Drivetrain Development 2003: Team UC Irvine Formula SAE

 

Goal: To research, design, and manufacture a reliable and simple drivetrain assembly for UC Irvine's Formula SAE racecar.

 

Specifications:

Reliabilty: must complete the endurance competition, hold up to drivetrain strains and stresses.
Simplicity: ease of manufacture and assembly, low part count.
Low weight: reduce rearward weight bias.
Low cost: affordability of part replacement by amatuer racer.
Packaging: occupy a small amount of space.
Safety: does not endanger driver and spectators.
Ease of maintenace: easy access to all components for disassembly, re-oiling, removal from vehicle.
 
 
 

 

 

Considerations (specs in depth):

Position of the center of the diff in relation to the center of the wheel.    
Easy assembly of all drive comps. Bolt access and removal. especially of pilow blocks  
Equal length half-shafts allows a more balanced transfer of torque. Can be done by using a longer stub axle on the right side of the diff or positioning the diff in the center of the wheels Main sprocket must align with the countershaft sprocket.
Accesssability to chain.    
Mounting of disc brake and caliper    
Rear shocks mounting    
Drivetrain loading: clutch dropping, hard acceleration runs, shifting can cause shock loading as well, and correct chain tensioning to limit amount of chain jerk on the drivetrain seen during shifting.    
consider amount of CV misalignment, degrees of operability.    
     
     
     
     
     
     
     

 

 

 

Parts List with criteria, est. cost, availabilty, resources:

Part
Criteria
Cost
Availabilty
Resources
  
Castle Nuts [2]          
Safety pins [2]          
Splined stub shafts to hub [2]          
Hubs (& studs set) [2]          
Tapered bearings and races for uprights[4]          
Bearing cups [2]          
Uprights [2]          
Bolts & lock nuts for CVs [24ea]          
Tripod CV bearings [4]          
Tripod CV housings/races [4]          
Tripod cover and boots [4]          
Circlips [4]          
CV grease          
Splined stub axles to diff [2] w/ CV adapters          
Pillow blocks [2]          
Pillow block mounts [2]          
Pillow block bolts & nuts [2ea]          
Bearings and races for pillow blocks [2?]          
Bearing retainers [2]          

Chain tensioners/tie rods/diff locators[2]

          
Rod ends [4]          
Tensioner mounts [4]          
Tensioner bolts & nuts [4ea]          
Differential (Quaife)          
           
           

 

 

Parts Diagram/Breakdown:

 

 

Exploded View Sketch: