Project Overview:
As part of my Advanced Mechatronics class (ME 338), I was involved in a team tasked with designing and constructing an RC car for a circuit race. Our design principles focused on flexibility, reliability, and simplicity, particularly emphasizing the car's chassis, drivetrain, and steering mechanisms.
Chassis Design:
My main responsibility involved designing the chassis. We opted for a modular design, incorporating cap fittings for battery attachment. After evaluating materials in Solidworks, we initially selected ABS but later transitioned to PLA due to availability. This change required reduced chassis thickness from 6.35 mm to 5.3 mm, effectively supporting the additional weight of the axles, battery, and gears. I also conducted stress, displacement, and strain analysis to ensure durability.
Steering Mechanism:
The steering design presented two significant challenges: maintaining modularity and managing the small chassis area. I contributed to designing a wide (220 mm) front axle for improved stability and traction. We settled on a single axle design, balancing stability with our modular design concept. The choice of PLA material allowed for rapid prototyping and strength assurance, especially during impacts.
Powertrain Development:
I designed a custom gear case with a triangular gear pattern for the powertrain to maximize space utilization and strength. The open design of the gearbox facilitated easy gear replacement, a crucial feature during testing phases. We utilized rigid white resin for gears to withstand the heat generated at high RPMs and a carbon fiber rod for the rear axle, balancing lightweight properties with high stiffness.
Add-Ons and Aesthetics:
As a fan of Formula 1 racing, I drew inspiration from F1 car designs for the additional aesthetic elements of our RC car. This influence is evident in the design of the front wing, rear wing, side skirts, and body, all of which were meticulously 3D printed. These components not only enhanced the car's visual appeal, resembling the sleek and aerodynamic profiles of F1 cars but also contributed to its aerodynamic efficiency and structural resilience. The front wing, in particular, played a dual role by improving aerodynamics and serving as a protective element for the steering system during impacts in testing and racing.
Post-Race Analysis and Improvements:
Despite our car's robust performance during the race, we encountered challenges with tire grip and powertrain reliability. Future improvements could involve adding weight to the front axle for better steering control and exploring metal gears for enhanced durability under high stress.
