Background of Formula-e (Elastic band powered)
Strategy, development, engineering, design fabrication
Artcenter College of Deisgn Formula-e project is designed to teach lessons in strategy, product development, science, engineering, design fabrication, branding and event planning......
2023 Formula-e Objective
Run as far as possible
Each team will run their vehicle (one at a time) in an attempt for their vehicle to travel the greatest distance along a course defined by the contest operators.
Our Concept
Horizontal vehicle with less gear sets
We challenged the conventional way, making horizontal cars because we can use fewer gear transmissions to reduce energy loss. The rubber band will drive the wheel only through one gear set. Throughout the entire process 3D printing method was highly involved for fast iteration.
Achievement
Break record, best-looking & design award
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We did 4.7 laps in the final, almost double the history record created by the program chair(2.9 laps).
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We won the best-looking car design award 2023.
My responsibility
Conceptualization, design engineering, making and testing
• Conceptualization: I proposed new concept that uses less gear sets to reduce energy loss, setting the correct direction for our project.
• Design and Engineering Synthesis: I iterated design by analyzing structure and mechanics to improve strength and weight of wheels and bearing structures.
structures.
• 3D Printing and Testing: I specialized in 3D modeling, printing, and hands-on model making, ensuring all parts can be produced and assembled properly.
Stage1
Rough mock-up, LEGO parts
We make the mock-up with lego parts, this the fast and cheap way to test if our assumption of the concept is going to work or not at the very beginning.
Stage2
Stronger material, MDF
The lego part cannot hold too much power from the band, so we laser cut the mdf board to make the stronger version. So, we could study how the band is gonna to perform under higher load.
Stage3
Triangle design, weight &strength improvement
MDF is heavy, so we designed the triangle pipe structure to reduce weight and improve strength to resist the torque. At this stage we also started designing the brake system which stop the band but let wheels run with one way bearing.
Stage4
Carbon fiber pipe instability
To further reduce weight, we decided to use 3 carbon fiber pipes and we did a complete race test. We found out that the material and structure twisted so much when we apply almost maximum loops of rubber band. So we decided to change the design next.
Stage5
Strong cabron fiber tube
So we used a big carbon fiber tube that is very strong. We designed parts to fit it and tried to make everything lightweight. At test, we found the front frame is shaking.
Final
Lightweight and strong structure design
Front frame was reinforced yet light weight, design and enginnering are blending together. We are proud to win best looking car award and break the record.