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Formula E Gen3

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

SPECIFICATION

Gen 2 Formula E

Spark SRT05e

Battery powered single seater racing car

Rear wheel drive

Carbon fibre/aluminium monocoque

174mph Top speed

45:55 Weight distribution

Formula E

Spark SRT05e

Regulations

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”

REGULATIONS

Design Specification

DESIGN SPECIFICATION

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

DESIGN

Concepts

CONCEPTS

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

Concept Sketches

CONCEPT SKETCHES

Pullrod Suspension System

CHOSEN DESIGN

Final Design

FINAL DESIGN

Chassis

CHASSIS

Material: AISI 4130 Steel

Mass: 52.6kg

Wishbones

WISHBONES

Material: AISI 4130 Steel

Mass: 4.489kg

Anti Roll System

ANTI ROLL BAR

Upright

UPRIGHT

Material: 7075-T6 Aluminium

Mass: 6.871kg

Camber and king pin inclination adjustable using shims

Kinematics

KINEMATICS

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

2D

Graphs

Camber Change in Bump

GRAPHS

Camber Change in Roll

Wheel Installation Ratio

3D Kinematic Analysis

3D

ANALYSIS

ANALYSIS

FEA Analysis

FEA 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

Upright FEA

  • Analysis of bump, braking and cornering loads
  • Mesh control focused on key regions
  • Minimum FOS achieved of 2.16
  • Minimum fatigue life of 40,000 cycles

Costing

Cost to one team for two cars for a season: £90,000

COSTING

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