Project Management Plan

for

(Formula SAE Suspension)

Prepared by: Chevy Butman Gregory Benjamin Manny Garcia Nicholas Schiavone Phillip Blitz Team Name: Redline Revision #:1 Team #:11

Table of Contents
1. Overview

1.1. Project Purpose, Objectives, and Success Criteria 1.2. Project Deliverables 1.3. Assumptions, Dependencies, and Constraints

2. Project Organization
2.1. Project Organization Chart 2.2. External Interfaces, Stakehold Major Subcontraers andctors 2.3. Roles and Responsibilities

3. Project Management Planning

3.1. Start-Up Plans 3.2. Work Breakdown Structure 3.3. Scope of Work 3.4 Schedule (2 semesters) 3.5 Deliverables 3.6 Budgets (man-hours and materials $s)

4. Project Management Monitoring and Control Plans

4.1. Requirements Control Plan 4.2 Schedule Control Plan 4.3 Budget Control Plan 4.4 Communication, Tracking, and Reporting Plan 4.5 Risk Management Plan 4.6 Configuration Management Plan 4.7 Quality Assurance Plan 4.8 Process Improvement Plan
1. Overview 1.1. Project Purpose, Objectives, and Success Criteria Formula SAE is an international, collegiate, engineering competition that challenges teams of students to conceive, design, fabricate, develop and compete with small, open-wheel formula car. We will be developing the suspension system for the

upcoming car. This requires many aspects of engineering, including kinematics, vibrations, and machine design. Some of the Objectives include: Compete against other Universities from around the world and place well To better understand how the car reacts in dynamic conditions Maximizing performance of tires through tire data and kinematics (maximum lateral force into the tires) Minimizing unsprung mass for a faster reacting suspension Determining ride and roll rates of the suspension to better control weight transfer and vibrations Design and fabricate components of the suspension

1.2. Project Deliverables The end goal of this project will be a fully developed suspension system much like those used in previous SAE competitions. The design should provide optimum track performance allowing a minimum of 2 inches of usable wheel travel, and 1 inch minimum of rebound. In addition to meeting bare minimum requirements, the suspension must perform. Since the competition involves over a hundred competing teams, a suspension that allows for superior handling and delivers reliability will be key. The suspension system is to be designed using SolidWorks for modeling and additional software packages will be used to perform structural and kinematic analysis of the design. The designs considered are either a pushrod, pullrod or some variant of these systems. The benefits of each will determine which design is a better fit for the performance characteristics desired.

In order to build the vehicle the required parts will have to be purchased. The parts necessary, such as the control arm (or A-arm), the dampers and springs, the uprights, the tie rods that connect to the steering input, the bell-crank and hub will be chosen based on the quality of the part as well as the cost considerations of our budget. The budget should also reflect practical application, allowing the design to be produced or replicated without exorbitant expense. The chosen components and materials should reflect appropriate quality, longevity, and safety standards that any sanctioning body would require. The intent is to have a design chosen by the end of the semester, and to finally build the system for the 2013 car during the upcoming fall semester, for real-world testing and refinement. This semester will be focused on the design phase, the pros and cons of different ideas, and a design that is optimally suited for track conditions will be selected. The fabrication will unfold in the following semester making extensive use of the SAE garage on campus due to the teams extensive manufacturing abilities and experience. Once again, applicable safety measures will be taken to ensure components are of high quality and have a long service life.

1.3. Assumptions, Dependencies, and Constraints Most of the design involving a Formula SAE car revolves around the suspension. It should be the first thing designed and then components such as the frame are designed around it. That being said, there will still be packaging issues in which we may have to make changes to accommodate another system of the car, such as drivetrain. In a system like this, everything is a compromise in order to make all the systems work in such a confined space.

