austria, Brazil, Canada, China, Germany, India, Italy, Russia, Spain, UK, USA.
    Several Universities course in Europe, USA, Australia and South America

    Formula Student Design and Manufacturing

    Do and Dont

    Some basic design errors you should and can avoid


    Illustrated with pictures mostly taken at Student Formula Japan 2016 and 2015

    Formula Student Design and Manufacturing Do and Dont


    Rod end in bending
    If this top wishbone would break
    Where do you think it would break?

    Right here!

    Formula Student Design and Manufacturing Do and Dont


    Rod end in bending
    What is the solution?

    Linkage axis going through


    outboard rod end center

    Formula Student Design and Manufacturing Do and Dont


    Rod end in bending
    Linkage axis going through
    outboard rod end

    Pull rod axis good


    but could have been better

    Formula Student Design and Manufacturing Do and Dont


    The suspension link axis must go through one node of the chassis
    Suspension
    links through the outboard upright point

    Formula Student Design and Manufacturing Do and Dont


    Decreased compliances with good design
    All these points should be
    in the same plane
    Reduce
    compliances
    causes!

    Formula Student Design and Manufacturing Do and Dont


    Suspension links axis not through a chassis node

    Formula Student Design and Manufacturing Do and Dont


    Suspension links not through a chassis node

    Formula Student Design and Manufacturing Do and Dont


    Suspension links not through a chassis node

    Determine your suspension points coordinates, then draw you frame,


    not the other way around!
    The chassis frame is one of the last things you should draw

    Formula Student Design and Manufacturing Do and Dont


    Suspension links through a chassis node
    Coud have been shorter

    Reduce
    compliances
    causes!

    Formula Student Design and Manufacturing Do and Dont


    Unnecessary compliances

    Too big distance

    Formula Student Design and Manufacturing Do and Dont


    Decreased compliances with good design

    Reduce
    compliances
    causes!

    Formula Student Design and Manufacturing Do and Dont


    Single shear attachment

    Big, unnecessary shear forces that will create compliances

    Formula Student Design and Manufacturing Do and Dont


    Double shear attachment
    Better forces distribution
    Less compliances

    Reduce
    compliances
    causes!

    Formula Student Design and Manufacturing Do and Dont


    Rocker attachment not at a chassis node

    Formula Student Design and Manufacturing Do and Dont


    Damper / Spring unit attachment not at a chassis node

    Formula Student Design and Manufacturing Do and Dont


    Unnecessary big rocker

    Formula Student Design and Manufacturing Do and Dont


    Same Rocker Ratio. Lighter

    Bigger is not better.


    Try to make each part light, stiff, simple and cheap to manufacture
    Make it compact.

    Formula Student Design and Manufacturing Do and Dont


    Anti Roll Bars are supposed to work in torsion not in bending

    Too big distance

    Very weak point

    Formula Student Design and Manufacturing Do and Dont


    Anti Roll Bars are supposed to work in torsion not in bending

    Formula Student Design and Manufacturing Do and Dont


    Anti Roll Bars compliances
    ARB bearing cap
    not at a chassis node

    Single shear

    Too big Distance

    Formula Student Design and Manufacturing Do and Dont


    Anti Roll Bars sizes

    Formula Student Design and Manufacturing Do and Dont


    Anti Roll Bars unnecessary compliances
    Droop link
    attachment point
    in the middle of
    suspension linkage

    Single shear

    Formula Student Design and Manufacturing Do and Dont


    Anti Roll Bars Design and Installation

    Bigger is not better.


    Do not start manufacturing anything until all drawings
    (including antiroll bars) are finished

    Formula Student Design and Manufacturing Do and Dont


    Overcomplicated chassis
    6 tubes
    2 Nodes
    ..so close to each other

    2
    1

    A
    5

    B
    4

    Unnecessary
    complicated

    Simple Recipe for good frame design:


    1. Triangulation everywhere. 2. Minimum amount of tubes and nodes!

    Formula Student Design and Manufacturing Do and Dont


    Unnecessary heavy uprights

    Heavy

    Lighter

    Formula Student Design and Manufacturing Do and Dont


    Unnecessary long suspension elements
    The longer
    each suspension element
    . the heavier
    . the more flexible
    Think
    - Small
    - Light
    - Stiff
    - Smart packaging

    Formula Student Design and Manufacturing Do and Dont


    Big, heavy radiator poor efficiency, aerodynamic drag
    The fan only sucks
    a small portion
    of the air going through
    of the radiator
    The air will follow the
    path of a lesser resistance
    Low cooling efficiency

    Does it need to be that big?

    Formula Student Design and Manufacturing Do and Dont


    A big radiator is needed.

    Because low fan use and no side pod ducting

    Formula Student Design and Manufacturing Do and Dont


    Cooling Efficiency

    Light, Efficient, Low Drag!

    Formula Student Design and Manufacturing Do and Dont

    Conclusions
    Weight is your enemy. Compliance too. Avoid compliances
    Make is simple, small and light
    Form follows function
    Claude Rouelle

    You might also like