UConn Formula SAE

UConn Formula SAE is a group of collegiate students who - over a year - design, build, and compete with a formula-style car. The UConn team is one of the highest-performing teams around the world, boasting a 4th overall finish at the international competition at the Michigan International Speedway, competing in a pool of 120 teams. Other notable accomplishments include 2nd overall at the Pittsburgh Shootout, 1st at the CART Autocross at Mohegan Sun, 5th in Autocross in Michigan, and 6th in Endurance in Michigan. 

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I joined the UConn Formula SAE team when I was a a freshman, working primarily within the suspension subsystem. 

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Electric Powertrain

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During my tenure as a suspension member, the idea of competing with an electric vehicle was thrown around and eventually pursued. The team chose to continue to produce an internal combustion vehicle, but also create the first iteration of a UConn FSAE electric vehicle. 

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As I had previously run for a position, I was approached by the president at the time and he recommended I run for EV Powertrain lead - the position at the forefront of the new vehicle. I was surprised by this, yet eventually understood, as he referenced my focus on detail and ability to document well as qualities needed to build a strong base for the future of the electric side of UConn Formula SAE. I considered his recommendation and decided to run. I won the election and began preparing. 

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In my preparations for the vehicle, I was a part of many - and a leader of some - meetings regarding the overall goals of the vehicle, and ideas people had. I believed the most important part of the process was that everyone involved was on the same page, with the same goals in mind. 

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Through research and communication with other teams, we began to realize a direction, though there was still much we didn't know. At the time, there were few members in the EV Powertrain system, and so we were spread thin. We often had meetings and moved through one project at a time, chipping away at our work, and slowly growing our knowledge base.

 

When the time came to design, I encouraged the team to follow the design process and principles I have come to live by - starting at the very basics of what and why, then figuring out how the part accomplishes those, and iterating until it does it as efficiently as possible (depending on that project's principal efficiency (cost, weight, time, etc.).

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Throughout the design process, the team consistently went back to our how and why. We went through many many iterations of design, using Ansys simulations each time to justify our changes. While Ansys static structural general simulation got us to what seemed like a proper design, we realized that due to the motion of the motor, a modal analysis was also needed. 

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After dozens of iterations, a design was finalized. The team selected stock material and created the parts in-house, something that had not been done before for a powertrain at UConn FSAE. Due to issues with the frame and extreme error between the model and the physical frame, changes were needed. Adjusted tabs and shims allowed for fitting the powertrain system, and many of these needed to be made in-house, sometimes the same day the issue was discovered. 

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I, along with the rest of the powertrain team, was able to create a functional system despite major constraints, setbacks, and knowledge limits. The car did not make it to competition due to battery issues, but it has since competed in more local competitions and is the basis for future designs. My time as electric powertrain lead was the biggest learning experience I have had during my time at UConn. 

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