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1970 Lotus Europa Front Suspension Redesign

1970 Lotus Europa Front Suspension Redesign. ME 462 Capstone Design Spring 2007 Sponsor: Bishop Steering Technology Kel Tiedman, Jason Wou. Team Members. Tom Filipucci Frank Faulkenberg. Brian Schludecker David Giles. May 3, 2007. Project Background.

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1970 Lotus Europa Front Suspension Redesign

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  1. 1970 Lotus Europa Front Suspension Redesign ME 462 Capstone Design Spring 2007 Sponsor: Bishop Steering Technology Kel Tiedman, Jason Wou Team Members Tom Filipucci Frank Faulkenberg Brian Schludecker David Giles May 3, 2007

  2. Project Background • 1970 Lotus Europa • 1470cc, 4-cylinder engine producing 78 hp • 120 mph top speed • 13-inch wheels • 2-piece control arms • Stamped & welded • Bolt-on ball joints • Coil-over shock & spring arrangement

  3. Customer Requirements • Maintain suspension geometry • Provide stable 200 mph ride • Maintain 5 inch ride height • Utilize 15 inch Audi wheels • Utilize current frame mounting points • Maintain wheel-to-wheel dimension • Attempt to utilize stock shock and spring size • Minimal bodywork modifications

  4. Engineering Targets

  5. Final Design

  6. Final Design • Upper Arm = 5.60 in • Lower Arm = 11.03 in • Scrub = 10 mm • Steering Axis = 16.5º • Rotor Clearance = 0.69 in

  7. Design Animation

  8. Design Animation

  9. Design Evaluation • Suspension Analysis • Four-bar Mechanism

  10. Design Evaluation • “Fourbar” Program – Norton • Evaluate each control arm length iteration • Rough wheel motion • “Four-bar Mechanism” - Matlab • Quantitative wheel motion • ProEngineer Mechanism output to Excel • “Camber Curve” - Matlab • Camber curve comparison

  11. Design Evaluation • Iteration Method • 2 Iteration Sets • First Set – 11 possibilities • Manipulated Variables • Scrub radius • Steering axis • Second Set – 6 possibilities • Same Variables • Smaller scrub radii • Larger steering axes

  12. Design Evaluation • Case 5: • Steering Axis – 16.5° • Scrub radius – 10.0 mm • Upper arm – 5.60 in • Lower arm – 11.03 in • Case 1: • Steering Axis – 16.0° • Scrub radius – 11.0 mm • Upper arm – 5.70 in • Lower arm – 11.04 in

  13. Design Evaluation

  14. Design Evaluation

  15. FEA Results

  16. Final Evaluation

  17. Conclusion & Recommendations • Conclusion • Kinematic motion requirements met • Verified some physical packaging requirements • Recommendations • Further finalization of arm shapes • In-depth finite element analysis • Close examination of control arms and knuckle attachment • One team for knuckle/brake and suspension design

  18. Questions?

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