Formula Student Race Car Research Articles

Response of safety belt webbing used for formula student race car in a frontal collision

A particularly important element for ensuring the passive safety of a vehicle is the seat belt. In automotive engineering, the study of this subassembly is given special attention, because it plays a key role among the multiple safety systems, active and passive, that currently equip a vehicle. The paper studies several ways in which belt webbing can be damaged during use and how these defects can influence the behavior of the webbing. For this purpose, using the Finite Element Method (FEM) based on a mechanical model that considers the vehicle-driver-seat belt assembly, the forces that appear in the seat belt in the event of a frontal collision are determined. Experimental determinations carried out in the laboratory by the authors provide the mechanical properties modified following the failures. By introducing these mechanical properties into the developed model, it will be determined how the safety belt webbing responds in the event of a collision with a wall. A comparison is made between the behavior of the “new state” belt and one with defects in order to estimate the damage that can be caused by the appearance of the defects considered in the work.

Performance analysis of electric motor for Formula Student Race car

Performance analysis of electric motor for Formula Student Race car

Design of SUPRA-SAE Student Version (A Review)

Abstract: The most important part of any vehicle is the Chassis. The chassis is the support system for all components in the vehicle. It is responsible for supporting all functional systems of a vehicle and accommodates the driver in the cockpit. Therefore, its design must sustain the weight of the components. Designing a chassis for driver’s safety is always been a concern, especially for a race car. In this report, a few techniques are mentioned on how to analyze a formula student race car chassis to ensure its structural stability for the driver’s safety

Wind tunnel testing of a Formula Student vehicle for checking CFD simulation trends

The aerodynamic performance analysis of Formula Student racecars has been mostly done by teams with CFD tools, for time and cost savings, that often lack proper validation. To address this, the FST Lisboa team performed a detailed wind tunnel (WT) test campaign, using a one-third scale model, under different configurations, including variable ride heights, bullhorn appendix, and rear wing flap settings, also replicated in CFD. The simulations used RANS with the SST k-omega turbulence model, with a 13.7 million polyhedral mesh for the test chamber region domain. Both experimental and numerical errors were estimated from the instrumentation and mesh convergence analysis, respectively. Comparisons were made between WT and CFD both in terms of local flow, using tufts for flow visualization, and global flow, using lift, drag, and pitching moment coefficients. Overall, the numerical streamlines agreed very well with the orientations of the tufts in experiments, but some discrepancies were found in regions of cross-flow and high-frequency unsteadiness, mainly caused by limitations of the visualization technique. The gamma transition model in CFD was abandoned as it could not replicate the WT observations. In terms of aerodynamic coefficients, a strong correlation was found between WT and CFD. The parametric studies revealed that the simulations captured the experimental sensitivity to each car setting parameter studied but the uncertainties did not enable a full quantitative evaluation of the aerodynamic performance. The drag reduction system significantly impacted the aerodynamic balance of the racecar, while the current bullhorn design proved to be ineffective. The ride height increase led to higher downforce, mostly due to the higher pitch angle of the vehicle, with negligible variation of the aerodynamic balance. This work validated the team CFD studies, building confidence in that trends estimated in numerical parametric studies are likely to be translated to the real prototype performance.

Double Optimization Design of the Formula Racing Car Frame Based on the Variable Density Method and the Joint Variable Method

In the Formula Student Racing Car, the frame is a fundamental component that supports the body. The frame’s anti-deformation ability will impact the four-wheel positioning parameters of the car, which subsequently affect the car’s stability. The quality of the frame directly determines the power and efficiency of the racing car, making the frame crucial to the overall race performance. Therefore, researching lightweight frame design is particularly important to enhance frame performance and reduce its total weight. In this paper, based on the variable density method, the global topology optimization of the frame is carried out to obtain the distribution of the frame material, realize the efficient utilization of the material, and improve the torsional stiffness of the frame. Compared with the previous local topology optimization, the global topology optimization involves a wider range, and the results are more accurate. Based on the adjoint variable method, the sensitivity analysis of the frame is carried out to obtain the influence level of each design variable. The size of the frame is optimized according to the variables with high influence levels. After optimization, the total mass of the frame is reduced by 12.8%; the performance in terms of maximum displacement and maximum stress is improved; and the lightweight design of the frame is realized as a whole.

