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Steering, Suspension, BrakesMichael Anderson, Emily Cook, Jackson Pogue, Bert Atwater A joint project of the Lafayette College ECE and ME Departments

BrakesThe braking system is responsible for locking all four of the cars wheels when applying a 200N force to the brake

pedal while under full power.Assembled Hub with Studs, Bearing, Rotor, Caliper

What We Accomplished

❖ Fully Assembled Hubs❖ New Brake Line, Brake Hose, Fittings

➢ 3/16” Line, Hose, and Fittings❖ Updated and Assembled Pedal

Configuration❖ Reformatted Matlab given increased

vehicle weight❖ Clevis and Pivot Pin allow for Brake

Pedal Bias

Components

Brake pads - Calipers - Rotors - Mounting Bolts - Brake Hose - Brake Line - Brake Fluid - Fluid Reservoir - Master Braking Cylinders - Brake Over Travel Switch - Potentiometers - Brake Pedal - Acceleration Pedal -Dead Pedal

Pedal Assembly with Dual Master Cylinders

The dual master cylinder setup used is able to send variable force to both the front and rear calipers.

Design Objectives❖ Braking must be operated on single

control❖ Implement over-travel switch❖ Act on all four wheels ❖ Maneuverable so that other systems are

not at risk of incurring brake failure

SuspensionThe suspension team is responsible for maintaining static ground clearance of 1” under all operating conditions.

Inventor Geometry of Shock Tower, Mounting Tabs, and Ohlins Shock

Assembled Shock Tower and Coil-Over Rear Suspension

Components

Shock Tower - Ohlins TTX25 Coil-Over Shocks - A-Arms - Pushrods - Wheel Hubs - Wheel Bearings - Bushings - Spacers - Wheel Studs - Lug Nuts - Variable Wheels and Tires

What We Accomplished

❖ Fully redesigned rear suspension system➢ Shock tower with current Ohlins

TTX25 shocks➢ New mounting tabs welded to

shock tower❖ New rear control arms

➢ Mounts to frame/uprights ❖ New bushings for front and rear

A-Arms/control arms ❖ Full rules compliance

Design Objectives❖ Maintain 1” of ride height❖ 2” of wheel travel, 1” of rebound and jounce❖ New rear suspension geometry to save

space for cooling and wiring❖ Incorporate rear control arms

We would like to acknowledge the Lafayette College Mechanical Engineering Fund for assisting in the acquisition of parts and funding towards team spending.

❖ Used Inventor to size new A-Arm mounting points❖ Used Inventor to model new shock tower design❖ Implemented pickup points into Optimum Kinematics ❖ Ran Full Car simulations incorporating pitch, roll, heave

(forces), and spring force, with weight (500kg/1100lbs) and assumed center of gravity

❖ Output➢ Pick Up Point Displacement➢ Steering Wheel Angle Change

SuspensionOptimum Kinematics played a large role in testing the new rear

design

Pickup Points on Optimum Kinematics with Coil-Over Shocks

Optimum Kinematics Pitch/Roll/Heave Inputs

Optimum Kinematics Output Displacement with Steering Angle

❖ Optimum Kinematics allowed us to maintain a ride height of approximately 3.5” to account for pitch, roll, and heave.

❖ Used these pickup points to size shock mount tabs

SteeringThe steering system is responsible for providing the driver with a minimum of a 9

meter (25.9 feet) outer turn diameter on a hairpin turn

Inventor Model Diagram of all Steering Parts - the control arm mounts are attached to the wheel hubs Picture of Steering Assembly inside

the car, fully assembled except for the control arms

Design Objectives❖ Driver controlled steering will act on front two wheels❖ Lock rear wheels ❖ Prevent bump steer in all wheels❖ Provide 9 meter outer turn diameter❖ Protect driver from moving parts

Components

Steering Wheel - Keyway Couplings - Upper Gearbox - Actuator - Actuator Couplings - Actuator Coupling Housing - Mounting Tabs - Clevis Tie Rods - Control Arms - Control Arm Mounts - Steering Housing

What We Accomplished

❖ New mounts for control arms to attach to wheel hubs

❖ New mounting solution and housing for actuator that prevents bump steer in control arms

❖ New keyway connection between rack and pinion actuator and upper gearbox, and upper gearbox to steering wheel

❖ New actuator couplings and clevis tie rods to connect control arms to actuator

Picture of New Mounts fully assembled in the hubs