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Sr. Project |
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Portal Box. What is it? |
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My senior project was to prove the concept of a portal box. The function of this box is to both raise the vehicle witout using a larger tire and to add another gear ratio to ease in racing conditions. Before funding was cut the plan was to attach this box to the existing independent suspended Mini Baja Competition car. However due to cost constraints on our team we instead chose to design it for a solid axle. Below are requirements for the portal box. |
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Quantitative Requrements
1) Weight of less than 30 lbs.
2) Minimum lift height of 3.5"
3) Two gear ratios, one between 1:2 and the other between 2:1
4) Withstand input torque of 50 ft*lbs.
5) Withstand forces of up to 1500 lbs vertically and horizonally and 1000 lbs laterally.
6) Attach to 4 bolt 2"x2" square bolt pattern
7) Monitor RPM's within 10 RPM.
Qualitative Requirements
1) Box must be sealed from the elements to prevent water and dirt entering the mechanism. |
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Testing was conducted for each of the above requirements. Most were simple pass or fail but the most challenging requirement was # 5. For this requirement we used a Universal Testing Machine. This machine could apply very precise loads and outut the total defection in the box. From this our team could determine that all deformation was either elasic or plastic. Through testing we could show that the box had little or no plastic deformation and in fact met all set requirements. |
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What's inside?
For internal views see Photos button. The portal box utilizes Gates belt and 25 and 40 tooth sprockets. |
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