Harness Mounts and Jigs
I created four pairs of chassis harness mounts to ensure the driver has a legal harness for Formula SAE Electric events.
What?
Manufactured AISI 1020 steel seatbelt lap mounts for the 5 point harness that is rules mandated
Four pairs of steel mounts must be structurally welded to the primary chassis structure
How?
Following the team's standards of technical drawings, I created one for these steel harness mounts. In addition, I created a .dxf to waterjet the steel blanks at our student machine shop.
When the steel blanks came in, there was no curve for it to mount concentrically to the chassis. I utilized a 1 inch drill on the manual mill to ensure the seatbelt mounts fit around the chassis tube.
To secure the mounts in place for welding, I designed and 3D printed a jig in SolidWorks that would slide through the mounts.
Results
These seatbelt mounts that were made ended up being tig welded to the frame and are able to withstand 15 kN of force
We passed technical inspection at both Michigan and New Hampshire, proving this was a completely SAE rules compliant harness
The positioning of these mounts enabled the sheet metal floor of the vehicle to fit appropriately
Held the driver securely!
Interchangeable Sprockets and Adapter
Designed a topologically optimized sprocket adapter and set of sprockets for UWFE's driveline subsystem
Motor Guard
Designed and manufactured an FSAE rules legal scatter guard to enclose the EMRAX 228
Chain Guard
Designed and manufactured an FSAE rules legal scatter guard for the driveline subsystem
Trace It
Trace It is a hands on target practice toy, utilizing two motors and an infrared gun
Capturally
An EV3 robot that can capture videos and images using tracking and keyframes
Curtiss-Wright Co-op Projects and Designs
Mechanical designs and rapid prototyping at Curtiss-Wright
Final Drive Ratio Analysis
Performed analysis on UWFE 2026 vehicle to determine appropriate gear ratios
Differential Assembly and Spacers
Ensuring critical rotation and mounting of the custom limited slip differential
Chassis Front Enclosure Mount
Created a laser cut jig in order to accurately position the front enclosure mount within 2 millimeters laterally and longitudinally
Half Shaft Plungers
R&D Propulsion task for UWFE Driveline subteam
LED Dice
Fully custom made LED Dice PCB
TT Motor Dynamometer
I constructed a dynamometer out of TETRIX to measure the speed and torque characteristics of a TT motor