Overview
This project was my first contribution to the Solar Car, Daybreak, in my freshman year.
The goal was to design a simple lock to constrict our battery box.
There were several criteria and constraints that had to be met:
- Simple and manufacturable
- Interface to kevlar-foam compostie sandwich
- If underneath bottom panel, 1" clearance from floor
- If on top of bottom panel, fit in a 3x3" area
- Easy method to unlatch
- Sustain a 5g impulse from 80kg battery box
Design & Process
I created an initial design in about 2 weeks, and met up with my lead (Cesar) to review it. The design was to complex with too many constraints and parts. It was ultimately junked and I started a new version. This time it was quicker to design since I knew what to avoid. I looked online for material prices, and pre-manufcatured parts like U-brackets and carbon-steel stock. The design was much smaller and easier to manufacture. All the parts could be bought from McMaster-Carr and were simple to machine.
Before reviewing with Cesar, I created a proof-of-concept using 3D printers to show how simple it is to make.
After reviewing with Cesar, a few adjustments were made to the base plate to optomize material volume and change location of bolting holes.
Results & Reflection
This project was my first real project on the team. It did take a while to complete, but I'm glad I was able to design a component, get it reviewed, restart and pivot quickly, create a prototype, and finalize something that would be used to compete. At this point, I was getting more comfortable using SolidWorks and finding how much authority/freedom I had in the club.