CVT guard
This project focused on designing and manufacturing a CVT guard for the Cornell Baja Racing vehicle. The guard serves as a critical protective component, shielding the continuously variable transmission (CVT) from external elements like dirt and water while also ensuring safety by containing potential flying debris from the CVT during operation. Another important aspect of the design was enabling sufficient air ventilation to prevent the CVT from overheating, making material selection crucial.
Design
Design Overview
-
Objective: Develop a CVT guard to protect the continuously variable transmission from external elements and ensure safety during operation, while allowing sufficient ventilation to prevent overheating.
Design Requirements
-
Fully enclose the CVT to comply with Baja SAE powertrain guarding rules.
-
Provide protection against dirt, water, and potential flying debris.
-
Enable efficient airflow to prevent overheating of the CVT.
-
Ensure the guard is easy to open and close for maintenance access.
Specifications
-
Materials:
-
Aluminum for the main frame due to its durability and lightweight properties.
-
Carbon fiber for finger protection to reduce weight while ensuring safety.
-
Rubber for gaskets to enhance water resistance.
-
Frogzskin and aluminum mesh for debris protection and ventilation.
-
-
Designed with tabs and screws for secure assembly and improved sealing.
-
Lightweight construction to minimize the impact on overall vehicle performance.
Constraints
-
Must comply with Baja SAE powertrain guidelines regarding materials and enclosure design.
-
Limited to materials and processes available through team resources and external manufacturing partners.
-
Must balance durability and weight to meet performance and safety standards.
More renders
Manufacturing
The design was first modeled using SolidWorks, and the CAD files were sent to FALSO, a facility equipped with laser cutting and welding capabilities.
Aluminum sheets were laser cut for the inner and outer guards, while separate tabs were welded for assembly. Additional components, including carbon fiber for finger protection, rubber for gaskets, and Frogzskin with aluminum mesh for ventilation and debris protection, were prepared and integrated.
Assembly involved joining the inner and outer guards, compressing the rubber gasket for a watertight seal, and carefully incorporating all components. After initial setbacks, such as improper alignment of parts, the manufacturing process was refined, resulting in a fully functional CVT guard that met all design specifications.
