BLOODHOUND SSC AMAD GEARBOX MOUNTING PLATE ASSEMBLY ABH

BLOODHOUND SSC AMAD GEARBOX MOUNTING PLATE ASSEMBLY ABH: E 0011 The following explains the AMAD gearbox mount plate assembly and some of the essential design decisions made in completing this part of the car. ENGINEERING ADVENTURE www. BLOODHOUNDSSC. com

AMAD GEARBOX INTRODUCTION/BACKGROUND : AMAD GEARBOX MOUNTING PLATE ASSEMBLY (Diagram explained) To Jet engine RH Chassis Rail mount position PTO Shaft ATSM control Valve. Bulkhead mount position Start Air in Exhaust Air out AMAD Gearbox (blue) LH chassis Rail mount position ENGINEERING ADVENTURE AC Generator Hydraulic Pump DC Generator www. BLOODHOUNDSSC. com

AMAD GEARBOX INTRODUCTION/BACKGROUND : WHAT IS AN AMAD GEARBOX? The AMAD (Air Mount Accessories Drive) gearbox is a piece of equipment Bloodhound are reusing from the Typhoon aircraft. It is a multifunction item and is essential in starting the jet engine and then running auxiliary systems (AC & DC generators and hydraulic pump) once the jet engine is running. AMAD GEAR BOX FUNCTIONALITY: - Starting the Jet Engine: When starting the jet engine a compressed air source is connected to the car at the ‘air start couple’ on the left hand side of the car. The compressed air is fed to the AMAD gearbox at the ATSM (the ATSM is essentially an air turbine). The compressed air rotates the turbine which in turn rotates the power output of the AMAD gearbox. The power output from the AMAD gearbox is connected to the jet engine via the PTO shaft. This spins the jet engine up to the correct start speed allowing the engine to be fired up. -Auxiliary systems power: Once the jet is running under its own power the jet engine rotates the PTO shaft which back drives the AMAD gearbox. When the AMAD gearbox is back driven by the PTO shaft the power is directed to the AC generator, Hydraulic Pump and DC generator which are mounted on the AMAD gearbox. All of these items are used in the car. ENGINEERING ADVENTURE www. BLOODHOUNDSSC. com

AMAD GEARBOX LOCATION & THE DESIGN PROBLEM AMAD GEARBOX AND MOUNTING PLATE LOCATION: The AMAD gearbox assembly has to be mounted circa half way down the length of the car, level with the front of the EJ 200 jet engine. It has to be here as this is where the PTO shaft engages with the Jet. THE AMAD GEARBOX MOUNTING DESIGN PROBLEM: To design a system allowing the AMAD gearbox assembly to be mounted in the car allowing full functionality of the AMAD gearbox to start the jet and run auxiliary systems. ABH – E 0011 ENGINEERING ADVENTURE www. BLOODHOUNDSSC. com

AMAD GEAR BOX MOUNTING PLATE DESIGN CONSTRAINTS: AMAD Gearbox mounting plate assembly design constraints: The AMAD gearbox mount plate assembly is used to mount the AMAD gearbox into the car in a predetermined location. The following are design constraints that effected the design of the assembly. • Compact Geometry - The plate assembly has to fit in the tight space available in the car and still allow as much access as possible to allow adjustment of the PTO shaft and over equipment on the car. The plate also has to mount to set hard points in the chassis that had already been designated for this purpose (these points couldn’t change as they were already in the structure of the lower chassis which had been completed. • Weight - The plate assembly has to be as light as possible • Strength - The plate assembly has to be strong/rigid enough to support the gearbox and ancillaries under the maximum acceleration and deceleration scenarios the car will exert. The plate assembly must also contain the gearbox and ancillaries in a crash case situation. • Design Flexibility - The AMAD plate needs to be adaptable to allow both gearbox configurations to be used (Bloodhound have 2–off AMAD gearbox’s a LH and RH version which are mirror opposites of each other). • Design Adjustability - The mounting plate design has to allow for lateral, vertical, horizontal and angular adjustment of the AMAD gearbox. This adjustment is essential to allow the gearbox and PTO shaft position to be tweaked to allow perfect alignment with the Jet engine. Unknowns: - No drawings were available from the MOD regarding the geometry of the AMAD gearbox. Although Bloodhound had the physical item from the MOD having no drawings had obvious major draw backs in coming to a design solution that would be guaranteed to interface with the gearbox first time. ENGINEERING ADVENTURE www. BLOODHOUNDSSC. com

