This project was undertaken alongside Patrick Rosaria
The dummy model was sourced from GrabCAD under the GrabCAD Terms of Use agreement
The Brief
High traffic congestion, pollution levels, and parking constraints in the Auckland CBD are all part of several major infrastructure issues being faced in Auckland. With congestion stalling main arterial routes and major traffic delays at peak hours on the motorway network, this project asked students to develop solutions to these issues by developing a compact commuter vehicle and city parking facility. Our team (fictionally incorporated as "Aurora Innovations") was split into two groups to address both parts of the problem.
Initial Appreciation
With Auckland Council being the client in this hypothetical scenario, our team firstly worked with the client in understanding the targets which the council was looking to achieve. Through multiple client interviews, and extensive research, our team developed an initial appreciation of the project - ensuring that key goals and specifications were commonly understood between the design team and the client. The team also produced mind-mapping models to help understand
Vehicle Research
The vehicle team started with conducting heavy research, particularly into the legal requirements for land, sea, and air vehicles - even before the final specifications were developed. One of the most critical factors for our team was trying to develop a commuter vehicle that not only met the client expectations but also could persuade current vehicle owners to switch to this new vehicle concept.
Our team quickly took to conducting research over several broad aspects. Determining what paradigm our vehicle was going to revolve around, it's kind of energy storage and propulsion technology, and how users would interact with the vehicle (and what were customer's priorities when they are looking to purchase a new vehicle).
Conceptual Design
Overtime, our team worked on a wide range of concepts for the hypothetical vehicle. All aspects of the vehicle were subjected to open interpretation - from the layout of the interior space, to how the vehicle was to be controlled.
The final vehicle centred around a streamlined 3-wheeled electric vehicle. With it's teardrop-like shape and low centre of gravity, we were confident that the design could be delivered using a low-cost pair of electric motors. The seating arrangement would consist of a fixed driver seat at the front, and a unique "scoop" seat in the rear, which could seat one adult or two smaller children. The rear seat could also fold down to allow for more luggage space.
Customers also wanted creature-comfort features, so we also ensured that features such as Smartphone connectivity and keyless start were included in the proposed design. We also made a strong case for adding a sensor array, which could be built upon in the future to add autonomous/self-driving capabilities to the vehicle.
Computer Aided Design (CAD)
Following the concept submission, the client decided to modify the initial criteria and specifications to put forward a small moped-like vehicle. Following an extensive development process, we then began creating an embodiment of our design concept using SOLIDWORKS. While our team had some experience with CAD , this was an opportunity for us to explore deeper functionality (such as rendering, simulation, and assembly features) within such software packages.
Our final concept was a combination of over 100 individual components, more than 10 different sub-assemblies, and featured the effective use of materials and simulation features.
Transmission
A transmission system was adopted to provide needed torque conversion and to pass down the drive power from motors mounted above. Using a chain and sprocket over a rubber belt would reduce overall maintenance and reduce slipping, especially under load.
By determining the maximum power output of our motor, along with comparing these with the expected maximum torque and velocities at the wheel in contact to the ground, we were able to develop specifications that our transmission system would need. We then used datasheets from our supplier to quickly specify, and then model a scale version of the transmission system implemented on our vehicle.
Structural Analysis
Safety of our vehicle's structure was paramount. Finite Element Analysis (FEA) was a valuable too that allowed us to evaluate the bending and stress characteristics of our frame easily, reducing overall costs on time spent on simulations using alternative methods.
Initial simulations of a frontal impact suggested that while the frame would not compromise enough to cause direct impact to the occupant, there were concerns pertaining to the compression of the battery cell. Using this feedback, we focused on the reinforcement of the frame in the area, increasing the thickness of the centre beam and chair support towers
