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SAE NAU Mini Baja Mid-Point Report

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SAE NAU Mini Baja Mid-Point Report SAE NAU Mini Baja Mid-Point Report Quinton Astgen Thomas Baker Brody Beebe Jon Bloot Jake Hinkle Dustin Odorcic 2016-17 Project Sponsor: Society of Automotive Engineers (SAE) Faculty Advisor: John T. Tester, David Willy Sponsor Mentor: John T. Tester, David Willy Instructor: David Willy DISCLAIMER This report was prepared by students as part of a university course requirement. While considerable effort has been put into the project, it is not the work of licensed engineers and has not undergone the extensive verification that is common in the profession. The information, data, conclusions, and content of this report should not be relied on or utilized without thorough, independent testing and verification. University faculty members may have been associated with this project as advisors, sponsors, or course instructors, but as such they are not responsible for the accuracy of results or conclusions. i TABLE OF CONTENTS DISCLAIMER .............................................................................................................................................. 1 TABLE OF CONTENTS .............................................................................................................................. 2 1 BACKGROUND ................................................................................................................................ 1 1.1 Introduction .............................................................................................................................. 1 1.2 Project Description ................................................................................................................... 1 2 REQUIREMENTS ............................................................................................................................. 2 2.1 Customer Requirements (CRs) ................................................................................................. 2 2.2 Engineering Requirements (ERs) ............................................................................................. 3 2.2.1 Drivetrain ERs ............................................................................................................ 3 2.2.2 Frame ERs .................................................................................................................. 3 2.2.3 Suspension ERs .......................................................................................................... 4 2.3 Testing Procedures (TPs) .......................................................................................................... 4 2.3.1 Drivetrain TPs ............................................................................................................. 4 2.3.2 Frame TPs ................................................................................................................... 4 2.3.3 Suspension TPs ........................................................................................................... 5 2.4 Design Links (DLs) .................................................................................................................. 5 2.4.1 Drivetrain DLs ............................................................................................................ 5 2.4.2 Frame DLs .................................................................................................................. 6 2.4.3 Suspension DLs .......................................................................................................... 7 2.5 House of Quality (HoQ) ........................................................................................................... 9 2.5.1 Drivetrain HoQ ........................................................................................................... 9 2.5.2 Frame HoQ ............................................................................................................... 10 2.5.3 Suspension HoQ ....................................................................................................... 10 3 EXISTING DESIGNS ...................................................................................................................... 12 3.1 Design Research ..................................................................................................................... 12 3.2 System Level .......................................................................................................................... 12 3.2.1 Existing Design #1: Drivetrain ................................................................................. 12 3.2.2 Existing Design #2: Frame ....................................................................................... 12 3.2.3 Existing Design #3: Suspension ............................................................................... 13 3.3 Subsystem Level ..................................................................................................................... 13 3.3.1 Subsystem #1: Drivetrain.......................................................................................... 14 3.3.1.1 Existing Design #1: Constant Velocity (CV) Axle ...................................... 14 3.3.1.2 Existing Design #2: Continuously Variable Transmission (CVT) ............... 14 3.3.1.3 Existing Design #3: Gearbox ....................................................................... 14 3.3.2 Subsystem #2: Frame ................................................................................................ 14 3.3.2.1 Existing Design #1: Seating ......................................................................... 14 3.3.2.2 Existing Design #2: Frame Geometry ......................................................... 15 3.3.2.3 Existing Design #3: Welding Method .......................................................... 15 3.3.3 Subsystem #3: Suspension ........................................................................................ 15 3.3.3.1 Existing Design #1: Spindles ....................................................................... 15 3.3.3.2 Existing Design #2: Steering ....................................................................... 15 3.3.3.3 Existing Design #3: Springs and Dampers .................................................. 16 4 DESIGNS CONSIDERED ............................................................................................................... 17 4.1 Drivetrain Designs .................................................................................................................. 17 4.1.1 CVT Linked w/ F/R Gearbox to Locking Differential.............................................. 17 4.1.2 CVT Linked by Jackshaft to a Solid Axle ................................................................ 17 4.1.3 CVT Linked to F/R Transaxle to CV Axles .............................................................. 18 4.2 Frame Design ......................................................................................................................... 19 4.3 Suspension Designs ................................................................................................................ 20 ii 4.3.1 Front Suspension ...................................................................................................... 20 4.3.1.1 Control Arm Systems ................................................................................... 20 4.3.1.2 TIB Design .................................................................................................. 21 4.3.2 Rear Suspension ........................................................................................................ 22 4.3.2.1 Triangulated Trailing Arm ........................................................................... 22 4.3.2.2 Equal Length Parallel A-Arm ...................................................................... 22 4.3.2.3 Trailing Arm with Camber Arms ................................................................. 22 5 DESIGN SELECTED ....................................................................................................................... 24 5.1 Rationale for Design Selection ............................................................................................... 24 5.1.1 Drivetrain Selection .................................................................................................. 24 5.1.2 Frame Selection ........................................................................................................ 24 5.1.3 Suspension Selection ................................................................................................ 25 5.1.3.1 Front Suspension ......................................................................................... 25 5.1.3.2 Rear Suspension .......................................................................................... 26 5.2 Design Description ................................................................................................................. 26 5.2.1 Drivetrain Analysis ................................................................................................... 26 5.2.1.1 Wheel Outputs and Component Selection Analysis .................................... 26 5.2.1.2 Engine Mounting Design and Analysis ....................................................... 28 5.2.2 Frame Analysis ......................................................................................................... 34 5.2.3 Front Suspension Analysis .......................................................................................
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