2017 Baja SAE Competition

Meet the Team

Enrique DeLeon Manjula Hodekar Keith Hernandez

Mechanical & Fabrication Lead

Public Relations & Logistics

Team & DesignLead

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Instructor:Raresh PascaliUH Professor

Alumni Advisor:Sean VanVactorUH MET Graduate

Undergraduate Colleague:Joshua ContrerasUH Industrial Design

Faculty Advisor:Marcus GaminoUH Dynamics Instructor

Project Scope

History & Events

Suspension Design

Vehicle Components

Project Management

Comments & Questions

Outline

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To design and build a vehicle that meets the rules and regulations of the 2017 Baja SAE competition and participate in the competition that will take place in Pittsburg, Kansas on May 25-28, 2017

Objective

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https://www.flickr.com/photos/auburnengineers/sets/72157629892864365/

• Continue and complete the original design and fabrication idea that was started by the Baja Brigade senior design team in 2015

• Use the fabricated frame and some of the parts available to complete the suspension design and fabrication in the early stages of the project

• Ensure that the original frame and suspension design complies with the rules and regulations of the 2017 Baja SAE Competition and the deliverables proposed

The Challenge

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Deliverables

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• Register for the 2017 Baja Competition in Pittsburg, Kansas

• Have a Baja vehicle that is mechanically complete with a functioning suspension assembled by December 2016

• Manufacture carbon fiber uprights for the suspension

• Achieve a vehicle weight under 400 lbs.

• Pass the Baja SAE inspection for the competition

• Achieve a top speed of 30 mph on a flat surface

• Design a vehicle that can achieve a flat jump of 7 ft.

• Implement instrumentation that is capable of data acquisition

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Baja SAE History

• First competition – 1976

• University of South Carolina

• Number of teams in the first competition – 10

• Number of teams in 2016 – 100

• 2017 total competitions - 7

• East, Midwest, and West - North America

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Dynamic 700 Points

Acceleration 75

Land Maneuverability 75

Hill Climb 75

Suspension & Traction 75

Endurance Race 400

https://www.facebook.com/michiganbajaracing/photos

https://www.facebook.com/

Michiganbajaracing/photos

Event scoring

Static 300 Points

Design 150

Cost 100

Presentation 50

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2016 2015 2014

University Univ. of Michigan Cornell University Cornell University

Team Michigan Baja Racing Big Red Racing Big Red Racing

Dynamic 696.40/700 683.35/700 672.87/700

Static 311.03/300 293.70/300 257.16/300

Overall score 1007.43/1000 977.05/1000 930.03/1000

Teams with high scores

• Continuous vehicle improvement from previous competition

• Maximum points in static event

• University/college funded vehicle

• Vehicle weight – Less than 400 lbs.

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• Kingpin Inclination

• The angle between the steering axis and the centerline of the wheel

• 10-15 degrees is common in Baja SAE

• Scrub Radius

• The distance between the kingpin angle and the tire centerline when they intersect the ground

• Minimizing the scrub radius improves the vehicles steering and handling

• Roll Center

• Minimizing the distance between the roll center and C.G. will reduce body roll

Suspension Geometry

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Optimum Kinematics

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Front Track Width: • 50”

Rear Track Width: • 47”

Wheel Base: • 75”

Kingpin Inclination: • 15.40 ̊

Scrub Radius: • 1.10”

Roll Center Height: • 3.95”

Ride Height: • 9”

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Frame

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• Currently using the frame designed by the Baja Brigade senior design team

• Material:

• A513-5 DOM

• 1.25” OD Tube

• 0.120” Thickness

Suspension Material Selection

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Multiplier Characteristic1020 DOM

