Project Goals & Deliverables

On the first year I joined Olin's FSAE team, I owned our HV pack mounting subsystem. For this project, I took it from requirements gathering all the way through to a completed design installed on the vehicle!

The main goals of this project were two-fold — my design needed to:

• Reduce the amount of time it took to install the HV pack (previous design to about an hour)
• Satisfy all rules requirements around the load it can withstand, the number of fasteners needed, and the spacing between fasteners

More details of my execution can be found in the slidedeck below.

Key Learnings

I had a lot of key learnings from this project since it was one of the first mechanical design projects I was able to own fully from the start to finish:

• DFMA is important — you need to make sure there's enough room for hands and tools, and also enough stock material for any machining procedure to clamp off of
• You can go really in depth on bolted joint analysis if you want to — I just barely scratched the surface with basic calculations for install torque and bolt tear-out/pull-out!
• Curvature-based meshing can help improve the accuracy of your FEA results, although weld joints are still hard to simulate in structural analysis

Detailed Slidedeck

Process Photos