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Sub Team : Suspension and Dynamics
Role : Suspension Project Manager 

The McMaster Solar Car Project is a student group based in McMaster University. We design, build and race a solar powered cruiser class car at the American Solar Car Challenge. 

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The American Solar Challenge (ASC) is a solar-powered car race that takes place in the United States. It is organized by the Innovators Educational Foundation (IEF), a non-profit organization that promotes STEM education and alternative energy. The race is open to universities, colleges, and non-profit organizations from around the world, and it is designed to promote the development and use of solar-powered vehicles.

The ASC typically takes place every two years and covers a distance of around 1,500 to 2,000 miles. The route changes with each race and has included cities such as Austin, Denver, Chicago, and Omaha. The race is divided into two classes: the Cruiser Class and the Formula Sun Grand Prix (FSGP) Class. 

It is considered to be one of the most challenging solar-powered car races in the world, as it requires teams to navigate through a variety of weather conditions, terrain, and traffic.

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The American Solar Challenge is a showcase of innovation, engineering, and teamwork. It promotes the development of solar-powered vehicles and encourages the use of alternative energy sources. It also helps to create awareness about the importance of sustainable transportation and the need to reduce dependence on fossil fuels.

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I joined the club in 2021 as a mechanical designer in the suspension team, I currently lead the rear suspension development team. I have taken on various projects and assisted others with theirs.

My main projects are listed below. 

Rear Suspension Development

Managing a team of 3 members in the design, testing, and manufacturing of the rear suspension of the vehicle.

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Braking System Design

This is the first project that I undertook in the club. I analyzed the braking requirements of the car with respect to the ASC regulations and selected the components accordingly.

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Suspension Load Analyzer - GUI

A tool with a graphic user interface that helps users analyze the loads on a Double Wishbone Suspension system for various Bump, Turning and Braking loads.

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Rear Rotor Design

A brake rotor, also known as a brake disc, is a component of a vehicle's braking system. Its purpose is to provide a surface for the brake pads to grip onto when the brakes are applied, thereby creating friction and slowing or stopping the vehicle.

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Suspension Control Arm Design

Control arms are critical components of a vehicle's suspension system, connecting the steering knuckle and the chassis while allowing for the movement of the wheels. They help maintain the proper geometry of the suspension, keeping the wheels aligned and stable, while also absorbing the shocks and vibrations from the road.

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Fastener Selector 

A tool that helps automate fastener selection and validation. The tool parses through all applicable fasteners in McMaster Carr and selects the best solution based on the input loads and physical constraints. 

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Dual Wishbone Suspension Load Analysis

Analyzed the loads acting on the suspension system as a result of the Bump, Turn, and braking loads. 
This was a crucial step toward the FEA testing and validation of control arms, rod ends, and upright/ steering knuckle. 

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Rod End Selection and Validation

Rod ends are the contact point between the upright and the control arms. This is one of the first points of failure in a suspension system. Thorough analysis of the system is required to ensure there isn't a failure.  

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