Shell Ecomarathon Car – Body

Overview

The main goal of this project is to manufacture the lightweight, aerodynamic body of the Penn State Eco-Marathon Urban Concept Car for competition in the 2022 Shell Eco-Marathon. A design from a previous semester was updated and manufactured.

Objectives

The objective of this project was to design and manufacture an aerodynamic vehicle that competes in the Shell Eco-Marathon competition.

Approach

– The team started by researching possible materials that could be used for the panels of the car
– An AHP matrix and Pugh Matrix were created so that we could weigh out our most important needs and specifications for the vehicle
– After meeting with Ryan, our sponsor, the team decided on using fiberglass due to its light weight and high strength
– Design changes were conducted on the front panel of the vehicle as well as the doors
– The first prototype was showcasing these design changes on the vehicle
– Other design changes were accomplished during the following weeks leading up to our beta prototype
– Testing was conducted on the CAD model using CFD analysis as well as FEA test and the results showed that changing the front panel created better efficiency when the car would be operating
– A beta prototype was done showing the tests conducted as well as panels of the vehicle being manufactured
– Finalizing the design and continuing manufacturing was the main goal leading up to the final prototype
– The Final prototype was demonstrated in the Learning Factory showing the manufacturing process

Outcomes

– The project demonstrated the aerodynamic efficiency of the updated body design via Computational Fluid Dynamics testing
– The project demonstrated the structural strength and durability of the body design via Finite Element Analysis on the door hinges and door handle
– The team manufactured nearly every panel of the vehicle body out of fiberglass, tested them for strength, and has provided detailed CAD models of each remaining panel for next semester to pick up where the project left off
– The team successfully conjoined several panels using additional fiberglass and epoxy, and demonstrated the capability and efficiency of this method for the continuation of the project next semester