Lecture is an example of the applied and industrially relevant type of teaching SHU is famous for
The concept is US in origin, the Formula SAE (Society of Automotive Engineers) being the original competition. Purpose is as described on the slide
Self explanatory
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
Self explanatory Most use a motorcycle engine Some add turbo or supercharging Safety is a key design requirement
Truly international
Truly international
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!
A screenshot of the analysis of the stresses on the space frame
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
Some early checking on whether the driver will fit in
More checking on the driver’s fit
He really does fit! Tested with the largest of the drivers Car in our automotive workshop Engine testing bays with dynamometers are adjacent
Self explanatory Check clearances etc
Front suspension arrangement showing the various linkages and the damper positioning
Rear suspension Drive shafts not fitted
Note the mandatory brake light Silver box is the fuel tank
Note the spray can of black paint
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
More detail Notice the racing slick tyres in the background
Steering rack and front end detail
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
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
Circuit diagram On the white board
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
As usual we use CAD to determine the actual shape
This is not a photo it is an impression of what the car could look like
Now painted – This is the 2008 car
Initial complete testing Note use of PC to tune the engine
2007 car during testing
Three purposes Firstly judging on the technical merits of the car Secondly safety related testing Thirdly judging on performance
Note the fuel tank in use
Must not tip over Must not leak fuel People in shot are members of last years SHU team
Must be able to lock all 4 wheels No ABS! Note the multinational sponsors
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