AMAD GEAR BOX MOUNTING PLATE DESIGN SOLUTION: The following shows the final geometry for the AMAD mounting plate assembly and how the design constraints were met. LH Chassis Rail AMAD Gearbox is bolted to mount plate using a series of clevis’ AMAD Plate Chassis Rail Mounts (X 2) AMAD Gearbox Mounting plate The mount plate utilises the gearbox’s existing Turnbuckles PTO Shaft (connects to Jet engine) AMAD Plate Triangulation Frame Assembly ENGINEERING ADVENTURE RH Chassis Rail Triangulation Frame bulkhead mount point www. BLOODHOUNDSSC. com

AMAD GEAR BOX MOUNTING PLATE DESIGN SOLUTION: The following shows the final geometry for the AMAD mounting plate assembly and how the design constraints were met. Gearbox Clevis lugs interface with AMAD gearbox (i. e. Twice quantity of lugs on mount plate to be compatible with both LH and RH gearbox's) Skeletonised webbed design help keep weight to a minimum Geometry of plate roughly ‘I’ beam between main chassis rail mount points AMAD plate only pocketed on one side to aid manufacturability ENGINEERING ADVENTURE Removable clevis to allow clearance when swapping between RH and LH side AMAD gearbox in “clash” position www. BLOODHOUNDSSC. com

AMAD GEAR BOX MOUNTING PLATE DESIGN SOLUTIONS: Design solutions for constraints from page 5: • Compact Geometry - To ensure the AMAD mounting plate assembly was as compact as possible it was designed in 3 d CAD with careful consideration paid to critical structures in the car in its’ vicinity. The part was also designed working closely with stress department to ensure the optimum geometry was achieved while not compromising strength or leaving excessive material in the structure of the components. Material choice was also crucial. • Weight - Working closely with stress department allowed the optimum geometry to be achieved while not compromising strength or leaving excessive material. Material choice was also critical. Material choices of the main components in the assembly are as follows: COMPONENT MATERIAL REASON BH-E 0019 – AMAD MOUNTING PLATE ALUMINIUM - 7075 T 6 HIGH STRENGTH , LIGHTWEIGHT, MACHINABILITY, COMPATIBLE WITH BLOODHOUND SUPPLIER MACHINING CAPABILTY (SEE DATA SHEET) BH-E 0021 – AMAD PLATE CHASSIS MOUNT ALUMINIUM - 7075 T 6 HIGH STRENGTH , LIGHTWEIGHT, MACHINABILITY, COMPATIBLE WITH BLOODHOUND SUPPLIER MACHINING CAPABILTY (SEE DATA SHEET) BH-E 0035 – AMAD TRIANGULATION FRAME ASSEMBLY ALLOY STEEL 4130 D STRENGTH, WELDABILITY, EASE OF FABRICATION ENGINEERING ADVENTURE www. BLOODHOUNDSSC. com

AMAD GEAR BOX MOUNTING PLATE DESIGN SOLUTIONS: Design solutions for constraints from page 5 : Strength - The plate geometry in the high stressed areas (between the two chassis mount points) is roughly the geometry of an ‘I’ beam. This geometry maximised rigidity and strength while minimising weight. Design Flexibility - The AMAD gearbox mounting plate has a series of Clevis lugs on it. These allow it to utilise the existing mounting points on the AMAD and allow it to be mounted in the same way it would be in the Typhoon. The plate has twice the amount of lugs required, 1 set compatible with the LH AMAD gearbox the other with the RH AMAD gearbox. Design Adjustability - The AMAD plate mounting arrangement has been designed to allow shimming in all directions to account for misalignment in the final car assembly (adjustment directions indicated by red arrow). • Lateral adjustment = Shim at AMAD mount-gearbox clevis interface • Horizontal adjustment = Shim at Triangulation frame-mount plate interface and at chassis rail mount • Vertical adjustment = Shim at Triangulation frame-bulkhead interface and under chassis rail mount • Angular adjustment = Altering turnbuckle lengths Angular adjustment using existing turnbuckles Lateral adjustment at clevis interface Horizontal adjustment at Chassis rail mount and triangulation frame-mount plate interface Vertical adjustment under Chassis rail mount and at bulkhead interface Bulkhead interface ENGINEERING ADVENTURE www. BLOODHOUNDSSC. com

AMAD GEAR BOX MOUNTING PLATE DESIGN SOLUTIONS: Unknowns - To overcome the fact there were no drawings of the AMAD gearbox a combination of hand measuring and 3 D scanning techniques were used. The 3 D scan allowed a representative model of the gearbox to be put in the car model space. This meant the mounting plate could be designed around the gearbox. The scan output is shown below. Manufacture : - The main mount plate and the chassis rail brackets were machined on a 3 axis CNC milling machine. For one offs/low volume items is the most economical method. - The triangulation frame was made with a combination of hand machining and fabrication. Conclusion: Once all items were manufactured the AMAD frame mounting assembly could be assembled/adjusted and mounted into the car. The photos highlight the space constraints of this assembly. ENGINEERING ADVENTURE www. BLOODHOUNDSSC. com