Most of the constraints are dependent on the rules supplied by Formula SAE. For instance, the suspension must be able to have one inch in each direction. The wheel base must be at least 60 inches with the front and rear tracks being no less than 75% different in length from each other. Other rules apply and can be found in [Ref 1]. 2. Project Organization

2.1. Project Organization Chart

2.2. External Interfaces, Stakeholders and Major Subcontractors

The main stakeholders in this project are the SAE club members, as the suspension design will be used in their competition car. In addition to that, the companies that sponsor the club are also stakeholders since they are providing the design team with funding. Local sponsors include the Society of Automotive Engineers and UCFs MMAE department. In addition, a host of other companies will be sponsoring the car, such as Lockheed Martin, Lucas Oil, Aerogas, MetTec, and others, listed in the reference section. In addition, Miller Bearings, as part of their sponsorship, will provide the design team with bearings for making the suspension. 2.3. Roles and Responsibilities a. b. c. d. e. Chevy Butman Program Manager Gregory Benjamin Operations Manager Phillip Blitz Tooling Engineer Emmanuel Garcia Process Engineer Nicholas Schiavone Design Engineer

3. Project Management Planning 3.1. Start-Up Plans The beginning of this project involves a significant amount of research. The basics of vehicle dynamics should be understood clearly by all team members. For this reason, the team is spending time researching vehicle dynamics through literature, as well as viewing information photos from previous years attempts at suspension design. At this phase, deciding on a software package to appropriately test suspension components is also crucial. The team is in the process of acquiring a premium vehicle dynamics software package that will be used to validate our designs. The next phase of the start-up process is the team deciding on a fundamental suspension design. This general design will be chosen from sketches, photos, and conversation where the pros and cons of each can be reviewed by the team. At this point, the team can begin working on 3.2. Work Breakdown Structure

Each task will have one team member who is assigned the task and will be lead on it. The lead of the task will be responsible for delivering on their individual responsibilities. The Program Manager will be in charge of dividing up tasks and making sure they get done. They will also be in charge of the final decisions on the project and having a clear view on what is needed to accomplish the task. The Operations Manager is in charge of Organization and making sure everything is done in a timely manner in order to complete the project. The Tooling Engineer is in charge of managing the manufacturing process of the project. He will determine how to make our components and divide up the components among team members to manufacture. The Process Engineer will figure out how accomplish our task more efficiently. The Design Engineer is charge of the design the components and making sure they are safe and up to the task of our application.

3.3. Scope of Work Task 1 Administration Preliminary meeting was conducted where team members are introduced, SAE Garage tour was held and objectives were discussed. 10 Hours per week minimum required, total 150 hours for this semester.

Weekly Meeting with Dr. Hewavitharana will be held Tuesdays at 7pm.

Organizational materials assigned (GroupMe, Dropbox, Facebook Group, Contact List, Schedules, Vehicle Dynamics Literature)

Technical Task 1: Conceptual Designs. The goal of this task is to create three conceptual designs of the suspension.

Technical Task 2: Kinematics. Using Optimum K software, provide points of where major components should be connected to gain the range of motion desired and to utilize the the tire the most we can.

Technical Task 3: A-Arm Design. Goal of this task is to design a lightweight, structurally compliant A Arm.

Technical Task 4: Damper/Spring. Goal of this task is to design a lightweight, structurally compliant Damper/Spring.

Technical Task 5: Push/Pull Rods. Goal of this task is to design a lightweight, structurally compliant Push/Pull Rod part.

Technical Task 6: Bell-Crank. Goal of this task is to design a lightweight, structurally compliant Bell-Crank

Technical Task 7: Steering Tie Rods. Goal of this task is to design a lightweight, structurally compliant Steering Tie Rod.

Technical Task 8: Uprights. Goal of this task is to design lightweight, structurally compliant Uprights.

Technical Task 9: Hub/Spindle. Goal of this task is to design a lightweight, structurally compliant Hub/Spindle.

