Hubs & Uprights

I led the design, development, and assembly of the Hubs & Uprights system for the Columbia's Formula SAE vehicle in the academic year of 2022-2023.

During the 2022-2023 design cycle, the suspension system was looking to standardize the outboard hardware to commercially available components that would ensure the strength and reliability of the system. The readily available components were larger than what our team typically used, and this decision posed significant constraints on upright packaging. Therefore I had to design for close component placement with tight clearances in order to be able to integrate the suspension and brakes systems together within hubs and uprights.

Skills developed:

  • System and component design

  • Cross-system integration

  • Engineering drawings

  • System assembly

  • Project logistics

Software utilized:

  • SolidWorks (CAD, FEA, drawings)

Tools put to use:

  • 3D printers

  • Hand tools

Integration with the newly introduced suspension hardware often required close attention to detail to accommodate the placement and integration of the suspension, brakes, and hubs and uprights components.

Using SolidWorks' FEA tool package, I ran multiple Finite Element simulations on individual components and their assemblies to verify the structural integrity of the system when it is subjected to the highest expected loading conditions.

In order to outsource the manufacturing of the uprights, I created engineering drawings and worked on arranging logistics such as obtaining a quote from the manufacturer, getting it approved for purchase, and arranging shipping of the part to campus.

Following the delivery of the components, I performed a quality check on the part, assembled the hubs and uprights system together, and assisted the team with further suspension assembly.