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Pullrod Suspension System
Group 20
W. Hammond, M. Harrey, T. Gray, M. Menzies and N. Sharratt
BRIEF
Design a bespoke front suspension system for the third generation of Formula E cars
Battery powered single seater racing car
Rear wheel drive
Carbon fibre/aluminium monocoque
174mph Top speed
45:55 Weight distribution
18" Wheels
Track Width 1553mm
Front wheel 7kg minimum
Minimum mass of vehicle and driver is 900kg
Active suspension systems prohibited
Materials: “all structural suspension members must be made of steel or aluminium alloys”
Performance: Outperform 'Gen 2' Front Suspension
Physical requirements:
• Must be with independent double wishbones,
• A single coil spring over a linear damper actuated via a rocker and pullrod
• Act independently on each corner of the suspension
Must last one race weekend minimum
Maintenance: setup must be done manually, with use of tools, outside of cockpit and when car is stationary
Target product cost (Two cars for one season): £100,000
DESIGN
Hand drawn sketches of our concept designs were produced to show layouts and design philosophies and to help us perform a matrix selection for the concepts
Examples of the criteria considered in the matrix selection:
Reliability
Ease of maintenance at the track
Cost
Weight
Final Design
Material: AISI 4130 Steel
Mass: 52.6kg
Material: AISI 4130 Steel
Mass: 4.489kg
Material: 7075-T6 Aluminium
Mass: 6.871kg
Camber and king pin inclination adjustable using shims
2D and 3D kinematic analysis was used to determine mounting points for the suspension system as well as to help establish the correct dimensions to allow us to meet our objectives vehicle characteristics
2D Kinematic Analysis
Camber Change in Bump
Camber Change in Roll
Wheel Installation Ratio
ANALYSIS
UPRIGHT FEA
Hand calculations were done to find the magnitude and direction of the forces acting on the upright
Using these forces, FEA analysis was carried out
Cost to one team for two cars for a season: £90,000