Problem
The previous e-ATV iteration suffered from high un-sprung mass, excessive camber variation during suspension travel, and insufficient durability of the wheel hubs and knuckles under off-road loading. The team needed redesigned components that were lighter, stronger, and optimized for competitive endurance performance.
Approach
I conducted a complete suspension geometry study using VSUSP and Lotus Shark to refine hard-point locations and improve dynamic behavior. Using CatiaV5 and load-path–based design methods, I iterated wheel hub and knuckle geometries and validated each iteration through static, fatigue, and nodal FEA in ANSYS. Manufacturing constraints and material distribution were integrated early to ensure feasibility, strength, and weight reduction.
Solution
I designed new wheel hubs with optimized PCD, revised load paths, and improved interfaces for the double-wishbone suspension and braking system. The steering knuckles were re-engineered using refined control-arm and tie-rod hard points, improving geometry and enabling significant weight savings. The final components balanced stiffness, durability, manufacturability, and ease of assembly, while integrating seamlessly with the overall suspension system.
Impact
Dynamic camber change was reduced by ~12%, anti-dive improved by 5%, and un-sprung mass significantly lowered with 0.45 kg (front) and 0.8 kg (rear) hub reductions, plus 0.5 kg (front) and 1.2 kg (rear) knuckle reductions. All components passed FEA validation with Safety Factor > 1.5, directly contributing to the vehicle’s strong performance at e-BAJA—6th in Suspension & Traction, 4th in Endurance, and 6th overall.