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Sheffield Hallam University Formula Student Virtual Lecture by  R Harris MSc, BEng, CEng, MIET
Lecture Objectives ,[object Object],[object Object],[object Object],[object Object]
What is Formula Student ? ,[object Object],Institution of Mechanical Engineers www.imeche.org
How does it relate to Formula SAE* ? ,[object Object],[object Object],* Society of Automotive Engineers
Basic Rules ,[object Object],[object Object],[object Object]
Basic Design ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Typical Designs ,[object Object]
India – Delhi College of Engineering,
Canada – University of Toronto
Sheffield Hallam’s  Formula Student car
Key Design Decisions Needed ,[object Object],[object Object],[object Object],[object Object]
Design Constraints ,[object Object],[object Object],[object Object],[object Object],[object Object]
Analysis of Spaceframe Design
Solid Model of Baseline Chassis
Driver Size Relative to Chassis
Does the Rollbar Meet the specificatioin?
Check with a Real Person
Suspension ,[object Object],[object Object],[object Object],[object Object],[object Object]
Front Suspension and Steering An initial Proposal
Front Suspension As implemented
Rear Suspension
Rear Suspension
Complete Chassis
Engine and Transmission ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Decisions Made ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Issues to Resolve ,[object Object],[object Object],[object Object]
Dynamometer Engine Testing
Engine in Frame
Front Suspension and Steering
SHU Racing Team ,[object Object],[object Object],[object Object]
SHU RACING 2007 PETROL TANK MATTHEW ROSS
MY PROFILE ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
FUEL PUMP ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
PROBLEMS WITH OLD TANK ,[object Object],[object Object],[object Object],[object Object]
 
 
[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object]
MIG WELDS ON NEW PETROL TANK
5 LITRE 4 LITRE NEW PETROL TANK OFFERS: 20%  WEIGHT REDUCTION INCREASED CAPACITY FROM 4 TO  5 LITRES
Initial Design for the Electrical System Circuit diagram
 
Body Work - Design Options
Bodywork designs and ideas
CAD drawings of body on frame
Profile Image of Car
Actual bodywork
Track testing
Initial Testing
At the Event
Each team car goes though rigorous testing process ,[object Object],[object Object],[object Object],[object Object]
Engine testing
Scruitneering
The Noise Test
Tilt test
The brake test
Practice
The BIG event! ,[object Object],[object Object],[object Object]
Starting grid
Video of the Race
The finishing line
[object Object]
The team

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Other Subject Related Lecture Formula Student Sheffield Hallam University

Notas do Editor

  1. Lecture is an example of the applied and industrially relevant type of teaching SHU is famous for
  2. The concept is US in origin, the Formula SAE (Society of Automotive Engineers) being the original competition. Purpose is as described on the slide
  3. Self explanatory
  4. Lots of rules! Rules and regulations are real world constraints for an engineer and so working within them to maximise your results is a great skill to acquire Can only refine a car for one year after its initial entry so each time a new design is needed Most teams have one car running and another under development for next year – just like the real world No professional input apart from academics and academic facilities
  5. Self explanatory Most use a motorcycle engine Some add turbo or supercharging Safety is a key design requirement
  6. Truly international
  7. Truly international
  8. And Sheffield Hallams 2007 entry Notice the safety marshalls with fire extinguishers Last year one car (not Hallam’s) sprang an oil leak onto the hot exhaust and there was an instant fire – fire extinguishers are needed The driver must under the rules (and this is checked) be able to get out from being strapped in within 5 seconds. When the car caught fire it was more like 0.5 seconds!
  9. A screenshot of the analysis of the stresses on the space frame
  10. A 3D model of the space frame chassis The space near the rear is where the engine goes – it is an integral part of the chassis
  11. Some early checking on whether the driver will fit in
  12. More checking on the driver’s fit
  13. He really does fit! Tested with the largest of the drivers Car in our automotive workshop Engine testing bays with dynamometers are adjacent
  14. Self explanatory Check clearances etc
  15. Front suspension arrangement showing the various linkages and the damper positioning
  16. Rear suspension Drive shafts not fitted
  17. Note the mandatory brake light Silver box is the fuel tank
  18. Note the spray can of black paint
  19. We have engine testing bays with dynamometers to allow us to optimise the engine performance Significant work is needed generate more torque at low speeds, the event requires repeated acceleration from low speed Different type of use the engine was designed for Many teams have overheating problems due to the low speeds leading to inadequate cooling
  20. More detail Notice the racing slick tyres in the background
  21. Steering rack and front end detail
  22. This presentation was part of his final year project He was assessed on it As an engineer you need to be able to communicate and discuss your ideas
  23. Not yet been drawn up fully Fairly simple We have concentrate on simplicity and reliability rather than unnecessary complexity and sophistication This solution is appropriate to this vehicle, complexity will not bring any benefits
  24. Circuit diagram On the white board
  25. First part of the process is to do some careful thinking about the design This is an example of the thinking, in this case about the body shell
  26. As usual we use CAD to determine the actual shape
  27. This is not a photo it is an impression of what the car could look like
  28. Now painted – This is the 2008 car
  29. Initial complete testing Note use of PC to tune the engine
  30. 2007 car during testing
  31. Three purposes Firstly judging on the technical merits of the car Secondly safety related testing Thirdly judging on performance
  32. Note the fuel tank in use
  33. Must not tip over Must not leak fuel People in shot are members of last years SHU team
  34. Must be able to lock all 4 wheels No ABS! Note the multinational sponsors
  35. These are rules from the Formula Student handbook
  36. Hallam Car ready to go
  37. We made it – many don’t!