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  • Team Xtreme 2017 Baja SAE Competition

    MECT 4276 Spring 2017

    Senior Design II Report VI

    May 06, 2017

    Keith Hernandez

    Team Lead

    Enrique DeLeon

    Mechanical Lead

    Manjula Hodekar

    Logistics Lead

    https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjxpdCu1pfQAhVq2IMKHQumCGcQjRwIBw&url=https://www.tech.uh.edu/&bvm=bv.137904068,d.cGw&psig=AFQjCNEDal2ca5V7o80cbvVagAaheRPnjQ&ust=1478643479539722

  • Team Xtreme

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    Abstract

    Team Xtreme will research, design, analyze 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. Using the existing frame from the Baja Brigade

    build, Team Xtreme plans to have the vehicle in rolling chassis form by the end of December

    2016. The team plans to achieve a top speed of 30 miles per hour on a flat surface and implement

    instrumentation capable of real time data acquisition. Currently the team is working on the

    braking fabrication and beginning the testing phase of the project. The suspension is complete

    and consists of an unequal double A-arm set up in the front and trailing arms in the rear. The

    steering assembly and the powertrain have all been fabricated. The project has an estimated cost

    of $9,712 and fundraising is an ongoing process. The team has implemented several tools to help

    stay on track and mitigate potential risks that may arise throughout the life of the project. A

    Gantt chart has been developed to keep scheduling of tasks on track. The teams progress is

    monitored throughout the project via the timeline and work breakdown structure that has been

    created. Weekly meetings and timesheets will also help the team schedule tasks and mitigate any

    unforeseen risks.

  • Team Xtreme

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    Executive Summary

    During the duration of the Senior Design I term, Team Xtreme could accomplish several tasks

    and goals that will aid in completing the project and the challenges proposed by Professor

    Pascali. The main challenge of the project consists of working with the frame that the Baja

    Brigade senior design team fabricated. We will complete the vehicle with the parts that the Baja

    Brigade team procured and raise funds throughout the senior design term for the remainder.

    The team has agreed on deliverables for the duration of the project and conducted a significant

    amount of research that will help in achieving the proposed deliverables. Team Xtreme also

    agreed to split the process of designing and fabricating a vehicle in two stages. The first stage

    was geared at meeting the deliverable of having a functioning suspension on the vehicle by the

    end of December 2016. The team established communication and a working relationship with

    Sean VanVactor, a key member of the Baja Brigade senior design team. With his help, the team

    could get a better understanding of the vision they had for the design and fabrication of the

    vehicle. Sean also agreed to be the teams graduate advisor and continues to assist with

    knowledge, resources, and support. In the second stage of the project the team will focus on

    designing and fabricating the rest of the major components needed to complete the vehicle such

    as: braking, steering, mounting of the engine, drivetrain and meeting all safety requirements.

    The research phase was a key part of the project that helped familiarize the entire team with the

    knowledge needed to design and fabricate a Baja SAE compliant vehicle. Due to the unique

    nature of the challenge the team faced, it was agreed to leave the research phase for all major

    components of the vehicle open for the duration of the project. The team has a project

    management plan in place to ensure timely completion of the goals. With the incorporation of a

    Gantt chart, project timeline, Work Breakdown Structure (WBS) and a Risk Matrix, the team

  • Team Xtreme

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    plans to ensure a timely completion of the project as well as the ability to mitigate any risks that

    may arise throughout the duration of the project. These tools will continually evolve from the

    projects conception all the way to the end and serve as critical tools for the teams success.

    The team finished fabrication on the frame by finishing the welding on all the members during

    the first semester. A selected design analysis was also done on the frame to ensure the safety of

    the driver. The team agreed to conduct a design analysis for two different crash scenarios. First, a

    roll over crash at a free fall height of 7 feet considering one of the deliverables is to achieve a 7-

    foot jump. The second crash analysis simulates a head-on collision at 30 mph considering one of

    the deliverables is to achieve a top speed of 30 mph. Currently the team is working on the

    braking fabrication and beginning the testing phase of the project. The suspension is complete

    and consists of an unequal double A-arm set up in the front and trailing arms in the rear. The

    steering assembly and the powertrain fabrication is complete.

    Team Xtreme has also registered for the 2017 SAE Baja competition in Pittsburg Kansas. The

    funds that will aid the team in the fabrication of the frame for the first semester goal have been

    raised. A website has been created to represent the progress of the team and serves as a resource

    to potential sponsors. Along the way the team has documented our trials and tribulations via

    pictures and video to produce a short video summary of the incredible ride to this point.

    Some lessons learned from Team Xtremes project are time management and forward planning.

    These two aspects of the project go hand in hand; the lack of forward planning has had a

    negative impact on the project. The team failed to plan the presentation dates accordingly and

    therefore left very little time to prepare and produce material for the second and third

    presentations. The first presentation was on 11/8/2016 which was very late into the first

    semester. The second presentation was 11/29/2016 only three weeks after the first. Our final

  • Team Xtreme

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    presentation was on 12/10/2016 only 10 days after the second. We learned from this and made it

    a point to be the first ones to schedule presentations at the beginning of the second semester. We

    could have roughly four weeks between each presentation to give sufficient time to prepare for

    each.

  • Team Xtreme

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    Table of Contents

    Introduction 8

    Team Objective 8

    Deliverables 8

    History 9

    Event Categories 10

    Dynamic Events 10

    Static Event 11

    Winning Strategy 14

    Major Components 15

    Chassis 15

    Suspension 24

    Engine 34

    Drivetrain 35

    Steering 37

    Brakes 42

    Accessories & Miscellaneous 43

    Project Management 44

    Budget 44

    Timeline and Gantt Chart 45

    Work Breakdown Structure 46

    Risk Matrix 47

    References 49

    Appendix 51

    Timeline 52

    Gantt Chart 54

    Inventory 55

    Weld Testing 56

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    Drawings 59

    SAE/IMechE Memberships 63

    Engine Schematics 64

    Brake Dimensions 70

    Competition Registration 72

    Competition Submitted Documents Confirmation 72

    Professional Development Hours (PDH) 73

    Community Service Hours 101

    Sponsorship Brochure 104

  • Team Xtreme

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    Introduction

    The Baja SAE Competition is one of the design series offered by the Society of Automotive

    Engineers (SAE) that University students from around the world can compete in. University

    students are required to design and fabricate a high performance off road vehicle. The

    competition is a real-world scenario that lets students demonstrate their knowledge in the design

    and fabrication of a dynamic mechanism. The Baja SAE Competition has a long list of rules and

    regulations to ensure the safety of all participants however students can use creative and critical

    thinking to design their vehicle in an innovative fashion. The focus of the Baja SAE challenge is

    to promote teamwork and project management skills between team members. These qualities

    become a key to producing a successful project.

    Team Objective

    The objective is to design and build a vehicle that meets the rules and regulations of the 2017

    Baja SAE competition. Team Xtreme will represent the University of Houston and participate in

    the competition that will take place in Pittsburg, Kansas on May 25-28, 2017.

    Deliverables

    Register for the 2017 Baja competi