Design phase: designing the MORE vehicle

In recent weeks, the MORE teammates have been busy designing and calculating for the MORE vehicle. We give you a sneak peak of our progress so far.

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The MORE vehicle

To start with an explanation of how the MORE vehicle is constructed. The picture below was the very first sketch that was set up. It consists of 3 parts that are easy to connect and replace. The yellow part concerns the middle frame and is the most important part this semester. The two purple parts are the front and back and can be attached to this frame on the red rectangles. The blue torsion box is the main part of the middle frame, it provides the greatest rigidity and from here the rest of the roll cage is designed and made around it.

 

 

 

 

 

After a few weeks of engineering and drawing, the main assembly with all parts so far looks like this:

 

 

 

 

 

 

 

 

It can be seen that the MORE vehicle is intended as a 2 person vehicle. For the time being, the vehicle will run on an electric motor (5KW) and a battery pack (3kWh). This pack is stored under the driver’s and co-driver’s seats to effectively use the space. A donor Volvo 940 is used for the wheel suspension.

The torsion box is the main part of the frame, which provides a torsionally rigid structure. In addition, this box is used as a connection to the front and rear and the rest of the parts such as the electric motor can be mounted on this middle part. In short, a versatile part, which requires a good analysis.

 

FEM simulations

In addition to making an assembly, FEM (Finite Element Method) simulations have also been made, which means that the stresses and deformations in the model become visible by means of strength calculations and analyzes. In this case we use steel as a material, but if other materials are used, this can of course also affect the results.

FEM simulation of the frame

 

 

 

 

 

 

FEM simulation of the torsionbox

 

 

 

 

 

 

The different colors indicate certain tensions. Thus, the red and blue color are the maximum tension that will occur. It can be seen that these, in both simulations, are not above 0,46 N/mm^2, which is good according to our calculations. In addition, a yield strength is also determined, this is a material stress limit at which you undergo permanent deformation when you load it above it. Our yield strength for the steel is 460 N/mm^2, this value is very high and we will never achieve that. The material is therefore more than 800 times stronger than is necessary to absorb the torsion.

 

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