Front Suspension Assembly
A Solar Car is a road vehicle completely powered by the sun, using solar cells mounted on the surface of the car. Solar Cars are designed to be extremely aerodynamic and lightweight as possible, to maximize efficiency using available energy from the sun. The car is being designed to participate in cross-country endurance rallies, notably the American Solar Challenge and the World Solar Challenge.
As the Solar Car is a road vehicle that will be run on freeways, it must be able to withstand loads from uneven road conditions, while protecting the driver and the car. The suspension systems designed in this project must meet these requirements, and additional objectives were considered to optimize performance.
The team was responsible for designing the suspension system based on some parameters given by the Solar Car team, including the target wheelbase (distance between front and rear wheels), the track width (separation between left and right wheels), and chassis angles. To ensure that the suspension system is safe for the driver and the car, and could be integrated with the rest of the car, the following requirements were established:
Must withstand structural integrity when wheels experience high instantaneous forces
Must provide independent wheel travel and a comforting ride for the car and driver
Must survive repeated loads and resist fatigue
In addition to the design requirements, the following objectives were established for designing the Suspension system:
Reduce overall weight for efficiency
Minimize cross section area to reduce drag
Minimize scrub radius
Minimize camber change
Minimize effects of roll
Be easy to manufacture to be completed within this project
To achieve these objectives, the Double A-Arm (Double Wishbone) suspension was chosen for its ability to provide independent wheel movement, control over suspension geometry, in maintaining minimal camber change on wheel travel. The development of the suspension geometry can be found in Programs/code.
After the suspension geometry was established, individual components were designed, to maximize strength-to-weight ratio. Each of the components designed and manufactured for the project are provided below.
The A-Arms must be able to do the following:
Connect the kingpin with the wheel assembly to the chassis.
Move up and down vertically to absorb bump loads.
Some changes made to the previous design were the following:
Straight cut angles for easier fabrication and welding.
Shorter to fit target track width.
The steering arm must be able to do the following:
Connects vehicle's suspension and steering mechanism together.
Some changes made to the previous design were the following:
Remove corners that could cause points of failure.
The brake caliper mount must be able to do the following:
Has the correct angle and length so that the brake caliper can properly squeeze the rotor.
Some changes made to the previous design were the following:
Weight reduction in removing material.
Remove sharp corners to reduce points of failure.
The hub must be able to do the following:
Connect wheel and brake rotor.
Mount onto and rotate freely on the spindle.
Precise mounting of the wheel.
Some changes made to the previous design were the following:
Different cutouts for a stronger component.
Evenly space out the bearing slots to provide greater stability.
The kingpin must be able to do the following:
Connects the spindle, A-Arms, steering arm, brake caliper mount, and wheel assembly together.
Some changes made to the previous design were the following:
Straight tubing for the A-Arms to reduce the amount of welding needed.
The steering arm plate allows for the flexibility of changing the steering arm if steering sensitivity needs to be adjusted.
Upper A-Arm
Lower A-Arm
Steering Arm
Brake Caliper Mount
Hub
Kingpin
2.2
1.3
6.0
1.9
1.3
2.8
Number of cycles: 10000000
Fully reversible cycles.
Results: All fabricated components have infinite life cycles according to SolidWorks FEA Simulation.
Destructive test on welded test pieces indicated that welds would not fail.
Wheel spun smoothly on spindle; brake rotor properly spaced within brake caliper
Mass of suspension system: 29.4lb (13.3 kg)
Suspension Geometry - Camber
0 degrees at neutral position
-2.8 degrees at + 2" bump
0 degrees at -2" bump