ISU Formula SAE
From Wikipedia, the free encyclopedia
ISU Formula SAE is a team of Iowa State University students that work together to design a formula style racecar. During the design process the team does not limit their focus to creating a high performance car; the students also place an emphasis on minimizing costs and developing an innovative design. The team gives engineering students an opportunity to put their design and manufacturing knowledge to use and allows business students to practice their marketing skills. The team is divided into eight categories: aerodynamics/body, controls/brake system, chassis/ergonomics, electrical system, engine, final drive, suspension, and business/market operations. Each year, these component teams work together to design a new racecar to be raced in the Formula SAE competition. The competition is held in May at the Ford Proving Grounds in Romeo, Michigan.
Contents |
[edit] Component Teams
These component teams allow individuals to focus on one part of the formula car. Each year they are expected to redesign and improve their specific area through analysis and testing.
Aerodynamics/Body – The aerodynamics and body team is responsible for making the driver’s seat, front nose, side panels, and front and rear wings. The majority of the body is composed of carbon fiber. To create the panel shapes, the team first cuts large pieces of foam to use as a mold. After the dimensions have been cut into the foam, the team lays out approximately three layers of carbon fiber on top of the foam mold. Once the carbon fiber has cured, the body panels are removed from the mold and placed onto the car in order to test their fit. With the proper fit verified, the panels are then sent for painting.
Controls/Brake System – The controls and brake system team is responsible for designing the steering wheel, brake and gas pedals, and shifter. The team also considers how these parts will function with their corresponding components. The controls must be designed with consideration for both functionality and ergonomics because the driver needs to be able to easily operate all the controls throughout the fast-paced racing events.
Chassis/Ergonomics – The chassis and ergonomics team designs the car's frame and ensures the driver's comfort within it. The chassis is made with one inch diameter SAE 1020 drawn-over-mandrel steel tubing. To assemble the chassis, the steel tubing is cut with a bandsaw, then ground to smooth and contour the edges before tig welding. For the ergonomics' portion of the component team, the task includes creating a design that permits the driver to easily operate all the controls without feeling restricted. The chassis must also be designed so the driver fits properly within the vehicle’s safety cage. This team works closely with the suspension team to ensure proper suspension mounting locations.
Electrical System – The electrical team designs wire harnesses for the engine, brake lights, driver switches, and traction control. They are required to work closely with the engine team in order to link the engine to the computer. After the two have been linked, data acquisition software is used to determine the settings necessary for maximum performance. The electrical team also provides the means to control the basic functions such as the fuel pump, fan, etc.
Engine – The engine team focuses on the engine and its supporting components: intake, exhaust, cooling, fuel, and ignition. This includes designing and manufacturing the intake and exhaust systems. It also involves tuning a custom fuel injection system to optimize the engine’s performance for the custom manifolding and air-restricted application. Although the engine is purchased from Kawasaki, it still requires extensive tuning to optimize its power output and driveability for the car.
Final Drive – The final drive team is in charge of everything in between the engine output and the rear tires. This includes the axles, differential, mounts, and chain tensioning. They set the car up with its torsen limited slip differential and dual outboard disc brakes.
Suspension – The suspension team designs the fully independent front and rear suspension. This team is responsible for designing the geometry for suspension and steering and obtains data for damper choices. The suspension’s design is an unequal length, non parallel, dual wishbone setup with adjustable Ackermann steering. The design needs to handle up to 1.2G’s of force in the corners. They also design and manufacture a-arms, hubs, uprights, and sway bars.
Business/Market Operation – The business and market operation group handles more of the organizational, management, and promotional aspects of ISU Formula SAE. One of their main duties is to track the progress of the other component teams and make sure they are on schedule in the design/fabrication process. They run weekly meetings to give updates on the team’s status along with upcoming events. The market operations side organizes promotional events for the team to find new sponsors and to encourage new students to join the team.
[edit] SAE Formula Event Rules
To make sure all formula teams have an equal opportunity, numerous rules and regulations are put on the cars and their teams. These rules include body design parameters, chassis design parameters, structural requirements, required driver and cockpit equipment, powertrain parameters, vehicle identification requirements and general rules.[1] Visit the SAE International Formula Website to get a full listing of the rules. The ISU Formula team members have to be up to date on all the rules in their design area. Non-conformance with these rules could result in disqualification.
