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Design and building of the prototype
IDRApegasus
Assistant Professor:
Ing. Massimiliana Carello (Mechanical and Aerodynamic Engineer Department)
Phd Student:
Dr. Andrea Airale (Mechanical and Aerodynamic Engineer Department)
The Team
60 Students Best Training
Team spirit
Innovation
Technical Demonstrator
3 Working Vehicle
The Shell Eco-marathon
200 Team
Rotterdam 2012
City circuit
5 tight corners
Energy saving
10 Laps
Max time: 39 minutes
Sx
0,28 m2
Front wheels covered
Carbon fiber monocoque Weight
33 kg
Rear steering system
Cx
0,093
Rear wheel
Design constraints
Rear wheel
Topology Optimization
Objective : minimun weight
Constraint : max displacement
Parameters : cyclic geometry
Video
Rear wheel
Analysis of results : how to use them
?
?
Rear wheel
High stress
No fatigue problems
Monocoque study
Monocoque
Front nose
Tail Cover
Targets
Low weight
Strength and structural stiffness
Safety
Carbon Fiber: T800 + Dynanotex
Honeycomb
Monocoque study
• Mesh 2D
• Tsai-Wu theory
• Study of the lamination of each surface
• Using honeycomb sandwich
• Layer orientation
• 5,5 kg
Monocoque study
Max displacement 2,5 mm
First test : torsional stiffness
Monocoque study
Max ply failure 0,59
First test : torsional stiffness
Monocoque study
Second test : entrance
Max displacement 1,5 mm
Monocoque study
Ply failure max 0,67
Second test : entrance
Monocoque study
Third test : exit
Max displacement
1 mm
Monocoque study
Third test : exit
Ply failure max 0,3
Monocoque Manifacturing
Milling model Vacuum to eliminate air Hand lay up
Final mold
Lamination
Setup mold Hand lay up carbon fiber Vacuum
Final body after extraction
Assembling
Bonding structural
parts
Final structure
Structural mass : 6,5 kg
Results
Vehicle characteristics
Strength
Mechanical reliability
Consumption : 337 km/kWh - 3023 km with the energy equivalent of one liter of gasoline
Light
Energy Efficient
Research Group Activity
Innovative Electric and Hybrid Vehicles
Dr. Andrea Airale, Phd in Mechanical Engineering (Team Leader and co-funder H2politO)
Ing. Massimiliana Carello, Assistant Professor Mechanical Department of Politecnico di Torino (Faculty Advisor and co-founder H2politO)
Dr. Alessandro Ferraris, M.Sc. in Mechanical Engineering (Project Manager and Technical Coordinator H2politO)
Research on Composites
CHEMICAL RESISTANCE
CRASH
FATIQUE
TRACTION
COMPRESSION
FLEXION
UV RESITANCE
TESTING
Static FEM Simulation
Dynamic FEM Simulation
VIRTUAL ANALYSIS
Model Validation
Contacts
Ing. MASSIMILIANA CARELLO
Assistant Professor
Mobile: +39 333 6373119
Ing. ANDREA AIRALE
Phd Student
Mobile: +39 366 3441 224
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