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Design and building of the prototype IDRApegasus

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  • 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. The Team60 StudentsBest TrainingTeam spiritInnovationTechnical Demonstrator3 Working Vehicle
  • 3. The Shell Eco-marathon200 TeamRotterdam 2012City circuit5 tight cornersEnergy saving10 LapsMax time: 39 minutes
  • 4. Sx0,28 m2Front wheels coveredCarbon fiber monocoque Weight33 kgRear steering systemCx0,093
  • 5. Rear wheelDesign constraints
  • 6. Rear wheelTopology OptimizationObjective : minimunweightConstraint : maxdisplacementParameters : cyclicgeometryVideo
  • 7. Rear wheelAnalysis of results : how to use them??
  • 8. Rear wheelHigh stressNo fatigue problems
  • 9. Monocoque studyMonocoqueFront noseTailCover
  • 10. Targets Low weight Strength and structural stiffness SafetyCarbon Fiber: T800 + DynanotexHoneycomb
  • 11. Monocoque study• Mesh 2D• Tsai-Wu theory• Study of the lamination of eachsurface• Using honeycomb sandwich• Layer orientation• 5,5 kg
  • 12. Monocoque studyMax displacement2,5 mmFirst test : torsional stiffness
  • 13. Monocoque studyMax ply failure0,59First test : torsional stiffness
  • 14. Monocoque studySecond test : entranceMax displacement1,5 mm
  • 15. Monocoque studyPly failure max0,67Second test : entrance
  • 16. Monocoque studyThird test : exitMax displacement1 mm
  • 17. Monocoque studyThird test : exitPly failure max0,3
  • 18. MonocoqueManifacturingMilling model Vacuum to eliminate airHand lay upFinal mold
  • 19. LaminationSetup mold Hand lay up carbon fiber VacuumFinal body after extraction
  • 20. AssemblingBondingstructuralpartsFinal structureStructural mass : 6,5 kg
  • 21. ResultsVehicle characteristicsStrengthMechanicalreliabilityConsumption :337 km/kWh - 3023 km with the energy equivalent of oneliter of gasolineLightEnergyEfficient
  • 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. Research on CompositesCHEMICAL RESISTANCECRASHFATIQUETRACTIONCOMPRESSIONFLEXIONUV RESITANCETESTINGStatic FEMSimulationDynamic FEMSimulationVIRTUALANALYSISModel Validation
  • 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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