Bill of Materials. Prepare a Bill of Materials for the SAE Suspension Design. This document shall include but is not limited to: A description of each item Cost, quantity, total Company/Store Name, and link (if ordered online)

3.4 Schedule (2 semesters) To begin this project, the Spring 2012 semester will be used for the design and analysis of the suspension system. All modeling and optimization can be done during this time to allow for the best choices in structural rigidity and longevity. The foundation of the suspension, which would be the mounting locations, would then be given to the SAE team. During the summer, the SAE team will be constructing the chassis for the car. This includes roll cage components, engine and driveline mounting, etc. When class resumes in Fall 2012, the construction of the suspension components can begin. Since the locations of the suspension components are pre-decided, team Redline can then begin fabricating and installing the suspension components. During the end of this semester, as well as the beginning of the Spring 2013 semester, the car should be operational for testing and tuning of the suspension to achieve optimal driving characteristics. Once this is complete, the car would only require small preperation for the SAE competition taking place in May 2013. 3.5 Deliverables Fully developed suspension system designed for optimum track performance and allowing

SAE rules

The assembly and individual parts of the suspension system will be designed and modeled using SolidWorks SolidWorks, along with additional computer-aided design software packages such as OptimumK will be used to perform structural and kinematic analysis of the design, before it can be implemented.

The designs considered are either a pushrod, pullrod or some variant of these systems using torsion bars.

In order to build the vehicle the required parts will have to be purchased. The parts and manufacturing of parts necessary, control arm (or A-arm) the dampers and springs uprights tie rods bell-crank and hub

The budget should also reflect practical application allowing the design to be produced or replicated without exorbitant expense. The chosen components, materials and manufacturing processes should reflect appropriate quality, longevity, and safety standards that any sanctioning body would require.

The intent is to have a design chosen by the end of the semester, and to finally build the suspension system for the 2013 Formula SAE Race Car during the upcoming fall semester. This semester will be focused on the design phase pros and cons of different ideas

The fabrication will unfold in the following semester making extensive use of the SAE garage on campus due to the teams manufacturing capabilities and experience.

3.6 Budgets (man-hours and materials $s) Based on previous years experience from SAE builds, an estimated budget can be predicted. Due to fabrication of components being in-house as well as the SAE team aquring multiple sponsorships, the suspension can be completed on a fairly conservative budget. Previous years suspension teams have set a budget of 1,750$ and achieved their goals for much less. The team plans to do multiple fundraising events to earn money as well as acquisition of new sponsorships to fill any voids between money earned, and money needed. With respect to man-hours for completion of the project, the SAE team meets twice a week on campus to work on the car and assemble components. Over the course of a semester, this allows for plenty of time for assembly of the requisite components for a suspension system. Once the design phase is complete, and the components have been designed, a more complete schedule of assembly can be developed. 4. Project Management Monitoring and Control Plans 4.1. Requirements Control Plan

The project requirements will be defined during the preliminary design phase of the project. Each necessary requirement of the individual tasks are defined and catalogued. These requirements will have to be met by the recipient of the task, then marked complete in the team Gantt chart. The requirements for design and manufacturing will be deemed completed upon approval by at least 2 team members. 4.2 Schedule Control Plan The schedule for the design and manufacturing will be planned on the Team RedLine Gantt Chart as well as on Google Calendar. The Team RedLine Gantt Chart will list out the scope of work and assign anticipated start and finish dates. The progress of each task will be updated regularly and maintained by all members of the team. The teams Google Calendar will have the scope of work and assigned deadlines for the schedule of tasks assigned for team viewing. 4.3 Budget Control Plan All procurement records will be stored and documented electronically and all hard copies of invoices and quotes will be stored in the procurement folder. An Expense Budget Control Plan will be created in Excel showing the amount available in balance, amount spent, amount expected to spend on future orders, monthly spending, and anticipated monthly spending. All orders will be placed using the Order form which contains description of item ordered, part number, company/store, price, quantity, total and link from website ordered from. 4.4 Communication, Tracking, and Reporting Plan Preliminary meeting was conducted were team members are introduced, SAE Garage tour was held and objectives were discussed. 10 Hours per week minimum required, total 150 hours for this semester. Making a grand total of 300 for the Senior Design schedule. Weekly Meeting with Dr. Hewavitharana will be held Tuesdays at 7pm. Organizational materials assigned (Google Document, GroupMe, Dropbox, Facebook

