IV - Final PDS Summary Table 4. 1 outlines the most important design specifications used to design the outboard suspension. Full list of design specifications can be found in Appendix A. Table 4.1: Important product design specifications necessary for a successful design. Design Criteria Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 5 2011 & 2012 parts interchangeable FSAE Team Back-up system in case of failure N/A N/A Customer defined Prototype 5 Centerlock nut retention with two threads exposed (FSAE rule) Driver Keep the wheel on the car On/Off On Driver’s Safety Nut cannot be removed in one step 4 Hub Weight FSAE Team Decrease weight Pounds 2lb Customer defined Prototype 4 Ease manufacturing FSAE Team/ Manufacturing Decrease complexity Machining time (min) 80 minutes Customer defined Prototype 3 Hub Cost FSAE Team Lower Cost Dollars ($) $200 Hub Customer defined Machine Shop invoice 2 Service Life FSAE Team/ Driver Ensure sufficient reliability Operating life (years) 5 year life Customer/ group FEA/Prototype
5 Suspension link connecting points FSAE Team Must provide same geometry as 2011 N/A N/A Customer defined Prototype 5 Must interface with 2012 wheels FSAE Team Must be able to mount 2012 wheel to the hub N/A N/A Customer defined Prototype 5 Drive axle FSAE Team Integration with existing equipment N/A N/A Customer defined Prototype 5 Floating Rotor FSAE Team Floating N/A N/A Customer defined Prototype 3 Hub/wheel assembly FSAE Team Easy to assemble Assembly time Hub: <50min Wheel: <1min Customer defined Prototype Cost Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 3 Hub Cost FSAE Team Lower cost Dollars ($) $200/Hub Customer Defined Machine Shop Invoice Production Quantity Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 4 Assembly Quantity FSAE Team Sufficient Part Quantity Quantity of assemblies 3 front and 3 rear assemblies Customer Defined Delivery Receipt Materials Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 4 Hub Material FSAE Team Must be steel ANSI Grade 4340 Steel or similar Customer Defined Prototype 4 Upright Material FSAE Team Must be aluminum ANSI Grade 6061-T6 Aluminum or similar Customer Defined Prototype Documentation Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 4 Full Engineering FSAE Team Project must be fully N/A N/A Customer Defined SolidWorks CAD files
Documentation documented 3 Installation Instructions Mechanic Full assembly instructions N/A N/A Customer Defined Word Document Rules and Regulations Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 5 Must adhere to all FSAE rules and regulations FSAE Rule Book Must pass tech inspection N/A N/A Customer Defined Prototype Legal (Patents, Product Liability) Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 4 Minimize product liability issues Design Team Avoid legal ramifications N/A Use practices to minimize catastrophic failure Design Team Prototype 4 No patent infringement Design Team Avoid legal ramifications N/A Design must be unique Design Team Patent Search Aesthetics Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 2 Aesthetically pleasing FSAE Team Must look well engineered N/A N/A Customer Defined Prototype Disposal Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 1 Recyclable Material FSAE Team Minimize Disposal Cost N/A N/A Customer Defined MSDS Testing Priority Requirements Primary Customer Goal Metric Target Target Basis Verification 5 Must complete testing sequence before first use FSAE Team Verify assembly integrity Hour 4 Design Team Complete Testing