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Published byElian Bilbo Modified over 2 years ago

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Blue Sky Solar Roll Cage Design

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Back Roll Cage Final Design

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Specifications Volume = 1.1017e-003 m³ Mass = 8.648 kg (Back Cage) + 1.7681 kg (Front Cage) Total Mass= 10.4161 kg 4130 Steel Pipe Yield Strength ≈ 435 Mpa

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Testing 6*force of gravity*mass of car ≈ 15000N Apply 15000N force for the following scenarios: – Car flips over and immediately the canopy gets stuck sliding backwards – Car flips over and immediately the canopy gets caught sliding forwards – Car flips over

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Car Flips and Canopy gets Stuck Sliding Backwards Force applied is shown as a purple arrow Maximum von-Mises Stress 3.9192e8 Pascals Maximum occurs at weld point shown by red circle. This is less than the yield strength.

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Car Flips and Canopy gets Stuck Sliding Backwards Maximum Deflection 0.0027699 meters Maximum occurs at top where force is applied. (Red section in diagram )

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Car Flips and Canopy gets Stuck Sliding Forwards Force applied is shown as a purple arrow Maximum von-Mises Stress 3.9192e8 Pascals Maximum occurs at weld point shown by red circle. This is less than the yield strength.

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Car Flips and Canopy gets Stuck Sliding Forwards Maximum Deflection 0.0027699 meters Maximum occurs at top where force is applied. (Red section in diagram )

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Car Flips Over Force applied is shown as a purple arrow Maximum von-Mises Stress 2.3277e8 Pascals Maximums occur at weld point shown in red circle This is less than the yield strength.

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Car Flips Over Maximum Deflection 0.0015313 meters Maximum occurs on arms where force is applied. (Red section in diagram )

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Front Cage Force down on beam or pushing from the side has the same stress analysis. The maximum stress is: 3.886e8 Pascals The maximum deflection is: 0.0011642 meters Both are within the constraints and should survive the impact the car flipping over or receiving a front end collision

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Front Cage Stress Analysis

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Front Cage Deflection Analysis

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Results and Final Considerations All displacements and stress values are within acceptable ranges at 6 times the force of gravity Decapitation Factor – The bars in front of the driver should help to deflect the array if it is to move during driving.

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Roll Cage inside Canopy As can be seen the roll cage tightly hugs the canopy thereby providing the most space possible for the driver. This will keep the driver from coming into contact with the roll cage in the event of an accident.

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