Group, Contact List, Schedules, Gantt Charts, Budget Control Plan, Team Calendar Vehicle Dynamics Literature). 4.5 Risk Management Plan One of the risks in this project is in the team running out of money for the design due to a comparatively limited budget. This risk can be mitigated by choosing a design that is cost-effective, as well as through fundraisers at Orlando Magic games on behalf of the club to gain more funding. The other main risk is the safety of the vehicle and its occupant on the track, and its a risk that has to be accepted in motor racing. To keep the driver safe, he shall be fitted with a helmet, fireproof suit, and the car will have a racing harness. In addition, the vehicles suspension system will be properly tested to handle the rigors of the track so as to minimize the risk of a suspension malfunction during the race, which could not only be dangerous to the driver but would also prevent the car from finishing the race, as ontrack repairs allowed are minimal. 4.6 Configuration Management Plan The majority of configurations will be made in the SAE shop however the dampers/spring will be used from prior suspension configurations. In the SAE shop, the following parts will be manufactured: A-Arms Push/Pull Rods Bell-Crank Steering Tie Rods Uprights Hub/Spindle

Each design configuration will have its own design folder in Dropbox. There is where all revisions will be stored. Modifications of the designs of configurations will be required to have revision numbers added in the filename once changes are made. All complete revisions must be saved in the Dropbox folder. If a revision is incomplete it must be stored in a folder marked In Progress for completion later on. This In Progress folder must be in that respective configurations design folder in Dropbox. Status of configuration items must be mentioned to team members via group meetings, or GroupMe regularly.

Upon completion of the design, manufacturing will begin. By this point all configurations are final modifications to manufactured parts should be kept to a minimum. Manufactured parts will be labeled and stored in the SAE garage. All individual parts will be assembled once adjacent parts are completed. Then quality tests will begin to ensure the theoretical expectations and concepts translates to real world applications. 4.7 Quality Assurance Plan Ensuring quality is a high priority for the project. Since safety for the driver and spectators is a major aspect, producing a quality system is crucial. Also, since a major portion of the event is based on endurance, long lasting components are a requirement. Utilization of appropriate software to model and test the suspension will allow for display of stress concentrations, potential flaws in the design, or any other weaknesses within the system. Once this is complete, choosing appropriate material components is the next step. Materials for the car will be chosen based on properties required for the component. An effort will be made to reduce the mass as much as possible. Calculations for fatigue, different stresses, impact, etc. will be factored in to choose a material that can serve the purpose for the component while minimizing weight. Frequent checks will be made to ensure that all the requirements of the house of quality are being met satisfactorily. After every component is manufactured, a detailed check will be performed to be sure that there are no imperfections or errors that will affect the cars performance or safety. 4.8 Process Improvement Plan The process improvement plan follows eight simple steps. There are Define Establish the overall objective and reasons for improvement; define the current and target state of the process. Ensure that the team responsible for ultimately implementing change is involved in this initial step. Communicate Communicate the desired end state and the rationale for change to all internal stakeholders (and external stakeholders as necessary). Ensure that there is broad understanding of the rationale and the benefits of change before you begin. Map measure and analyze the current performance. Plan

Identify and verify root causes of current failure. Generate and select solutions, and map a proposed new process.

Test Drive To the extent possible, engage in a test drive of the new process to see whether the envisioned efficiencies materialize. Identify additional improvements, refine, and prepare for roll-out. Implement Plan, execute and monitor the implementation. Evaluate Evaluate the result of the implementation and compare it to the target state defined earlier. Standardize Plan for further improvements of the process. If these rules are followed and well maintain this will lead to a well produced product.

Reference 1. http://knightsracing.cecs.ucf.edu/sponsor.html 2. http://students.sae.org/competitions/formulaseries/rules/2012fsaerules.pdf