2017 Baja SAE Competition

Meet the Team

Enrique DeLeon Manjula Hodekar Keith Hernandez

Mechanical LeadPublic Relations

Design LeadLogistics

Team LeadProject Management

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Instructor:Dr. Raresh PascaliUH Professor

Alumni Advisor:Sean VanVactorUH MET Graduate

Undergraduate Colleague:Joshua ContrerasUH Industrial Design

Faculty Advisor:Marcus GaminoUH Instructor

Objective

Deliverables

History & Events

Major 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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• Register for the 2017 Baja Competition in Pittsburg, Kansas by the November 14, 2016 deadline

• 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

Deliverables

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• Baja SAE History

• Originated – 1973

• Two seats vehicle

• First competition – 1976

• University of South Carolina

• Under the direction of Dr. John F. Stevens

• Number of teams in first competition – 10

• Total competitions – 7

• East, Midwest , and West – North America

• Brazil, Korea, South America, and Mexico- International

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History

http://students.sae.org/cds/bajasae/history.pdf

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Dynamic 700 Points

Acceleration 75

Land Maneuverability 75

Hill Climb/Rock Climb 75

Suspension & Traction 75

Endurance Race 400

Static 300 Points

Design 150

Cost 100

Presentation 50

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

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

Main Events Scoring

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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

• University/college funded vehicle

• Vehicle weight – less than 400 lbs.

• Maximum points in static event

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Winning Strategy

• Continuous vehicle improvement from previous competition

• University/college funded vehicle

• Vehicle weight – less than 400 lbs.

• Maximum points in static event

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Frame - Design

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Function

• Series of tubes connected together to form a coherent structure

• Provides a rigid connection between the front and rear suspension

• Creates structural support for other necessary systems

• Provides protection for the driver

Frame - Design

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• In order to meet our deliverable by December 2016 we will use the frame that was designed and fabricated by the Baja Brigade senior design team

• The team will reconsider the material and design in the second semester and modify it accordingly

• Advantages of spaceframe design

• Inherent structural properties

• Easier to fabricate

• Easier to modify

Frame - Fabrication

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• Original frame was only tack welded

• Completed welding on frame members

• Arc Welder - E6013 Welding Electrodes

• Prepared frame to apply primer paint coat

Frame – Possible Material Reselection

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http://www.clienttest.spryox.com/quality_forge/imag

es/steel_images2.jpg http://p.globalsources.com/IMAGES/PDT/B1135131129

/Seamless-mechanical-tubing.jpg

http://www.aedmotorsport.com/images/uploads/products/

aluminum-tubes.jpg

MaterialDensity

(lbs./in3)Tensile Strength

(psi)Modulus of Elasticity

(ksi)Workability

(1 low-10 high)

AISI 1018 Steel 0.284 63,800 29,000 7

AISI 4130 Chromoly 0.283 97,200 29,700 7

6061 Aluminum 0.0975 45,000 10,000 4

Frame – Design Requirements

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• Load Restrictions

• Weight: Minimum requirement to carry a driver weighing 250 lbs.

• Height: Minimum requirement to fit a driver that is 75 in. tall

• Vehicle Dimension Restrictions

• Width: Max of 64 in. at the widest point

• Length: Max of 108 in.

Suspension - Basics

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• Camber

The angle of the wheel relative to the road

• Caster

The angular displacement of the steering axis from the vertical axis of the wheel

• Toe

The symmetric angle that a wheel makes with the longitudinal axis of the vehicle

Suspension - Linkage

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• Double Wishbone

• Equal A-arm Setup

• Unequal A-arm Setup

• Multilink

• Trailing Arm

Transmission

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• Automatic Transmission (CVT)

• Good for acceleration

• Fit for all terrains

• More complex and heavier

• More challenging to tune

• Manual Transmission

• Lightweight

• Cheaper than a CVT transmission

• Torque and speed are restricted on gear shifting

ATVRiders.com

Engine

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• All teams in the competition have to use the same engine

• Briggs & Stratton Model 19

• Horsepower: 10 HP

• Engine displacement: 305 cc

• Bore: 3.12 in

• Stroke: 2.438 in

• Compression ratio: 8.0 to 1

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The highest costs for the entire project

includes the suspension, registration fees

and the travel expenses for the 2017 Baja

SAE competition in Kansas

Component: Cost:

Chassis $1,000

Suspension* $2,000

Steering $650

Engine $250

Drivetrain $1,000

Brakes $400

Tires and rims $900

Seat $60

Safety equipment $300

Instrumentation/electrical $350

Registration fees* $1,250

Travel & lodging* $1,500

Total: $9,660

Contingency 20%: $1,932

Total with contingency: $11,592

BudgetMitigation:

• Suspension - Use available donated parts

• Registration Fees – Make fundraising a

weekly focus throughout the semester

• Travel & Lodging - Use our own

vehicle/trailer to reduce the cost of travel

and check routinely for deals on lodging

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Timeline

Completed

In progress

Not started

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Baja Vehicle

Research

Rules/safety

requirements

Major

components

Materials

Cost analysis

Design 1

Chassis design

Suspension

design

Design analysis

Fabrication 1

Frame

fabrication

Suspension

fabrication

Design 2

Braking

Steering

Powertrain

Instrumentation

Fabrication 2

Braking

Steering

Powertrain

Instrumentation

Testing

Mechanical

Electrical

Instrumentation

Completed

In progress

Not started

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Risk Matrix

5

4 3

1 2 3 4 5

1

2

Severity

12

34

5P

rob

abili

ty

Mitigation

1 Funding Continue talking to potential sponsors and use donated parts

2 Manufacturing Recruit industry help

3 Fabrication Recruit experienced welder

4 Time Management Hold weekly meetings and track time sheets

5 Meeting SAE requirements Consult with previous teams and review rulebook

Risk

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Two Content Layout with Table

Class Group A Group B

Class 1 82 85

Class 2 76 88

Class 3 84 90

• First bullet point here

• Second bullet point here

• Third bullet point here

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Two Content Layout with SmartArt

• First bullet point here

• Second bullet point here

• Third bullet point here

Group A

Task 1

Task 2

Group B

Task 1

Task 2

Group C

Task 1

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Suspension - Uprights

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• Critical to locating different suspension geometries including the outer most control arm points as well as the tie rod connections

• The location of these points relative to the mounting locations on the chassis determines caster, camber, toe, and Ackerman

• Lightweight & strong

• FEA Analysis

• CNC Machining

• Manufacturing & Fabrication

SAE Competition Documents

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• Frame documents

• Pre-check documentation including material test reports

• Frame and weld specifications

• Cost report

• Cost calculations

• Cost supporting documents

• Design documents

• Design drawings

• Design specifications

Body Material

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• UHMW

• 200% elongation

• Easy fabrication

• Cost saving

• Available in verity of shapes and sizes

• Light weight