The Baja SAE rules mandate robust guarding around all rotating drivetrain components. My task was to design the safety guard for the high-speed coupler connecting the CVT to the gearbox. The primary challenge was to create a lightweight guard that could safely contain a catastrophic coupler or U-joint failure, all while being packaged in an extremely tight space and allowing for quick service access.
I began the design process by modeling the guard directly within the top-level vehicle assembly in SOLIDWORKS. This "top-down" approach was critical, as it allowed me to create a precise digital "envelope" around the CVT coupler and shafts. I ran interference detection throughout the process to ensure the guard maintained a safe, consistent clearance from all moving and vibrating components.
The entire component was designed from the ground up using SOLIDWORKS' sheet metal tools to ensure it could be fabricated efficiently and accurately. This involved:
Material Selection: Choosing a suitable gauge of steel to prioritize impact resistance and containment over weight savings, as safety was the paramount concern.
Defining Features: Specifying proper bend radii and reliefs to prevent cracking during the forming process.
Flat Pattern Generation: A key deliverable was the creation of a "flat pattern," which serves as the 2D DXF file sent directly to the waterjet or laser cutter. This step is the crucial link between the 3D model and the physical manufacturing process.
The final design resulted in a strong, form-fitting safety guard that successfully integrated into a highly constrained assembly. This project was a fantastic practical application of Design for Sheet Metal Manufacturing (DFSM). It taught me the entire workflow, from creating a 3D model around existing components to generating the 2D flat patterns that drive the fabrication process. It solidified my understanding of how to design simple, robust, and serviceable parts that are critical for vehicle safety and reliability.
Tools & Skills: SOLIDWORKS Sheet Metal, Flat Pattern Generation, Design for Sheet Metal Manufacturing (DFSM), Top-Down Assembly Design, Packaging, Interference Detection, Design for Serviceability