The Application of an Engineering Design Methodology - Coursework Example

The application of an engineering design methodology and the production of 2D technical drawings 0 Methodology 1 Problem Identification The production of oil in UK and the world over is not stable. For example, in the 1970 onward, an oil production drop of 5% resulted to a price rise of 400% (Howden, 2007). At the moment, 31% of the crude oil production in the world, comes from the Middle East, and with the continuing wars and political hitches in these nations, it is obvious that the crude oil use is limited and the transportation of petrol may end sooner than anticipated (BP Energy Statistical World Review of June 2012, 2012). The trends in fuel consumption drop trends are now starting to manifest. For instance, in Europe, about 35% of the 15 000 000 new automobiles consisted the small vehicles, this translates to about 3.5 % increase annually. This tendency is expected to go on as fuel prices increase and hard-hitting CO2 regulation. ("Small cars take bigger share of the market", 2007) The United Kingdom government instigated a tax in regards to CO2 in which automobiles that give out enormous quantities of CO2 will be taxed. By the year 2009, it had planned to raise this this penalty to a bigger one of £1000. From the Table below, quite a number of automobiles are in the Bracket A where the maximum emissions of CO2 is 100 g/km. Normal sized saloons like the Audi A4 falling the succeeding uppermost bracket F, implying that the UK government is more strict on emissions from vehicles. Bracket CO2g/km A 225 Tax (pound 0 35 115 140 165 205 300 Table 1 United Kingdom Carbon Dioxide emissions taxes source: ("UK green Vehicles CO2 Emissions Directory", 2007) As indicated above; the 2 key concerns of the private transportation industry are as follows: • The diminishing fossil fuels supply. • The harmful effects that the fossil fuels burning has on our environs. These 2 main problems are pushing social initiatives and governments to seek substitute transportation. Alongside with newfangled inducements, advancements in new technology is helping the progress of substitute transportation. This report checks by the substitute vehicles presently accessible and inspects in aspect, the antiquity, and prospect of developing electric car. 1.2 Detailed design specification The attached figures show the component design evolution by incorporating the solid works CAE. The innovative mount suspended consisted of steel, and verified both with lab testing and virtually. Subsequently it was established to have met the set requirements; the design was established by the use of aluminum. This means that a saving of 6kg weight on the mount of automobile was made eventually. Additionally, this increased the vehicle efficiency. In this respect, this project had 2 main objectives • To be a working model electric automobile. • To contest at the World challenge competitions. Due to these 2 factors, the caliper had an exceptional design specification. Its design was not only for prototype view point or commercial and some conciliation were made to tolerate the vehicle to compete in any World Challenge competition. Therefore the following considerations were critical: (i) Environment The vehicle will be applicable outside in a variety of climate so the vehicle construction ought to withstand outside temperatures range of -12°C to 52°C, and must also be wind resistant and water proof. (ii) Life in Service The vehicle ought to be in a design that will allow it to have the normal vehicle life time of between 15 to 20 years. (iii) Finish, Appearance, and Aesthetic The vehicle must be appealing to the eye for the market out there and be modern. (iv) Materials The vehicle will be constructed from countless natural products, focusing more on lightweight cutting-edge materials that meet the performance in the sports world. 1.3 Development of concept designs The design of the Modern vehicle design uses monocoque framework; 99% of cars produced are made with a steel monocoque framework. A monocoque framework is one structure that defines the complete vehicle shape (Ashley, 2006). While ladder frame, space frame, and backbone chassis’ provide members for loading and require the body to be built around them, a monocoque chassis is already incorporated with the body in a single piece. A typical monocoque chassis is made by welding several steel pieces together. The advantages of a monocoque framework include good brake performance in addition to efficiency in space use. Aluminum monocoque framework was cast-off by Audi with the A4 in an effort to cut the mass chassis. The body of the lightweight steel body automobile framework was a remarkable style of the monocoque framework with introducing research into the application of composite constructions as a substitute to the steel packed framework of the past (Ashley, 2007). Monoquce framework’s produced from combination of materials such as carbon fiber and fiber glass have become prevalent; due to their low weight, so they have been in use in the racing competitions from the year 1998 (Wan, 1998). 