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Our main goals in suspension/steering/brakes system are to:
Make the system as easy to tune or adjust as possible to accommodate changes in racing environments and situations.
Maximizing suspension response to keep contact between tires and track surfaces.
Reduce unsprung mass as much as possible while maintaining good structural integrity.
Suspension Type
Suspension Type
Teams in FSAE competition mostly use Double wishbone suspension configuration due to its good handling, more suspension geometry options, and it's also easier to tune or adjust the suspension setup. Therefore, for these reasons and the time window in the design process, we decide to choose the Double wishbone suspension configuration too.
Spring & Damper layout
Spring & Damper layout
In the FSAE competition, most of the competitors use the rocker arm and aluminum rod to transfer vertical loads from each wheel to its spring and damper instead of transferring vertical loads through them directly. This allows engineers more freedom in designing wheel travel, without worrying about the limitation of spring and damper travel.
There are 2 types of spring & damper layout found in FSAE competitors, push-rod which is easier to tune the spring & damper, and pull-rod which provide a lower center of gravity due to its spring & damper location. We decide to choose the push-rod layout. The first reason is that the push-rod layout is way more simple to design and analyze its mechanism so we can make it done in a limited time. The second reason, the spring & damper location in the push-rod layout sits higher in the chassis, which makes the system easier to assemble, and the spring & damper can also be tuned or adjusted easily.
Disc brake Type
Disc brake Type
Teams in FSAE competition mostly use Disc Brake Type configuration due to its :
Resistance to heat fade.
Better cooling brake system.
Easy maintenance.
Better control over lateral forces during braking and cornering.
Wheel properties
Wheel properties
Our priority is to reduce unsprung mass for maximum handling capabilities for our driver. A 10-inch diameter, one-piece wheel made of carbon is the most desirable solution due to its lightweight properties. However, after careful consideration, we have decided to use magnesium alloy instead. This material provides a significant upgrade over aluminum, being 30-50% lighter, and is only slightly heavier than carbon, with a difference of 10-15%. Additionally, magnesium alloy is more readily available in the market and is more cost-effective to manufacture.
Tire properties
Tire properties
In FSAE competition, most teams opt for smaller and softer tires that is compatible with the selected wheel size, with Hoosier 16.0x7.5-10 made with LC0 being the most prevalent choice. Although there are two options for tire material (R25B and LC0), LC0 is the more dominant option in the competition due to its superior grip, achieved through its softness, with a trade-off of reduced durability.
Type of structure
Type of structure
There have 2 types of vehicles, Spaceframe and Monoque, we decide to design a formula EV in the type of Spaceframe. First reasons, Spaceframe is way more simple to design, analyze, and manufacture because of its low-poly geometric design and homogenous materials being used, and second, we have less time to design formula EV in Monoque. and from fsae 2022, ranking 10-15, they design structure in Spaceframe
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