1. Manufacturing
Unit 5

2. Today:
Today you need to come up with some ideas... without the restraints of specifications. To do: Get a blank sheet of paper.. label it. On this paper, draw 15 thumbnail sketches of car ideas.. side view, top down view... it doesn't matter. You just need 14 unique, small. anything goes designs. Feel free to look up CO2 cars on the internet for ideas. In the end, you will have 7 different cars with 2 views each.

3. Manufacturing
Make something on a large scale using machinery

4. Assembly Line
a series of workers and machines in a factory by which a succession of identical items is progressively assembled
Henry Ford created the first assembly line to build a car

5. Steps of manufacturing

6. Design
With the help of computer-aided design equipment, designers develop basic concept drawings that help them visualize the proposed vehicle's appearance.
Thumbnail sketches, concept drawings, etc
Based on this simulation, they then construct clay models that can be studied by styling experts familiar with what the public is likely to accept.
Aerodynamic engineers also review the models, studying air-flow parameters and doing feasibility studies on crash tests.
Only after all models have been reviewed and accepted are tool designers permitted to begin building the tools that will manufacture the component parts of the new model.

7. Manufacturing process
Gather all components that you will need to build the car
Chassis
Frame that everything sits on
Sits on the assembly line and everything (gas tank, transmission, etc) is place in it’s spot
Body
Shell of the body is first
Welded together
Then door frames, roof, body are assembled with robots

8. Process continued… Inspection Paint Interior Mate
Shell of the body is painted inside and out
Interior
Wiring, doors, radios, pedals, etc are all added now
Windshield is added using robots
Seats and trim added
Mate
Body is added to the chassis
receive final trim components, battery, tires, anti-freeze, and gasoline.
Vehicle can be driven now

9. Quality Control
Making sure everything works perfectly

10. CO2 Cars

11. Drag
Air resistance

12. Friction
the resistance that one surface or object encounters when moving over another

13. Lift
Upward reaction of a car to the flow of air over the shape of the body

14. g force
A force acting in the opposite direction of the acceleration

15. Acceleration
Increase in the rate of speed

16. Speed
The rate at which something is able to move or operate

17. Inertia
Tendency to remain unchanged

18. Specification
Detailed description of design criteria for a piece of work

19. Principles of Engineering a CO2 Car

20. Mass Weight of the car Advantages
Comes into play when deciding which balsa block to chose
Advantages
Cars with less mass go faster
Disadvantages
Cars with less mass are less stable and less durable

21. Drag Advantages The resistance of wind moving over an object
Think about making the body as aerodynamically clean as possible.
Advantages
Aerodynamically shaped cars are less “draggy” so they go faster
Disadvantages
Aerodynamically “clean” cars are more difficult to build

22. Friction Advantages Disadvantages
Friction on a CO2 car happens in 3 main places: between the wheels and the ground, between the axles and the car body, and between the eye- hook and the fishing line track
You cannot eliminate friction, so you have to try to reduce it
Advantages
Friction filled cars are easy to build, are slow, but more durable
Disadvantages
Reducing friction takes a lot of time, effort, and patience

23. Design Envelope
In the real world most everything has a limit. That limit could be technology available, labor available, materials, or cost. Our CO2 cars also have a set of minimum and maximum dimensions, called a Design Envelope.
Advantages
Cars that follow a design envelope can compete equally and safely
Disadvantages
Cars may go faster without following the design envelope, but they will be disqualified

24. Types of CO2 Cars

25. Rail
Easy to make
Narrow “rail” that connects the front axle to the back of the car
Wheels are on the outside of the body
Body of the car is lower to the ground in the front and middle, then rises up abruptly to hold the CO2 cartridge
Pros
Easiest to build and design
Thin rails reduce weight
Can be built by anyone using common wood working tools
Cons
Greater risk of breaking
Exterior wheels are bad for aerodynamics
More drag

26. Shell Pros Built for speed Cons Internal wheels
Low drag
Capable of high speeds
Cons
Requires special parts
Difficult to build
Little room for creativity
Requires specials tools such as a CNC machine and CAD experience
Built for speed
Internal wheels
Clean aerodynamic shape
Hollow underside

27. Show Not built to race Stunning design Very creative Pros Cons
Cool to look at
Builds design and manufacturing skills
Cons
Can’t race it
Fragile
Requires special tools
Not built to race
Stunning design
Very creative

28. Transportation Modeling
Pros
Cool challenge
Fun to look at
Cons
Usually don’t race
Are slower
Uses special parts
Look like cars you see in real life
Not really meant to race

29. Normal Cars These cars uses characteristics of other car styles Pros
Built to race
Wheels are usually external
Pros
Always race and usually do well
Doesn’t require any special tools or parts
Cons
none

30. Project Requirements

31. Thumbnail Sketches Concept sketches
Small quick sketches used by engineers and designers to quickly communicate ideas
They should not be detailed or even carefully done
This is your chance to be super creative

32. Design Sketching
Take your favorite thumbnail sketches and draw them on a larger scale and with more detail.
Draw both the top and side views

33. Design Specs

34. Axles / Axle Holes / Wheelbase Power Plant ( CO2 Cartridge Hole)
Dragster Body
Dragster body length 200 mm mm
Dragster body height at rear with wheels 75 mm
Dragster body mass / weight with wheels 45 g 170 g
Dragster body width at axles – front & back 35 mm - 42 mm
Dragster Body width (including wheels) 90 mm
Axles / Axle Holes / Wheelbase
Number of axles 2
Bottom of axle hole above bottom of dragster 5 mm mm
Rear axle hole from rear of dragster 9 mm mm
Wheelbase 105 mm mm
Power Plant ( CO2 Cartridge Hole)
Power plant: depth of hole 50 mm - 52 mm
Power plant: housing thickness (around entire housing) 3 mm
Power plant: lowest point of chamber diameter to race surface with wheels 26 mm - 36 mm
Screw Eyes
Screw eyes (2) distance apart at farthest point 155 mm 270 mm

35. Working Drawing Precise 1:1 drawing of your car and it’s features
This is what we’ll use for rough cutting your car blank

36. Your Goal:
Using your sketches, design the car you want to create on graph paper (Ms Kerr has the paper)
Make sure you are following the design specs!
Use pencil so you can erase!