Design and building of the prototype IDRApegasus

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Design and building of the prototype IDRApegasus

  1. 1. Design and building of the prototypeIDRApegasusAssistant Professor:Ing. Massimiliana Carello(Mechanical and Aerodynamic Engineer Department)Phd Student:Dr. Andrea Airale(Mechanical and Aerodynamic Engineer Department)
  2. 2. The Team60 StudentsBest TrainingTeam spiritInnovationTechnical Demonstrator3 Working Vehicle
  3. 3. The Shell Eco-marathon200 TeamRotterdam 2012City circuit5 tight cornersEnergy saving10 LapsMax time: 39 minutes
  4. 4. Sx0,28 m2Front wheels coveredCarbon fiber monocoque Weight33 kgRear steering systemCx0,093
  5. 5. Rear wheelDesign constraints
  6. 6. Rear wheelTopology OptimizationObjective : minimunweightConstraint : maxdisplacementParameters : cyclicgeometryVideo
  7. 7. Rear wheelAnalysis of results : how to use them??
  8. 8. Rear wheelHigh stressNo fatigue problems
  9. 9. Monocoque studyMonocoqueFront noseTailCover
  10. 10. Targets Low weight Strength and structural stiffness SafetyCarbon Fiber: T800 + DynanotexHoneycomb
  11. 11. Monocoque study• Mesh 2D• Tsai-Wu theory• Study of the lamination of eachsurface• Using honeycomb sandwich• Layer orientation• 5,5 kg
  12. 12. Monocoque studyMax displacement2,5 mmFirst test : torsional stiffness
  13. 13. Monocoque studyMax ply failure0,59First test : torsional stiffness
  14. 14. Monocoque studySecond test : entranceMax displacement1,5 mm
  15. 15. Monocoque studyPly failure max0,67Second test : entrance
  16. 16. Monocoque studyThird test : exitMax displacement1 mm
  17. 17. Monocoque studyThird test : exitPly failure max0,3
  18. 18. MonocoqueManifacturingMilling model Vacuum to eliminate airHand lay upFinal mold
  19. 19. LaminationSetup mold Hand lay up carbon fiber VacuumFinal body after extraction
  20. 20. AssemblingBondingstructuralpartsFinal structureStructural mass : 6,5 kg
  21. 21. ResultsVehicle characteristicsStrengthMechanicalreliabilityConsumption :337 km/kWh - 3023 km with the energy equivalent of oneliter of gasolineLightEnergyEfficient
  22. 22. Research Group ActivityInnovative Electric and Hybrid VehiclesDr. Andrea Airale,Phd in Mechanical Engineering(Team Leader and co-funderH2politO)Ing. Massimiliana Carello, AssistantProfessor Mechanical Department ofPolitecnico di Torino (Faculty Advisorand co-founder H2politO)Dr. Alessandro Ferraris, M.Sc.in Mechanical Engineering(Project Manager and TechnicalCoordinator H2politO)
  23. 23. Research on CompositesCHEMICAL RESISTANCECRASHFATIQUETRACTIONCOMPRESSIONFLEXIONUV RESITANCETESTINGStatic FEMSimulationDynamic FEMSimulationVIRTUALANALYSISModel Validation
  24. 24. ContactsIng. MASSIMILIANA CARELLOAssistant ProfessorMobile: +39 333 6373119massimiliana.carello@polito.itIng. ANDREA AIRALEPhd StudentMobile: +39 366 3441 224andrea.airale@polito.it
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