[edit] Judging Categories
| Static Events | Points | |
|---|---|---|
| Presentation | 75 | |
| Engineering Design | 150 | |
| Cost Analysis | 100 | |
| Dynamic Events | Points | |
| Acceleration | 75 | |
| Skid-Pad | 50 | |
| Autocross | 150 | |
| Fuel Economy | 50 | |
| Endurance | 350 | |
| Total: | 1,000 |
[edit] Fuel
ISU Formula SAE is one of just a few teams that use the alternative fuel ethanol for their formula car. The use of E85 ethanol fuel demonstrates that its performance can compete with that of straight gasoline. E85 ethanol is a mixture of fifteen percent gasoline and eighty-five percent ethanol. Ethanol is becoming more popular because of its environmental benefits and its domestic production.[2] Most ethanol is made from corn grown in the United States, therefore making the United States less dependent on other countries for fuel. Currently the United States uses three billion gallons of ethanol per year, but proposed legislation could increase that to more than five billion gallons per year.[3] ISU Formula SAE promotes the use of E85 and shows that E85 is just as successful as gasoline.
[edit] Shop
The ISU Formula SAE shop is located in the Nuclear Engineering building at Iowa State University. This is where the team designs and fabricates the car. The fabrication requires the use of numerous shop machines. The shop contains a manual mill, 2-axes CNC Mill, threading lathe, drill press, sheet metal brake and shear, horizontal and vertical band saws, tubing bender, metal grinder, engine dyno, plasma cutter, MIG and TIG welders and various hand and power tools. Although most of the car is fabricated in this shop, some complex components are sent out to be manufactured or purchased.
[edit] Budget
The team’s yearly budget is $50,000 in cash and $50,000 in donated parts, services, and materials. The cash is received from sponsor and university funding. Although the budget is a total of $100,000, the team tries to minimize the car costs in order to boost their cost analysis score. A component of the cost analysis score is the comparison of the cost of the ISU Formula Car to the cost of the other teams’ cars in the competition. Each year, the car production costs total about $25,000. The remaining budgeted $75,000 is used for functions such as shop upkeep, shop updates, replacement tools, and funding for additional small projects the team works on throughout the year.
[edit] Current Car
The 2006-2007 car is almost entirely a replica of the successful 2005-2006 car. New changes will include Motec® engine management with traction control, an aerodynamic package for better handling, use of National Instruments® data acquisition software for design, a revised control system with a steering wheel mounted dash, and a redesigned paddle system.
[edit] 2005-2006 Specifications
- Weight: 450 lbs
- Power: 85hp and 47ft-lbs torque
- Engine: Kawasaki ZX-6R 600cc motorcycle engine, 4-cylinder, 4-stroke, liquid-cooled student integrated and tuned fuel injection system, student engineered intake and exhaust systems
- Transmission: 6-speed sequential manual
- Final Drive: Student designed chain drive, equal length drive shafts, student built Zexel Torsion differential
- Tires: 13” Hoosier racing slicks
- Chassis: Student welded mild steel tubing (SAE 1020)
- Wheelbase: 66 inches
- Track Width: 49 inches
- Suspension: 4 wheel double wishbone Stratos El Jeffe coil-over shocks, inboard shock mounting (F1 style)
- Brakes: Dual front disc/dual outboard rear discs
- Controls: Adjustable aluminum gas and brake pedals, carbon fiber removable steering wheel, hand-operated clutch/shifter
[edit] Previous Cars
| Year | Name (#) | Place | Teams |
|---|---|---|---|
| 2005-2006 | Lucky Seven #15 | 7 | 120 |
| 2004-2005 | Shrek #138 | 18 | 140 |
| 2003-2004 | Aardy #32 | 63 | 140 |
| 2002-2003 | Lucky #43 | 22 | 125 |
| 2001-2002 | Homer #104 | 83 | 125 |
| 2000-2001 | Dick #41 | 39 | 123 |
| 1999-2000 | Al #72 | 55 | 104 |
| 1998-1999 | Little Red #15 | 72 | 100 |
| 1997-1998 | Big Red #20 | 63 | 94 |
| 1996-1997 | #43 | ? | ? |
