Mounts
(2022 - 2024)
The first and second image portrays the latest design I produced before graduating, which main purpose is to reduce the horizontal footprint of the dash layup such that the driver's hands on the steering wheel will not interfere with the dash. In addition, the angle of the dash will allow for the display to be more perpendicular to the driver in order to reduce glare and improve visibility. Button placement and dash enclosure was done with help from another team member.
The last two images shows the redesign I produced in 2022-2023, which is very similar to the initial design from the year before me. It features a cutout for the driver's hands as well as a steeper angle for the display, however the newest design solves the two problems in a more efficient and effective way.
(2022-2023)
I redesigned the battery mount after the previous year's Velcro design was rated poorly by the FSAE judges. I combined the battery shield and mount into one piece, lowering the mount's complexity and weight from the old design.
The mount features a single sheet of ASTM A36 steel, cut and bent around the terminals with mounting slots on the front and back. Neoprene foam is also adhered to the inner walls to induce tension between the mount and the battery, reducing vibrations and increasing stability between the floor and the battery. The open bottom allows for the battery to be easily changed out with a fully charged one when unscrewed from the car floor.
(2021-2023)
The three main electronics on the car floor starting from the top in clockwise order are: live telemetry, power distribution module (PDM), and engine control unit (ECU). The 2021-2022 car did not have the PDM, and as such the ECU was centered below the live telemetry unit. However, the 2022-2023 car included the PDM module and required additional space to be allotted for that electronics, so the positioning had to be reevaluated.
One requirement for the ECU and PDM is that their connectors needed to face downwards, as all the wires in the car were set to lead to that point. And as the ECU is quite heavy and important, mounting brackets are required and I designed them to hold the ECU in place, in addition to using Velcro. The initial plan used aluminum tabs, but by moving to carbon fiber, weight can be saved.
(2021-2023)
Due to FSAE rules, brake lights have to have a certain size, luminosity, and location on the car. Upon working out what would be the best for all the rules, I came up with a mounting design in 2022-2023 that would be just below the driver's shoulder and in 2021-2022, the rear shockpots so that the brake lights would be somewhere around the seated driver's shoulders. The brake lights are simple trailer lights found on Amazon, and can easily be screwed onto the mount. The first two pictures display the design with cutouts to minimize weight for the most recent design while the last two show my first project design for the previous year's car.