Analysing a technology readiness assessment framework through the development of a composite prototype vehicle suspension system :case study the UJ solar car project

Abstract: A uniquely configured vehicle suspension system, manufactured primarily of lightweight composite materials, is required for the University of Johannesburg’s 2014 Solar Powered race vehicle. For this design to reach successful completion, an assessment framework has been introduced to analyse every phase of the development. The focus of this dissertation is on the design and development of a prototype composite vehicle suspension system and the framework implemented to control the research and development process. The National Aeronautics and Space Administration (NASA), as well as Departments of Defence and Energy in the United States of America, have established a technology assessment model known as a “Technology Readiness Assessment” (TRA) [1] [2] [3]. The purpose of this assessment model is to identify those elements and processes of technology development that are considered critical to ensuring the intended operation of the system is reached, and ultimately that the project is a success. The Technology Readiness Assessment (TRA) can be viewed as an expansion on the scientific method, with a hypothesis tested and communicated results then taken further to be implemented on a demonstration platform and final system [10]. The TRA assessment comprises of various technology readiness levels (TRL), which are an indication of the progress level or maturity of a technology element, with the TRL scale ranging from 1 (basic principles observed) through to 9 (the total system has been used successfully in project operations) [1]. Beginning with the lowest level of technology readiness (TRL 1), for this assessment the problem background has been summarised, and design requirements as well as parameters formulated based on both design goals and competitive platform safety regulations for a new vehicle suspension design. This was followed by a literature review focusing on suspension, steering and braking design theory as well as advanced composites. Once the relevant theory and summarised design requirements were in place, the design concepts were generated and finalised based on these requirements, which would allow for the eventual complete computer aided design (CAD) model of the system to be completed. This constitutes a TRL 2 level assessment, with the primary deliverable being a complete CAD model and the identification of critical technology elements or “at risk” design elements that require further investigation and validation prior to their respective inclusion in the final system. These “at risk” elements then formed the basis of the experimental programme. For the various composite components required in the lightweight suspension system, the TRL 3 assessment was modified to incorporate the development of manufacturing processes and procedures. In primarily making use of a resin infusion composite processing technique, an accurate and repeatable procedure was needed for component development and in order to create samples required for laboratory scale and relevant environmental testing...M.Ing. (Mechanical Engineering