Right Rocker Remanufacturing

Owned by Saheed Quadri
Last updated: Sept 09, 2024
3 min read

 

Due Date: Aug 18, 2024

Contributor Log

Name

Contribution

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

image-20240713-014202.png
Joint in misalignment
image-20240713-014308.png
Desired alignment

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.

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

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

  • Jul 15, 2024 (date and name)

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

  • Etc.

Relevant Documentation Links

  • 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