Innovative Vehicle Design

Teacher Training WorkshopSaturday, Sept 22, 2013

I gotta’ teach what…? Schematics Basic Electronics Battery Safety and System Requirement Calculations Design Calculations - Gear Ratios, Tire Sizes, Motor V/RPM, Velocity

& Acceleration Processes – Drilling, Tapping, Filing, Cutting, Hand Tools &

Safety The Purchasing Process Time-Line Softwares – What are the milestones, when is it

due, who’s responsible…Oh Boy!

Where do I find all that stuff?• Remember…This is an educational and fun

experience.

• Use the internet!

• Mentors are Great!– Build that Bridge!

• Students are wonderful researchers! Pair em’ up and watch em’ go!

Use the Math U know! Pick a common bike tire size in Dia “

16”…what is circumference? Pi x D How far around the tire? How long is a mile? How many times does the tire have to rotate

to travel a mile? If your top speed desired is 30 mph, how

many revolutions does the tire have to turn to cover 30 miles in 60 mins?

How many rpm’s should your tire turn???

What gear ratio do we use?• Gear Ratio will be dependant on your

tire rpm…

• You’ve already selected a motor…what’s its rpm at 80%?

• Does your tire turn faster or slower than the motor?

More ratio #’s… • For talking purposes… the motor

peaks at 3000 rpms at 24 volts.• 80% of that is 2400 rpms• Let’s say your tire rpm needs to be

740• Divide your motor rpm by the tire rpm

– 2400/740= 3.24 to every time your tire turns 1 revolution…so 3.24 : 1 is your ratio!

Let’s pick the sprockets!• Remember your ratio of 3.24 to 1

• If your motor shaft is ¾ -1”, you can get 13 teeth around it easily, so let’s take a 13 tooth sprocket.

• 13 x 3.24 = 42.12 or 42 tooth sprocket for your axle…based on your numbers your sprocket set is a 13 and 42…let’s get em’ and try it!

When we’re all done calculating…

Motor Size

• Lots of Internet HP calculators!• Pick a weight for your vehicle, decide

on your top speed ( less than 35mph)• Give a time to reach that top speed

and the calcs will give you the HP required to make it happen!

• Go Shopping!

What should this look like?• Many free design packages out there.

• ProDesk Top is one, easy to use and free, comes with tutorials.

• Many schools have SolidWorks.

• Design centers around???

• Aerodynamics!!! Lightweight!!!

What does “Innovative” mean?

• To Introduce a new idea

• To use an existing product in a totally new way

Have your student purchase items…• They all spend money!

• How is it done with a company’s $?

• Invite a “bean counter” to guest speak in class!

• Let students make the calls, get quotes, and write the purchase reqs!

What’s Incoming Rc’vng Inspection?• Every Automotive company conducts it!

• Is what I recv’d, what I ordered?

• Sign off and then accounting gets the packing slip and BOL, why?

• That’s the Purchasing Loop!

• We get our stuff and everyone gets the $$$!

IVD Guidelines

Questions?

What can we expect at MIS?• A great experience!!!

• Bring 2 chaperones…• Have your MIS release forms signed and

ready to give to the gate attendant.• Bring signed photo releases and a

completed Project Synopsis form• Pick your pit stall and unload.

MIS Inspections

• Inspections– Driver weigh-in with dry ballast 150 # min

– 30 degree Tilt test

– Brake lane test - 25 mph stop in 40 feet

– Helmet Regulations check – height, DOT

– Overall Inspection• You will rec’v an official checklist for your own

preliminary inspection at your sight

MIS Events

• Your team will compete on one of four figure 8 test tracks for 30 minutes to test the durability of your steering, brakes and chassis structure.

• All teams will be on the “Big Oval” at 12 o’clock noon for the “Big Event”. This will be a one hour energy management event.

Trophy Time!

• Drum rolls, Please! After the events are completed, the judging is tallied and voted on by the SquareOne Board…

It’s’ Trophy Time!

• Pictures and applause are encouraged!

• We should be out by 2:30 – 3:00 p.m.

Questions?

What Now?

• Next Steps (Refer to Appendix)– Assemble a team of students and volunteers– Get kids excited and find some big ideas– Assemble Gas Kart and Test

• Acceleration Rate, Top Speed, Range, Others…?– Install Electric Drive and Re-Test– Start Innovating– Have fun!– Ask when you need to!!! WE’re all here for

each other success! Remember, it’s all about kids!

Their Story!

Thanks SquareOne!!!