Steel4130

Chromoly Carbon Fiber

4 Cost 5 3 1

3 Weight 2 4 5

2 Strength 3 4 5

1 Workability 5 4 2

Total 37 36 31

(1 – Least Favorable, 5 – Most Favorable)

http://www.acpsales.com/OnlineStore.php?cat=4663http://fbmbmx.com/blog/stedfast-frames/http://derbo-group.en.made-in-

china.com/product/ZormvQhVgCGJ/China-ASTM-A519-1018-

1020-Dom-Steel-Pipe-Seamless-Steel-Pipe.html

Front Suspension Components

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Fox Racing Air Shocks•

Mud Wolf Tires•Honda TRX• 250 brake rotors, knuckles, & wheel hubs

Knuckle assembly will serve as a •blueprint for fabricating the carbon fiber uprights

Steering

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• Thin Line Rack & Pinion

• 11 in. from center of eye to center of eye

• Spline Shaft - 3/8 in. x 36 Spline

• Gear Ratio – 1.5:1

• Travel – 4.5 in.

• Reliable – less chance of failure compared to other steering systems

Transmission Selection

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Multiplier CharacteristicCVTech

AABPolaris P-90

CVT

Comet Magnum 44

CVT

3 Cost 4 4 5

2 Workability 5 3 2

1 Performance 5 4 5

Total 14 11 12

(1 – Least Favourable, 5 – Most Favourable)

http://forums.bajasae.net/forum/preferred-

cvt_topic140_page2.html

https://www.minibuggy.net/forum/driveline/14719-1000-cvt-

questions-3.html

CVTech AAB Polaris P-90 Comet Magnum 44

Engine

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All teams in the competition use the •same engine

Briggs & Stratton Model • 19

Horsepower: • 10 HP

Engine displacement: • 305 cc

Any modifications to the engine are •STRICTLY PROHIBITED AND WILL RESULT IN DISQUALIFICATION

Project Progress

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• Front suspension – Assembly

• Fabricated control arms with adjustable ball joints which allow for increase or decrease in camber

• Achieved negative camber – Less than 5 degrees

• Better cornering stability as well as better traction

• Too much negative camber has adverse effect on steering response and suspension geometry

Original Assembly Adjusted Assembly

Project Progress

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Submitted required •documents to SAE for competition

Completed front right •suspension

Waiting on ball joints and •bushings to complete assembly for entire front suspension

Acquired material for rear •suspension fabrication

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BudgetComponent: Estimated Cost 9/15/16: Adjusted Cost 2/23/2017:

Chassis $1,000 $200

Suspension $2,000 $350

Steering $650 $350

Engine $250 $250

Transmission $1,000 $250

Brakes $400 $215

Tires and rims $900 $0

Seat $60 $0

Safety equipment $400 $250

Instrumentation/electrical $350 $270

Registration fees $1,250 $1,250

Travel & lodging $1,500 $1,500

Total: $9,760 $4,885

Contingency 20%: $1,952 $489

Total with contingency: $11,712 $5,374

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Semester 1 Timeline:

Semester 2 Timeline:

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Baja Vehicle

Research

Rules/safety

requirements

Major

components

Materials

Cost analysis

Design Part I

Chassis design

Suspension

design

Design analysis

Fabrication Part I

Chassis

fabrication

Suspension

fabrication

Design Part II

Braking

Steering

Powertrain

Instrumentation

Fabrication

Part II

Braking

Steering

Powertrain

Instrumentation

Testing

Mechanical

Electrical

Instrumentation

Completed

In progress

Not started

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7 3

6 5

1 2 3 4 5

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Severity1

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Pro

ba

bili

ty

ID Risk Mitigation

1 Funding Continue talking to potential sponsors and use donated parts

2 Manufacturing Recruit industry advisor for composite material manufacturing

3 Fabrication Recruit experienced welder

4 Time Management Increase working hours and create weekly short term goals

5 Meet SAE Requirements Consult with previous teams and review rulebook

6 Vehicle Weight Implement lightweightcomposite materials on components

7 Defective Parts Reorder parts needed ina timely manner

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