Retracted: Retrospection of the Optimization Model for Designing the Power Train of a Formula Student Race Car

Retracted: Retrospection of the Optimization Model for Designing the Power Train of a Formula Student Race Car

Autonomous Electric Race Car Inverter Development: Revving up the future with resource efficient drive technology

As the electric drive finds its way progressively into important industry sectors like mobility, transportation, agriculture, production, and supporting services, it becomes increasingly important to have individually optimized technical solutions for the manifold applications. Therefore, a high number of engineers with interdisciplinary competencies will be needed soon to comply with the demand of the worldwide markets. A key component for an often-used variant of the electric drivetrain is the full-bridge inverter, which is subject to a wide spectrum of different requirements. In 2021, the University of Denver (DU), started a cooperation with the University of Applied Sciences Augsburg (UASA) to develop a full-bridge inverter for an autonomous, electrical Formula Student race car, using four permanent magnet synchronous machines as an all-wheel drive. To improve the performance of the race car, the inverter must be lightweight, package optimized, electromagnetic compatibility compliant, safe, and reliable when it distributes a maximum of 80 kW instantaneous power from the battery at a voltage between 420 V and 600 V individually to the four wheels. This article documents the inverter development process using silicon carbide MOSFET power modules, with the goal of using future results in the race car and the knowledge transfer for the education of engineering students. This transatlantic partnership between DU and UASA also serves as a success story for intercontinental collaborative development based on modern communication and decentralized development techniques.

Simulation and Discussion of Vehicle U-turn Trajectory based on Four-wheel Model with Weight Transfer

A Formula Student race car is an open-wheel race car designed and manufactured by university students, and it is a good engineering practice. The Formula Student race cars are always raced on small tracks comprised of different corners including S-turn and U-turns. Turning performance is one of the key criteria to judge whether the car has a good overall handling performance or not. Therefore, it is necessary to study the turning performance of vehicles. This paper will mainly focus on the U-turn trajectory of a vehicle when the effect of weight transfer is counted, and the difference between the four-wheel model and the two-wheel model. Acceleration and breaking during the cornering will not be discussed in this paper to simplify the research. In other words, this paper will mainly discuss the condition of steady-state U-turn. A more realistic trajectory compared with the trajectory obtained by using a two-wheel model will be generated in this paper.

A Multi-Disciplinary Approach for the Electrical and Thermal Characterization of Battery Packs—Case Study for an Electric Race Car

A novel, multi-disciplinary approach is presented where experiments, system simulation and Computational Fluid Dynamics are combined for the electrical and thermal characterization of an air-cooled battery pack. As a case study, a Formula Student race car is considered and the procedure proposed consists of three steps: (1) experimental characterization of the battery cells under several thermal conditions; (2) thermal and electrical modeling of the battery stack with system simulation; (3) three-dimensional, time-dependent Conjugate Heat Transfer simulation of the whole battery pack to investigate the cooling performance of the chosen design, and to access fundamental quantities of the batteries, such as state of charge, temperature and ohmic heating. Future improvements of the current work are discussed, including the extension to a liquid-cooled design, battery aging consideration and model integration into a full vehicle system model.

Design and Fabrication of Composite Monocoque Chassis for Formula Student Racing Car

This study uses a combination of analytical, simulation, and experimental methods in the design process of a sandwich-structured composite monocoque chassis. The analytical method, which determines the stiffness value of the composite, depends on the number of layers and the orientation of the fiber angle. The simulation method, which is based on the finite-element method, is used to validate the stiffness value. The experimental method involves a 3-point bending test used to verify the effectiveness of the design produced by analytical and simulation methods. After all model designs were validated through simulation and experimental methods, the next stage is fabrication. The stiffness and strength are achieved with variations, which have combined layup orientation angles of 0° and 45°. This can be applied to all panels, regardless of the number of layers. Based on the design results, the processes involved in fabricating the monocoque chassis begin with the manufacture of molds and the lay-up of carbon fiber. The process is continued by inserting the prototype into the oven, after which the final product then undergoes finishing to prepare it for use. The fabricated monocoque chassis has been used in 2 events in Japan’s annual Formula SAE student racing car competition.

