Support Side Bracket

Designed a support side bracket for the powertrain team new 2023 CAD design updates.

Began with referencing the assembly for the support side puck and motor placement. The support side bracket would attach to these two parts to add additional support to the motor placing more stresses on this part and not on other sensitive more expensive parts such as the motor.

Deformation was to not exceed 0.003 inches and a minimum factor of safety was 1.5.

Applied all of the forces experienced due to fastener attachments as well as roller sliders. These roller slider were place respectively on where the bracket came in contact with the motor and the puck. Sliding forces would be experienced here since the part would come in contact with some friction with these components. On the fastener holes 1268 Newtons would be applied.

Created various cuts at first began by removing excess material on the left since only two arms would attach in the bottom to the chassis. Created one arm on the left to connect and reduced weight as much as possible since stresses were not as present there as in right side.

Bottom right of the part also had much room for material removal which I removed a good chunk of.

Used various h-adaptive curvature based mesh at maximum fine mesh. Ran FEA and realized that part could have more support in the bottom fastener attachments to the chassis. Lots of forces were experienced in the top right of the part where motor came in contact with the bracket.

My first design looked very unsupported along the chassis tab attachments.

Second design fixed much of these things by adding more support on the top side of the bracket. Bottom had the most material removed since there was not as much stress in that area.