1.4 Design isolation exercise The steering, braking system and suspension and braking system of a motor sport vehicle is a crucial mechanical constituent. Though these structures have been developed for quite a number of years it is not thinking that this region could be merely imitated from a present vehicle powered by petrol fuel. The Un-sprung mass entails all the weight that is not suspended by the spring and shock. The ratio of un-sprung mass is the un-sprung mass to sprung mass ratio; the greater the ratio the bigger the mass of un-sprung in relation to the overall weight of the vehicle. The Un-sprung mass affects the comfort of the occupier comfort. The greater the ratio, the more the vehicle is susceptible to accelerations and deceleration whereas it’s moving over road bumps (Aulock, 2007). These accelerations up and down are the cause of occupier feeling uncomfortable in the vehicle. Incorporating a conservative suspension system of vehicle would provide a great un-sprung mass ratio because of the design of a lightweight vehicle for sports. Re-forming braking is a portion with the prospective of undergoing broad development and research in the next years, particularly in respect to its likelihood to entirely change automated braking (Field, 2009). If this becomes realism, the regenerative braking use on all 4 wheels of an automobile would be valuable for the motive below; The use of braking in vehicles for braking would lessen the un-sprung mass auxiliary to the automobile by the motor use. Drum and disc brakes are comparatively dense, and since they have requirements in performance, they must be made of materials of heavyweight like steel. If these can be eliminated, the un-sprung mass would reduce considerably, paving way to a comfy ride and lightweight vehicle weight. Excluding the re-forming braking, many hybrid automated vehicles use a hydraulic braking system. Most authorities of transportation do not permit re-forming braking as a possible verified technique of stopping and slowing an automobile. Thus, engineers and designers are linking the 2 systems to adhere to these guidelines, while testing is carried out to ascertain the regenerative braking system safety. The effectiveness of an automobile is cut down by hydraulic brakes use. The additional brakes mass lead to fuel energy increase (Aulock, 2007). This is where the brakes often rub, by the fuel energy use. Consequently, efficient vehicles braking systems must have braking pads to return that do not wear or rub on the disc of the brake. 1.5 Documentation The suspension was initially put in a design that would fit a framework, and therefore integrated the components for mounting. The suspension support was made of sheet 6061 aluminum and was anodized after being cut using water jet cutter. The mounting ducts was also made from aluminum of thickness 40mm and was cut in an outline by the use of a water jet; the complete design of the brake disc is shown on the diagram attached. The upright front part was a composite casting, with its design made by the use of Solid works and so the upright was prototyped rapidly. Then, it was designed by the use of cast aluminum (Aulock, 2007). The upright is both useful and strong with steering mounting points and brake calipers incorporated into this vehicle design. To meet the LVVTA requirements, 2 mechanisms of braking were incorporated. Hydraulic brakes were incorporated on the vehicle front wheels, with re-forming braking on the back. The front brakes on the automobile were of the disc rotors in place of the drum and in place of the brake shoes had the aluminum caliper. Generally, the braking system on the vehicle great but had some issues. The main concern was the system of hydraulic braking being dominant in segregation (Field, 2009). On investigating, it was evident that the wrong master piston was in use. The re-forming braking was exceptional; drivers would use the redesigned braking to halt the vehicle without the necessity to use the vehicle system of hydraulic braking. References Ashley, S. 2007. Lightweight car prototypes. Mechanical Engineering, 119(5), 8. Ashley, S. 2006. Composite car structures pass the crash test. Mechanical Engineering, 118(12), 59. Aucock, R. 2007. Electric Potential. Automotive Engineer, 32(7), 20. Field, F, & Clark, J. 2009. A practical road to lightweight cars. Technology Review, 100(1), 28. Read More