ВЫПОЛНЕНИЕ ГЕНЕРАТИВНОГО ДИЗАЙНА И АДАПТАЦИЯ К ИЗГОТОВЛЕНИЮ ПОВОРОТНОГО КУЛАКА. ЧАСТЬ I

The paper describes the calculation of input parameters for static strength analysis or generative design of the steering knuckle of a Formula Student race car. The initial data were: overall and mounting dimensions of the rim and tire, hub and brake disk, the magnitude of the force acting on the contact patch of the wheel with the road, the magnitude of the sliding friction force between the brake disk and brake pads, the force acting on the tie rod attachment, the location coordinates ball joint mounts and brake caliper. During the calculations, bearings were selected and forces on the coordinate axes were calculated, which must be applied to the part to simulate work loads. The calculation was performed by static methods. As a result, six load cases were obtained, simulating work in right and left turns with oversteer and understeer, as well as work during braking with maximum negative acceleration. Also, a 3D model of the steering knuckle was built, which has excessive strength (factor of safety is higher than 6). Padding values of the unchangeable areas have been defined, that prevent the generative design algorithm from subtracting material from important structural features of the part. The offset values were verified using additional finite element calculations.

Optimizing Torque Delivery for an Energy-Limited Electric Race Car Using Model Predictive Control

This paper presents a torque controller for the energy optimization of the powertrain of an electric Formula Student race car. Limited battery capacity within electric race car designs requires energy management solutions to minimize lap time while simultaneously controlling and managing the overall energy consumption to finish the race. The energy-managing torque control algorithm developed in this work optimizes the finite onboard energy from the battery pack to reduce lap time and energy consumption when energy deficits occur. The longitudinal dynamics of the vehicle were represented by a linearized first-principles model and validated against a parameterized electric Formula Student race car model in commercial lap time simulation software. A Simulink-based model predictive controller (MPC) architecture was created to balance energy use requirements with optimum lap time. This controller was tested against a hardware-limited and torque-limited system in a constant torque request and a varying torque request scenario. The controller decreased the elapsed time to complete a 150 m straight-line acceleration by 11.4% over the torque-limited solution and 13.5% in a 150 m Formula Student manoeuvre.

Investigation of generative design for powder bed fusion technology in case of Formula Student race car components using Ti6Al4V alloy

In case of the racing car of the Formula Student competition, there was a need to use more modern solutions in the development of metallic parts. In the context of the joint research on the applicability of metal additive manufacturing, a methodology has been developed that will enable more efficient use of metallic parts in the future, from component selection across the generative design and 3D printing process steps to the validation of the results. As a further result of the research, we applied the new methodology to the 4 rocker components in the suspension of the racing car chassis, and as a result, we achieved a weight reduction of 40 % per component and three times higher load capacity. The built-in rocker's in-service testing and final approval took place on the ZalaZone proving ground.

Performance-Driven Engineering Design Approaches Based on Generative Design and Topology Optimization Tools: A Comparative Study

The advent of Additive Manufacturing (AM) is uncovering the limits of the current CAD systems and, at the same time, is highlighting the potentials of the Topology Optimization (TO) and Generative Design (GD) tools that had not been fully exploited until now. Differently from the traditional design approach in which designers occupy a predominant role in each stage of the design process, the introduction of such tools in the product development process pushes toward simulation-driven design approaches which imply a significant change in the role of the designer. To this end, the paper presents a comparison of two different design methods for Additive Manufacturing based on the adoption of TO and GD tools. The comparison aims to offer a reflection on the evolution of the traditional approach when TO and GD tools are used, and to highlight the potential and limitations of these optimization tools when adopted in an integrated manner with the CAD systems. Furthermore, this comparative study can be a useful and practical source for designers to identify the most appropriate approach to adopt based on their needs and project resources. The comparative study is carried out through the design study of a prototype of a rocker arm and a brake pedal for the Formula Student race car. Their results, compared in terms of mechanical performances, show that both TO and especially GD tools can be efficiently adopted early in a design process oriented to AM to redesign components to make them lighter and stronger.

