Problem Statement based on the pre-existing design

01 Bending loads acting on the Main Hoop Bracing tube

In the event of a rollover, the metal brackets of the older design could transfer loads to the main hoop’s support tubes, compromising the main hoop’s function. Furthermore, it would not be rule-compliant.

02 Excessive vibration & compliance operation

Although the wing elements were stiff. the entire rear wing as whole would vibrate and displace during cornering & running.

03 Unnecessary weight

Although the potential to reduce weight is incentive enough, it’s high positioning impacts the CoG notably.

0.0 kg (84%) of weight savings

Weight of new mounting assembly: 720 g

Weight of old mounting assembly: 4.4 kg

Analysis & Design

In order to reliably & effectively improve the design of the new mounting system, the applicable loading scenarios & effective load at each element needed to be derived.

Modelling the system

The known forces & unit vectors were denoted in a 3D system, and the model/system was not further simplified. This was to ensure that the forces acting on each component of the system were effective captured, especially in the case of cornering as the system of forces would not be symmetric.

As shown below, the system contains more than 6 unknown component forces & moments (22 to be precise) which would make the system indeterminate if simply analyzed without taking to consideration the effect of deformation.

I decided instead to perform a multi-body analysis on ANSYS MECHANICAL by modelling contacts, joints & supports. The Carbon Fibre tubes below the wing & the main wing element were modelled as rigid bodies as it was assumed that deformation in these components will be minimal. Rodends were modelled as sphecial joitns at the bracket’s bolt connections as hinges.