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Due Date:

Contributor Log

Name

Contribution

Saheed Quadri

Project Manager

Senna Barborini Vedha Mereddy

Owner

Skills

  • Solid works

  • Lathe

  • Milling

  • 3D Printing

Task Description

The first manufacturing revision of the carbon fiber drivetrain chassis was completed in W24. The right rocker subassembly currently has a joint in misalignment.

image-20240713-014202.pngImage Removedimage-20240713-014308.pngImage Removed

This is the joint that connects the bogie to the rocker subassembly.

image-20240713-014202.pngImage Addedimage-20240713-014308.pngImage Added

During epoxy, the joint was secured to the carbon fiber with the aid of 3D printed jigs that align the components in the desired orientation. Vacuum forces fought against the joints getting epoxied, and this is speculated to have caused misalignment.

IMG_1404-20240909-193112.jpg

The scope of this task is to improve the design of epoxy jigs to ensure proper alignment and fully remanufacture the right rocker arm.

image-20240713-152802.png

In the first revision of rocker arm remanufacturing, vacuum forces were fought by pushing against the joints and keeping them in place with random heavy elements

The epoxy jig is now required to linearly constrain the joints of the subassembly against vacuum forces while the epoxy cures. Additional constraints to ensure the joints remain in the desired orientation is recommended

Task Breakdown

  •  Remanufacturing and reassembly of right rocker arm
  •  Step 1 - Purchase required material stock
  •  Step 2 - Iterate on epoxy jig design and provide justifications for improvements in a one paragraph report in the progress journal
  •  Step 3 - Machine motor joint
  •  Step 4 - Order carbon fiber tubing and make work request for the following
    •  Welded MR24-DT-P001 ~ MR24-DT-P008
    •  Welded MR24-DT-P008 ~ MR24-DT-P009
  •  Step 5 - 3D Print epoxy jigs; fabricate and purchase miscellaneous components
  •  Step 6 - Rocker arm assembly and epoxy

Prerequisites

This task is a pre requisite to the drivetrain reassembly task

Progress Journal

  • (date and name)

    • brief update on whats done and what are the next steps, photos and images and videos are preferred

  • Etc.

  • Wheel joint CAD Model number : MR24-DT-P034

    • Drawings can be found in Kenesto Sandbox / David Choi

  • In drivetrain assembly (MR24-DT-A00.00) do the following:

    • Check out the file using Kenesto

    • Create a derived configuration from ‘Frame Epoxy Support Setup’ titled “Revision 2”

    • Make updates to the epoxy jig assembly with improved design

    • Confirm assembly revision with Saheed Quadri

    • Save file and check in drivetrain assembly