Scope of Carbon Fibre-Reinforced Polymer Wheel Rims for Formula Student Racecars: A Finite Element Analytical approach

Wheel rims are vital components critical to the safety of an automobile. Conventional wheel rims have utilized monolithic materials like aluminium and magnesium alloys in replacement to heavier steel rims. To reduce the weight of the formula car, lightweight composite wheel rims with higher stiffness are explored in the current work. Composite wheel rims are still in their nascent stage for commercial automotive applications, although they are commonly seen more in motorsports. The factors like complex design, high cost, and difficulty in fabrication are some of the demerits of composite wheel rims. Formula Manipal racing has been building race cars for Formula India events for over 13 years, on which aluminium wheel rims were standardly fitted. In the current work, the design and finite element analysis of carbon fibre wheels rims were undertaken to replace the aluminium wheel rims after a thorough consideration of other potential materials also. The modelling was carried out on CATIA3DX®, and finite element analysis was carried out using the ANSYS COMPOSITE PREP/POST (ACP)® module for laminate stackup and structural analysis tools for mechanical response. From the studies, the carbon fibre rims reduced the weight significantly by 42% while improving the factor of safety by 41% as compared to the current aluminium wheel rims while thermally outperforming magnesium and titanium alloys.

Numerical analysis on space frame chassis of a formula student race car

The present work aims to design and perform the numerical analysis on the space frame chassis of a formula student race car using computer aided software tools by proposing a new chassis style that meets the standard rules of FSAE. The chassis style could be a distinctive one as a structural component to stiffen the weaker, open cockpit section that has not been done before in FSAE. The space frame chassis was modelled in CATIA, and the analysis was carried out using SOLIDWORKS software. For the proposed space frame chassis, the different load tests were conducted viz. Frontal Impact, Torsion test and side impact test. It was observed that the proposed space frame chassis design is a safe one for the driver. As many works are available in the same format, but as we observe that while designing the space frame, triangulations are provided to increase the strength of the space frame and to reduce the degree of freedom of the chassis to make it stiffer. The load paths are the main thing which we taken care of while designing the chassis so that with the minimum number of tubes only the design criteria was taken care and the rules and guidelines are complying.

Retrospection of the Optimization Model for Designing the Power Train of a Formula Student Race Car

This article describes the power train design specifics in Formula student race vehicles used in the famed SAE India championship. To facilitate the physical validation of the design of the power train system of a formula student race car category vehicle engine of 610 cc displacement bike engine (KTM 390 model), a detailed design has been proposed with an approach of easing manufacturing and assembly along with full-scale prototype manufacturing. Many procedures must be followed while selecting a power train, such as engine displacement, fuel type, cooling type, throttle actuation, and creating the gear system to obtain the needed power and torque under various loading situations. Keeping the rules in mind, a well-suited engine was selected for the race track and transmission train was selected which gives the maximum performance. Based on the requirement, a power train was designed with all considerations we need to follow. Aside from torque and power, we designed an air intake with fuel efficiency in mind. Wireless sensors and cloud computing were used to monitor transmission characteristics such as transmission temperature management and vibration. The current study describes the design of an air intake manifold with a maximum restrictor diameter of 20 mm.

