COURSE OVERVIEW

The course will allow students to understand how product innovation depends on the interdependence of systems and their continual evaluation. Students will work in teams to design, manufacture and race an electric-powered vehicle. 

Students will consider: 1) What is the most efficient shape for a chassis, taking into account weight and strength, and its consequent effect on speed? 2) What is the benefit to the designer of using detailed CAD models? 3) How are electronic circuits assembled and tested? 4) How can material selection affect the performance of a product? 5) How can testing and evaluation help to improve the performance of a product?

• Introduction & Challenge Setup: Designing and building the fastest electric vehicle. Discuss key design skills required (curiosity, analysis, determination, solution focus, investigation).

• Investigate Propulsion Systems: Research and analyse at least 3 propulsion systems, focusing on the electric motor (how it works, pros and cons). Team members create individual research slides.

• Investigate Forces & Aerodynamics: Research and explain assigned forces (Drag, Thrust, Friction, Weight/Mass, Aerodynamics) and demonstrate one of these forces. Discuss the effect of these forces on vehicle performance.

• Design Proposal & Analysis Review: Finalise design ideas for the chassis shape, weight, and strength. Define the idea proposal and conduct a summative quiz/review of concepts.

• Initial Design & Sketching: Discuss design methods (sketching, modelling, peer review) and begin concept sketching for the vehicle. Annotate sketches considering appearance, size, strength, stability, weight, aerodynamics, and speed.

• Modelling (Card/Corflute): Use sketching and modelling to develop an effective prototype. Focus on translating the design from a sketch to a physical model using card and corflute.

• CAD Modeling: Create detailed CAD models for the final components, reviewing the benefits of using CAD models for design.

• Manufacturing Preparation: Review design constraints (battery pack, motor, wheels, materials) and the manufacturing process (craft knife, hand drills, glue gun, 3D printing). Focus on creating components with precision and accuracy.

• Chassis & Wheel Installation: Manufacture the chassis, ensuring neat cut lines and correctly installing axles and wheels. Discuss how material selection affects product performance.

• Electronics Assembly & Testing: Assemble and test the electronic circuits for the electric vehicle. Secure wires and work on the motor housing/fan mount design and installation.

• Fan Mount & Final Assembly: Install the fan mount neatly into the chassis and complete the full assembly of the prototype.

• Initial Testing and Data Capture: Design and conduct initial testing (Test 1, 2, 3) over a measured distance to capture speed data. Introduce methods for testing acceleration, speed, weight, strength, and wheel balance (roll test).

• Evaluation and Iteration: Analyse initial test results (What Went Well/Even Better If). Evaluate how to make iterative improvements to increase performance, aerodynamics, and the power/strength/weight ratio.

• Implementation of Improvements: Apply design changes based on evaluation. Manufacture and assemble improved components for the final vehicle version.

• Final Testing & Technical Drawing: Conduct final testing to validate the iterative improvements. Create a final technical engineering drawing (side, top, and projected front view) of the improved Air Racer design.

• Final Showcase: Race and Presentation: Compete in the final electric-powered vehicle race. Students present their design rationale, manufacturing process, and evaluation data to justify their iterative improvements.