Mark Kohler wrote: > > Because chassis design is very complex. It's not likely > that a small > > company with limited resources will get it right the first > (or second > > or > > third) time. A simple, straightforward metal frame is much easier to > > design, test, and fabricate. > > What if the work has been done several times, since 1994. > Also, a company that knows composites may do a better job at > chassis design than if that group tried the tradional metal > frame route.
Hi Mark, I apologize for joining this thread late - I'm way behind on keeping up with the list. I've seen lots of good responses. I see a few make-or-break issues. Lee is correct that chassis design is very complex. I don't know what kind of funding your company can throw at this, but understand the big guys throw millions at chassis analysis. Just the non-linear analysis packages and the training to use them are a huge investment in themselves, before you start throwing millions at a particular project. And then you still have to crunch lots of prototypes to verify. Also keep in mind that composites crunch differently from steel, so analysis may not help as much. Somehow I doubt this is the work you refer to that has been done several times since 1994. How much does your company know, for example, about how to design a seat for crash safety? Or where to place air bag sensors? You're talking about an extremely dense science here. Building a non-certified buggy or people-mover isn't in the same league. If you insist on all composite construction, I as a (admittedly over-informed) customer wouldn't go near it until its safety is proven in the real world. A steel tube chassis, however, is relatively simple to get right. Most race car builders could tell if you were on the right track just from looking at it. Development to meet FMVSS would take much less time. Rick Woodbury will tell you just how daunting FMVSS certification is. You _need_ to know exactly what it will cost ($10-15M?) and how much Engineering time it will take up front. You have a lot of research ahead of you just to get to that point. Another issue is sub-systems and components. I found when I was sketching out my three-wheeler design that all the stuff I was hoping to use from a donor car would make the finished vehicle too heavy. You will have to get creative to find components that are available, will remain available, and are truly suitable for your design. It's a big challenge. What this comes down to is that if your company wishes to be a manufacturer of cars sold to the general public, you had better make sure you can run with the big dogs or stay on the porch. The risks in such a venture are great. I hope you guys have the expertise to pull it off. Someone, somewhere, _has_ to get over the hurdles and get a good EV to the general market. Chris