Analysis of the Cooling Concept of the Braking System of a Formula Student Racing Car Using CFD Simulation and 1D Simulation

In order to guarantee the performant operation of the braking system of a racing car under high load an optimized thermal design of the braking system is an important factor. Especially in motorsports, a lot of braking energy is converted into heat due to short and intense braking events. Therefore, a suitable cooling concept is a crucial point to ensure a reliable thermal management of the braking system to dissipate the generated heat. In this work, the braking system of the formula student racing car of the UAS Esslingen is analysed using the racing car of the season 2019. A transient 1D simulation model of the heat balance of the braking system is created. For the determination of the heat transfer coefficients a steady 3D Conjugate Heat Transfer (CHT) simulation model is set up. The logging data of a real race are used for the validation of the presented model (s). The heat balance of the braking system, its entire heat flows as well as the time-dependent temperature evaluation of the brake disc are analysed and compared. The results of this analysis are used to create a cooling concept for the racing car’s braking system, to ensure an optimized braking performance over the entire race. Several different (geometrical) variants of the thermal design of the braking system are investigated using the above mentioned numerical models and the results are presented. Furthermore, the implementation of a cooling duct for the braking system is studied.

Generative design and analysis of a double-wishbone suspension assembly: a methodology for developing constraint oriented solutions for optimum material distribution

Purpose The purpose of this paper is to implement the generative design as an optimization technique to achieve a reasonable trade-off between weight and reliability for the control arm plate of a double-wishbone suspension assembly of a Formula Student race car. Design/methodology/approach The generative design methodology is applied to develop a low-weight design alternative to a standard control arm plate design. A static stress simulation and a fatigue life study are developed to assess the response of the plate against the loading criteria and to ensure that the plate sustains the theoretically determined number of loading cycles. Findings The approach implemented provides a justifiable outcome for a weight-factor of safety trade-off. In addition to optimal material distribution, the generative design methodology provides several design outcomes, for different materials and fabrication techniques. This enables the selection of the best possible outcome for several structural requirements. Research limitations/implications This technique can be used for applications with pre-defined constraints, such as packaging and loading, usually observed in load-bearing components developed in the automotive and aerospace sectors of the manufacturing industry. Practical implications Using this technique can provide an alternative design solution to long periods spent in the design phase, because of its ability to generate several possible outcomes in just a fraction of time. Originality/value The proposed research provides a means of developing optimized designs and provides techniques in which the design developed and chosen can be structurally analyzed.

Formula Student Race Car Chassis Design and Analysis

SAE (The Society of Automotive Engineers) tarafından düzenlenen resmi bir proje yarışması olan Formula Stu-dent, dünya çapında birçok üniversite öğrencilerinin kendi bilgi birikimlerini kullanarak belirlenen kurallara uygun bir şekilde Formula tipi bir yarış arabası tasarlamasını amaçlayarak, öğrencilerin otomotiv sahasındaki bilgilerini geliştirmelerine imkan tanımaktadır. Bu çalışmada SolidWorks 2018 programı ile Formula Student yarış aracının şasi sistemi tasarım kriterleri dikkate alınarak yeniden tasarlanmıştır. ANSYS 16.0 ve SolidWorks Simulation programları kullanarak şasi sisteminin mekanik zorlanmalara karşı olan dayanımlarını belirlemek için optimizas-yon çalışmaları yapılmıştır. Şasi tasarımı yapıldıktan sonra şasinin ön darbe analizi, arka darbe analizi, yan darbe analizi, ön torsiyonel rijitlik analizi ve arka torsiyonel rijitlik analizi yapılmıştır. Bu çalışmada Formula Student yarış aracında kullanılmak için tasarlanan şasinin, gerçekleştirilen analizler doğrultusunda, hedeflenen tasarım kriterleri ve rijitlik derecesine fazlasıyla sahip olduğu belirlenmiştir. Yapılan analizler neticesinde yarışma kuralları doğrultusunda, hedeflenen tasarım kriterleri daraltılarak daha hafif ve rijit tasarımlar elde edilmiştir. Bu çalışmada yeniden tasarlanan araç şasisi muadillerine göre bir nebze (%30) ağır olsa da, rijitlik ve ergonomik olması bakımın-dan oldukça üstündür.