Our goals for the TCNJ SAE Baja Project, is for each subsystem to meet SAE standards and perform well amongst the other top vehicles at competition.
Other goals/challenges for the vehicle:
- Follow SAE Guidleines
- Integration of Subsystems
- Lightweight Design
- Fully Functional for Competition
- Aesthetically pleasing
Frame/Ergonomics
The goal for the frame and ergonomic section is to ensure all members and subsystems can safely and comfortably fit into the vehicle. This entails that all interactive subsystems are easily within the driver’s reach. Design alterations will be made to the original frame to conform to the rules set forth by SAE—effectively mounting all updated subsystems while reducing the total weight by 1-2%. As the Primary Business Manager, there is an overarching commitment to meeting all SAE requirements and developing a business plan that positions TCNJ MotorLions as the exclusive manufacturer of vehicles designed for an off-road race. This race will be organized for the SAE, with venues to house all supplies and manufacturability for increased production thoroughly researched.
Drivetrain
The primary goal regarding the drivetrain for the 2023-24 Mini Baja Competition year is to design, manufacture, and test a system that incorporates a two-speed transmission to improve overall vehicle performance with the new 14-hp Kohler engine. Research will be conducted into whether an AWD or 4WD system is best suited for the current application and how advancements in CVT selection and tuning will enhance torque and top speed in specific events. Additionally, new differential systems will be analyzed for their potential benefits in maximizing traction, reducing wait, and minimizing overall footprint. Revisions will be evaluated via the standardized SAE tests used to analyze the acceleration of the previous team’s vehicle and via theoretical calculations of the power-to-weight ratio.
Front Suspension
The primary objective regarding the front suspension for the 2023-24 Mini Baja vehicle is to design and manufacture a safe and effective front suspension system according to the 2024 Mini Baja Competition rules. This will be done by researching suspension geometry, travel, weight reduction, and mounting locations to improve upon previous designs in these areas. Various suspension geometries including the effects of shock mounting points and control arm design will be evaluated through simulation and vehicle testing to increase travel by 10%, reduce weight, and decrease turning radius. The design intends to achieve these goals in conjunction with new drivetrain and steering system improvements, while maintaining the capability of enduring the rigorous competition course.
Rear Suspension
The primary objective for the 2023-24 rear suspension is to design and manufacture a functional and safe rear suspension system to successfully compete in the 2024 SAE Mini Baja Competition. This will be accomplished by analyzing different suspension geometries and previous data for the purpose of reducing the weight while increasing overall efficiency. Changes will be evaluated by comparing the calculated weight to travel and the overall safety. Increased shock travel will be accomplished through the adjustment of linkages and the vertical placement for an increase of 10%. Lastly, the wheel carrier’s design and material will be redesigned to improve the overall manufacturability and reduce the cost of production. Post manufacturing the team will design a testing protocol for.
Steering
The 2023-24 Mini Baja steering system will strive to effectively and ergonomically control the vehicle while withstanding operational loads and impacts. The new design will integrate with all other subsystems to efficiently utilize the space in the front of the vehicle, and a redesigned wheel hub will be constructed to accommodate the suspension and steering systems. The original system weight will aim to be reduced by 10%, while significantly improving handling through a reduced steering ratio and optimized geometry. Geometry will be determined via analysis and testing with a focus on ideal Ackerman, toe, camber, caster angles, and steering stops. Driver ergonomics will be evaluated to determine final steering wheel position, and quick-release systems will be researched for improved modularity.
Braking
The primary goal regarding redeveloping the braking system for the 2023-24 Mini Baja Competition year is to maximize the vehicle’s braking performance following the 2024 rulebook. Research and calculations will be conducted to determine the best combination of brake system components to lock all wheels consistently, given R&D performed on the 2022 vehicle. Manufacturing and testing an improved pedal-master cylinder assembly and overall braking system will demonstrate the team’s ability to coordinate a multi-system design with exceptional standards. As the Secondary Business Manager, there is an overarching commitment to meeting all SAE requirements and developing a business plan that positions TCNJ MotorLions as the exclusive manufacturer of vehicles designed for an off-road race hosted by SAE.