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Concept Design through Optimization and
Simulation at the Hydro2Motion Team
Johann Lohr & Bastian Henneke
www.hydro2motion...
Introduction H2M
26.06.2014 Hydro2Motion @ Altair EATC 20142
Problem
• Until now the team has been focused on getting the
car to finish the race distance.
• This season we won 5th pla...
26.06.2014 Hydro2Motion @ Altair EATC 20144
Frame requirements
• Space for driver, fuel cell, tires, batteries, etc.
• Dri...
26.06.2014 Hydro2Motion @ Altair EATC 20145
Frame concept
• 5 cm roll bar clearance over head
• Steering angle of at least...
26.06.2014 Hydro2Motion @ Altair EATC 20146
Load steps
• Most demanding load cases and constrains
• Roll bar test with 800...
26.06.2014 Hydro2Motion @ Altair EATC 20147
Optimization result
• Starting designing the
new frame
• Position of the beams...
Steering
26.06.2014 Hydro2Motion @ Altair EATC 20148
26.06.2014 Hydro2Motion @ Altair EATC 20149
Knee Lever
• Aluminium
• drilled and milled
• Weight: 99,7 g
• Displacement: 0...
26.06.2014 Hydro2Motion @ Altair EATC 201410
Version 1 PA12
• PA12
• SLS by eos
• Weight: 19,2 g
• Displacement: 0,1 mm
26.06.2014 Hydro2Motion @ Altair EATC 201411
As good as possible?
26.06.2014 Hydro2Motion @ Altair EATC 201412
Version 2 PA12
• PA12
• SLS by eos
• Weight: 16,5 g
• Displacement: 0,09 mm
Result
• Reduction of mass 83%
• Total increase of displacement over the whole
system less than 10%
• Better integration o...
Thank You!
26.06.2014 Hydro2Motion @ Altair EATC 201414
www.hydro2motion.de
info@hydro2motion.de
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Concept Design through Optimization and Simulation at the Hydro2Motion Team

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Concept Design through Optimization and Simulation at the Hydro2Motion Team

  1. 1. Concept Design through Optimization and Simulation at the Hydro2Motion Team Johann Lohr & Bastian Henneke www.hydro2motion.de Hochschule München www.hm.edu 26.06.2014 Hydro2Motion @ Altair EATC 20141
  2. 2. Introduction H2M 26.06.2014 Hydro2Motion @ Altair EATC 20142
  3. 3. Problem • Until now the team has been focused on getting the car to finish the race distance. • This season we won 5th place at Shell Eco Marathon Rotterdam and 2nd place at Educ Eco near Toulouse. Driving a distance of around 200km. • In order to be able to win those competition we have to redesign our whole car concentrating on aerodynamics and weight. 26.06.2014 Hydro2Motion @ Altair EATC 20143
  4. 4. 26.06.2014 Hydro2Motion @ Altair EATC 20144 Frame requirements • Space for driver, fuel cell, tires, batteries, etc. • Driver overview as good as possible • Low center of gravity • Meeting all competition regulations
  5. 5. 26.06.2014 Hydro2Motion @ Altair EATC 20145 Frame concept • 5 cm roll bar clearance over head • Steering angle of at least 12° • No aerodynamic aspects
  6. 6. 26.06.2014 Hydro2Motion @ Altair EATC 20146 Load steps • Most demanding load cases and constrains • Roll bar test with 800 N • Driver getting in and out • Braking, steering and accelerations
  7. 7. 26.06.2014 Hydro2Motion @ Altair EATC 20147 Optimization result • Starting designing the new frame • Position of the beams because of the force flows • Available design space and joints • Aerodynamic development next to the space frame development
  8. 8. Steering 26.06.2014 Hydro2Motion @ Altair EATC 20148
  9. 9. 26.06.2014 Hydro2Motion @ Altair EATC 20149 Knee Lever • Aluminium • drilled and milled • Weight: 99,7 g • Displacement: 0,0004 mm
  10. 10. 26.06.2014 Hydro2Motion @ Altair EATC 201410 Version 1 PA12 • PA12 • SLS by eos • Weight: 19,2 g • Displacement: 0,1 mm
  11. 11. 26.06.2014 Hydro2Motion @ Altair EATC 201411 As good as possible?
  12. 12. 26.06.2014 Hydro2Motion @ Altair EATC 201412 Version 2 PA12 • PA12 • SLS by eos • Weight: 16,5 g • Displacement: 0,09 mm
  13. 13. Result • Reduction of mass 83% • Total increase of displacement over the whole system less than 10% • Better integration of functions • Design of part more beautiful • But biggest archievment through change of material instead of optimization 26.06.2014 Hydro2Motion @ Altair EATC 201413
  14. 14. Thank You! 26.06.2014 Hydro2Motion @ Altair EATC 201414 www.hydro2motion.de info@hydro2motion.de

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