Problem

As part of the Dynamics subteam on the Formula SAE Electric team at Berkeley, I was tasked with designing the wheel assembly on an accelerated timeline. Due to time constraints, the team decided to solely redesign the upright and not the wheel hubs or wheel.

The challenge was to design a lightweight rear and front upright that would reduce weight by 25% from the previous iteration of the car while incorporating adjustability and specs from dynamics simulations.

Solution

I designed both front and rear uprights entirely out of 6061-T6 Aluminum. Due to aggressive weight optimization, the rear upright weight was reduced by 25% (883 → 660 grams), while the front upright weight was reduced by 25% (998 → 745 grams). We incorporated adjustability in our design, allowing for entirely adjustable wheel camber up to an extra -1.5 degrees and unlimited positive camber.

To keep brake caliper stable under high temperatures, we used distorted-thread lock nuts on brake caliper mounting. Additionally, we incorporated cutouts in bearing holes for added functionality.

Impact

Rear Upright weight reduced ~25% from previous iteration of car (883 → 660 grams)
Front Upright weight reduced ~25% (998 → 745 grams)
Incorporates adjustability, wheel camber is entirely adjustable up to an extra -1.5 degrees, and unlimited positive camber

Lightweight Wheel Assembly Reduces Car Weight 25%