hardware fea design-for-service

Rear wheel adapter

Asked everyone what annoyed them about the old one, then reproduced every complaint myself before believing it.

The problem

A load-bearing rear wheel adapter that was heavy, awkward to adjust, and could not be serviced without dismantling more of the car than the job warranted.

What I did

New to the team, started by asking other members what was wrong with the assembly and then reproducing their complaints rather than taking them on trust. Set 4 explicit objectives before drawing anything.

What happened

A 52% lighter assembly, serviceable with a hex key and manufacturable in the team's own shop, with a safety factor of 2 on the vertical load case in FEA.

What I learned

Checking cornering and braking was worth the time even though neither governed - the car travels slowly enough that the vertical case dominates, and knowing which case governs is what let the mass come out.