2009 Florida Tech Formula TeamSummary and Plan Presentation

September 10, 2008

Team  Organization

Team Lead

Kyle Meier

Chassis

Keith Reihl

Kyle Meier

Suspension and Braking

Jeff Grubesich

Guido Carelli

Drivetrain

Mert Candarli

Joachim Agou

Joel Zahlan

Talal Almoayed

Driver Interface

Earle Jackson

Sebastien Griveau

Formula SAE Competition

Challenges students to design, build and compete small formula style race carsAssume the car is being made for a design firmVehicles need to be very high performanceCars are judged in static and dynamic eventsCars are expected to be designed and built with good engineering practice

Important Team Deadlines

Registration with FIT by September 12, 2008

Registration for FSAE Michigan begins October 6, 2008

Team members must be SAE Members in order to register for competition

Chassis Sub‐team

Clemson University Chassis DesignKeith ReihlKyle Meier

Chassis Sub‐team

Comply with all rules and specs for the chassis

Design for a chassis weight of 50 lbs.

Design for the minimum wheelbase of 60 in.

Obtain a torsionalrigidity greater than 3000 lb/degree

Chassis Sub‐team

Design concept started to be modeled in Solidworks

Cockpit template, motor, 95 percentile male and wheels modeled

Dimensions of cockpit, leg tunnel given by FSAE rules

Chassis Sub‐team Plan

•Chassis modeling will be completed by October 15, 2008•Prototype of chassis will be completed by October 26, 2008•Building of the chassis will commence on October 27, 2008•Rolling Chassis will be expected on December 1, 2008

Suspension Sub‐team

Cane Creek Shock Absorber

Jeff GrubesichGuido Carelli

Progress Summary

Engine size decided, weight and force calculations are viable

Opted for standard double A design

Push rod actuated coil‐overs

Variable dampers

Pictures from 2007 FIT REV car

Future PlansCreate Pro‐E model for suspension

Combine with chassis model

Static analysis on Ansys of full frame

Dynamic analysis on ADAMS

New Ansys analysis with dynamic loads

Build suspension arms

Purchase dampers

Install and perform 

extensive testing

Suspension Diagram

Brakes & Tires

Choose wheel sizeStandard disc brakesConsider weight and price

Goodyear Dry Tires Goodyear Wet Tires Dynalite Single FloaterCaliper

DrivetrainSub‐team

Clemson University Drive Train Assembly

Mert CandarliJacob AllenbaughJoachim AgouJoel ZahlanTalal Almoayed

Torsen T‐1 Traction Differential

The TORque SENsingT‐1 Differential is ideally suited for rear, center, and all‐wheel drive applications.Consists of internal gearing and washers to transfer power from the engine to the wheels

Torsen T-1 Differential

Torsen T‐1 Traction Differential

T‐1 can handle 5,200 N*m of sprocket (or ring gear) torque.

The Torsen differential is simply a torque multiplier that works through the use of friction generated by thrust forces from the internal gearing.

TBR or Torque Bias Ratio, represents the "locking effect" of the differential.

Indicated how much torque is sent to each wheel with more traction Torsen T-1 Differential

Engine Choices

Three options for the formula car

The smallest and lightest Honda CRf450x, one of the most popular motors in dirt bikes for the past 5 years.

The most powerful Yamaha F‐R6 or Honda600CBR, heavier than the rest 

ApriliaV‐Twin 550, very good power to weight ratio, but expensive and rare

We choose the 450cc engine due to its lightweight and ease of tuning

Turbocharging or supercharging of the motor is still undecided

Yamaha 600 Aprilia 550 Honda 450

HP 120 70 48.5

Weight 120 72 70

Yamaha R6

Engine Specs

599cc

4 cylinder

16 Valve

Compressio: 12:4:1

120Bhp

Fuel Injected

Weight‐120lb

Yamaha R6 Engine

Aprilla SXV 550Engine Specs

549cc V‐twin

4 Valves

12:1

Fuel Injection

70Bhp

Weight‐72lb

Aprilia SXV 550 Engine

Honda CRF450x

Engine Specs• 449cc• Single Cylinder• Compression: 

12:0:1• 4 Valve• Weight 70Ib• 48.5Bhp• 46.8Nm• Carborator

Honda CRF450x Engine

Garrett GT12

•Garrett GT12 has ranges of:

•Horsepower: 50‐150Hp

•Displacement: 0.4L‐1.2L

•More power potential, but decreased fuel economy

•Tuning will become more difficult

•May not be efficient for a one cylinder engine

Garrett GT12 Turbo Assembly

DrivetrainGantt Chart

Driver Interface Sub‐team

Earle Jackson

SebastienGriveau

Wilwood Steering Rack [6]

Overview of Progress

•Research top teams designs

•Reviewed the rulebook

• Scanned machine shop for useful parts

• Created a rough list of parts to buy/fabricate

Tilton Pedal Assembly

Design Plan

Communicate with previous teams about past problemsReuse as much as possible to keep costs downKeep everything lightweightMinimize cockpit clutterComply with all rules and regulations

Preliminary Thoughts

Steering components available on side‐mount carStock cluster for 600cc inexpensive and accurateMotec engine management available in the machine shopSeats, steering wheel, shifter can all be fabricatedEngine kill switch

What We’ll Need to Buy

Race gear (Helmet, Suit, Gloves, etc.)Safety harnessesPedals (If not available from side‐mount car)Other gauges

Racepak Digital Display

Driver Interface Gantt Chart 

Questions?