We make mistakes.
With a miscommunication / understanding of how a particular laser cutter programed their CNC input in the machine we ended up with a double size part. With tight deadlines and long leadtimes associated with this type of work we opted to have the re-make plasma cut to save time.
The second generation part is not as accurate and has been slightly welded incorrected we now have a snow-ball effect with the harness mounts not sitting in the designed location withing the chassis.
This actually has strict rules within the technical criteria of the FSAE competition and it had to be double / triple checked that our car would still be compliant. LUCKY the design had inplace a few backups for suck errors with multiple locations for the harness eye-bolts to mount, this accomodated for the new further back position in the chassis.
The part on the left is the marginall under-sized plasma cut part (fully tig welded up here) and on the right is the double size part that was incorrectly laser cut due to an error on our end. (the part on the right is only roughly welded together as a gimic to ourselves to show the error that was made)
Just a reminder to us to be extra cautious even in times when we are pushed to make the car ready on time rushing small things can create much more hassel.
Even the marginally uder-size plasma cut part means that it now sits 30mm further back in the chassis even though the difference from design size to manufactured part is minimal it can create a big impact.
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