Suspension Cody Dykman Jesse Ramer Jesson Salyards Frame Warren Starbuck Brett Schuler Doug Romoth Drive Train Josh Voorhees Corey Saner Spencer Garland Kyle Werkele 2010 SAE Mini Baja Competition

Our goal was to design, test, and manufacture a safe, light weight, and rigid off road baja car that would withstand a series of rigorous off road tests. This included components of the frame, drive train, and suspension of the vehicle.

Single Passenger 10 hp Briggs & Stratton Engine SAE Rules and Regulations

Goal: -12 inches ground clearance under vehicle weight -10 inches suspension travel -14 foot turning radius -Withstand rollover to 30 degrees

Springs and Dampers: Gas/oil Springs -Nitrogen over oil design integrates spring rate and damping coefficient in one compact unit -Spring rate and damping coefficients adjustable over a wide range of values -Readily available and low cost

Front End Design: Unequal length double A-arms -Excellent axial and lateral strength -Easily adjustable -Provide constant point of contact between tire and ground (eliminates bump steer)

Rear End Design: Laterally supported trailing arm -High strength with 3 lightweight members -Easily adjustable -Eliminates Driveshaft Plunge

Suspension Components -Double A-arm -Single A-arm -Trailing Arm -Integrated Trailing Arm Shocks/Springs -Gas -Coil Over -Torsion Bars

Achieved: -12 inches ground clearance under vehicle weight -12 inches suspension travel foot turning radius (without cutting brakes) -9.2 foot turning radius (with cutting brakes) -Withstands rollover to 43 degrees

Protect the driver Accommodate suspension and drive train components No continuous tubing with multi-plane bends Less than 450 total weight Comply with all SAE Rules

Material Type -Aluminum -Composites -Steel Tubing -Square -Round Construction Methods -MIG -Oxy-Acetylene -TIG

Frame Red Members Specified By SAE 1” OD, 18% Carbon 0.12” Wall Thickness Or Equivalent Strength and Stiffness Blue Members Specified By SAE 1” OD 0.035” Wall Thickness

Frame Tubing Bending Strength Bending Stiffness=E*I

Frame Tubing Selected Tubing 4130 Steel 1.25” Outside Diameter Wall Thickness

Frame Model Visual Analysis Drew Model and Specified Properties of Members Applied Loads Forces and Moments Deflection In Members Stress in Members

Fabrication Bent Tube Construction Notched Tubing TIG Welded Tubing Frame Weight 75 lbs

Goals -Maximum speed~ 25 mph -Drive train weight ~ 60 lbf -2 rotating shafts

No load engine rpm = 3800 Loaded engine rpm = Due to efficiencies of the CVT, planetary gear reduction, and bearings Max speed of 21.3 mph -Tire Diameter = 25 in. -Differential rpm ≈ 287

Engine to Differential Gear Reduction = 56.8:1 (engagement) to 10.6:1 (top speed) CVT Reduction -Maximum Reduction: 3.71:1 (engagement) -Minimum Reduction: 0.69:1 (top speed) After CVT Reduction = 15.5:1 -Through Planetary = 5:1 -Sprocket to Differential = 3.1:1

Design (1 st Stage): Continuously Variable Transmission -Primary Clutch -Secondary Clutch -Belt

Planet gear Annulus Sun gear Planetary gear fixture Design (2 nd Stage): Planetary Gear Reduction

Design (3 rd Stage): Sprocket to Differential Reduction -Drive Sprocket -Driven Sprocket (Differential) -Chain

Design (4 th Stage): Drive Shafts -U Joints -Drive Shafts -CV Joints

CVT with a planetary reduction and a single chain drive gear reduction CVT with single stage direct gear mesh CVT with double stage direct gear mesh Hydraulic system

Achieved -21 mph -67 lbs -2 rotating shafts

Schedule

Registration$ 1, Frame$ 1, Suspension$ Drive Train$ Travel$ 4, Total$ 8,279.65

2010 SAE Mini Baja Car Competition was held in South Carolina April 8 th -11 th 3 Static Events: -Design Report -Evaluation -Cost Report 5 Dynamic Events: -Acceleration -Pulling -Maneuverability -Suspension -Endurance

Machined Sprockets Multispeed Transmission Coil Over Shocks Shorter Wheelbase Narrower Track Width

Cowboy Racing would like to give a special thanks to: 2009 UWYO SAE Mini Baja Team NAPA Uniwyo Federal Credit Union Allen Canete Engineering Advisors: -Dr. Paul Dellenback -Mr. Scott Morton

Thank You for your time. Questions? Please ask them now.