How It’s Made: Alfa Romeo 4C

Alfa Romeo released this footage of the assembly line that puts together their new 4C sport coupe. The chassis starts life as flat pieces of pre-impregnated carbon fiber fabric before being CNC cut to the correct shapes for assembly. Since carbon fiber doesn’t have the same strength in all directions (it’s non-isotropic), each layer of the carbon fiber fabric has to have a specific alignment. Once all of the layers are overlapped and compressed together, the piece will be customized to be strong enough to withstand the specific force loading of that area of the chassis. After all of the pieces of carbon fiber fabric are assembled, the chassis is wrapped in plastic vacuum bags and placed in an autoclave where it’s baked under pressure. All of these steps are taken to ensure there are no air bubbles in the resin that holds the carbon fibers as it cures. Expelling all of the air is the key to making strong carbon fiber that won’t shatter when loaded. The completed chassis then heads to the Maserati factory (Ferrari, Maserati and Alfa Romeo are all owned by the Fiat group) where the rest of the aluminum subframes, composite body panels and 240 hp 1.8 liter direct injection engine are installed.


Source: Axis of Oversteer on YouTube

The Astounding Athleticism of Quadcopters

Check out this TED Talk by Raffaello D’Andrea if you need another reason to think electric vehicles are cool. D’Andrea and his team have programmed quadcopters to perform amazing feats inside a zone where they use external camera feedback to locate themselves similar to GPS. Quadcopters are agile because they are inherently unstable. There are a bare minimum number of motors and propellers to influence the four degrees of freedom: roll, pitch, yaw and acceleration. A high resolution of control is afforded by the fact that electric motors are essentially perfect digital actuators fast enough to keep up with processors. The controller supplies a current to the motor which results in a precise amount of torque output almost instantaneously. That’s what makes these quadcopter tricks possible just like digital control over pulse width modulation (blinking really fast) and color in LED’s has ushered in a new era of 3D Projection Light Shows. Watch the video to see mind blowing acrobatics like holding a reverse pendulum, triple flips, gesture control, adapting to broken propellers and teams of quadcopters tethered together with a ball catching and throwing device dubiously named the Skynet:


If the power of mechatronic control algorithms can do that with quadcopters, think of what we can do with electric cars. Instead of four propellers on a quadcopter, picture the controllers managing four electric motors driving the wheels of a car. We can now hook a processor up to simultaneously read wheel slippage, accelerations in all directions, and yaw thousands of times a second. It can then apply both positive and negative torque to each individual wheel to make the chassis performance match the driver’s input in a huge array of conditions. Give that same processor access to active aerodynamic flaps or ground effect fans and we may be entering a new era of racing technology with electric cars. This is the kind of innovation that made the different propulsion modes on the Mercedes-Benz SLS AMG Electric Drive so mind blowing to Chris Harris when he got to drive it. The SLS E-Drive has individual drive motors for each wheel and may be the first real performance electric car to take advantage of these mechatronic control algorithms to manipulate chassis dynamics.

If you find any of this at all interesting, then you owe it to yourself to check out the DIY Drones open-source community and start tinkering!

Source: TED Talks on YouTube

2013 Isle of Man TT Zero

The podium for the 2013 Isle of Man TT Zero electric motorcycle time trial looks a lot like the 2012 podium. MotoCzysz took the top place with their E1PC and Mugen/Honda came in second with their revised Shinden Ni (the Japanese god of lightning). The Isle of Man TT YouTube channel released some on-board footage from both bikes that should dispel a lot of notions about electric vehicles being slow and not sounding very cool.

Here’s Michael Rutter on the MotoCzysz E1PC:

 

This is Isle of Man TT Master John McGuiness on the Mugen Shinden Ni:


Source: Isle of Man TT on YouTube

Porsche by Design – North Carolina Museum of Art

The North Carolina Museum of Art here in Raleigh, NC will be hosting an exhibit of historic Porsche cars from October 12, 2013 to January 20, 2014. They’ve released a series of videos on Vimeo to showcase the panel of experts, collectors, designers and curators that have come together to make this happen. The introduction talks about why automobiles should be considered “hollow rolling sculptures” and the signature Porsche shape that has remained constant in its entire lineage of cars:


Rolling Sculpture
from The North Carolina Museum of Art on Vimeo.
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