IPG tools application in the Formula Student competition using the ...

IPG tools application in the
Formula Student competition
using the example of

01 Formula Student
02 The cars
03 The team
04 Formula CarMaker
05 Suspension design with IPGKinematics
06 Vehicle optimisation with CarMaker
07 Results

Formula
The
Student.
Competition.

Formula
1981
1999
2006
Student Competition.
Formula Student History
Founding of Formula SAE by the Society of
Automotive Engineers (SAE) in the United States.
Founding of Formula Student England based on
the Formula SAE model.
First holding of Formula Student Germany
by the VDI.
International Flair
9 worldwide competitions.
Teams from all over the world.
Language of competition: English.

Formula
Student Competition
.
The Exercise
Design, construction and manufacturing of a single seater
Formula racing car for weekend racing drivers.
1 Time of realization: 1 year
2
3
Specified regulation
Budget: 25.000$ at a fictitious number of 1.000 each year

Formula
Student Competition.
Targets of the Formula Student Competition
Completion of studies through intensive practical experiences.
1
2
3
Construction and manufacturing under real budget
conditions.
Project management and independent financing.
Teamwork, motivation, staff and time management.

Formula
Skid-Pad
Acceleration
Autocross
Endurance/
Fuel Economy
Student Competition.
Dynamic Events
Eight with diameters of 15,25 m each,
driven twice.
Accelerating from standstill up to
75 m.
Ca. 800 m long handling course with
straights, hair pins and slalom
sections.
Reliability and speed over 22 km.
Judgement of fuel consumption after
the event.

Formula
Cost Event
Design Event
Presentation
Event
Student Competition.
Static Events
Judgement of the cost structure
of the production.
Presentation of the technical
concept.
Businessplan presentation in
front of potential investors.

Formula
Student Competition.
Static Events…
- Design Event (150 points)
- Cost Event (100 points)
- Presentation Event (75 points)
Dynamic Events…
- Acceleration (75 points)
- Skid Pad (50 points)
- Autocross (150 points)
- Endurance (350 points) and
Fuel Economy (50 points)
Total: 1000 points
The Competition in Points

The
cars.
KIT07 and KIT08.

The
Cars.
Spaceframe made of 15CdV6
Our first one: the KIT07
Wheelbase: 1600 mm, track width: 1210 mm
4 cylinder, Honda CBR 600 PC 35 engine
Pneumatic gear shifting automatization
0 to 100 km/h under 4 s
Power: 64 kW
Weigth: 260 kg

Complete harness
The
Cars.
This year: the KIT08
Wheelbase: 1600 mm, track width: 1200 mm
Variable intake
manifold
Bosch Motorsport ABS
Variable anti-roll bars
Power: 72 kW
Weight: 230 kg

The
Who
Team.
are
we?

The
Team.
The Team
01/2006: start of project with 50 members
Since 11/06: incorporated society
56 active members in 2008
Constant recruiting

The
Team.
What gives us the motivation, to sleep three hours in three days?
For us...
KA-RaceIng
offers...
And last but
not least...
... being an engineer is more than a job.
... teamwork is everything that matters.
... the practical application of studied
theory is important.
... the unique chance to attend a project
from the first concept until the finished
product.
... excellent contacts to industry and
research.
... a lot of fun!

The
Predevelopment
Construction
Drivetrain
Frame & Body
Engine
Suspension
Elektric & Elektronics
Ergonomics & Saftey
Team.
Organisational Form
Assembly
Marketing
Organization
Projekt Management
Time Management
Budgeting
Knowledge
Management

The
Requirement
based
construction
(Functionality)
Productionoriented
construction
(Time, Costs)
Team.
Construction and Manufacturing Targets
High efficiency in respect of the
given task.
Easy adjustability and assembly.
Reduced complexity.
Low weight.
High reliability.
Light, lighter and even lighter!
Low manufacturing costs.
Low production time.
Low expenditure of resources.

Top-Down construction
The
Team.
Milestones in Development
Suspension
kinematics
Ergonomics
(seat box)
Definition of
constructed space
Parallel development of
each assembly
Simulation and calculation
True-to-detail CAD-modell
(ca. 95% of the real car)
Validation of the virtual
prototype
Conduction of drawings for
manufacturing
Regular consulting and trouble shooting
Concept Develpoment
Validation
and
Implementaion

Formula
The
CarMaker.
IPG Support Programm f
or Formula Student.

Formula
CarMaker.
IPG’s Formula CarMaker Programm
Two free licences for CarMaker
and IPGKinematics each for
every registered team.
Latest version of CarMaker with
“Racing Driver” option.
Ready-made, realistic datasets.

Formula
CarMaker.
CarMaker for racing cars

Formula
CarMaker.
… and a comprehensive and competent support
Support team advices on
questions and problems.
Free attendance of Formula
CarMaker workshops.
Customised user guide for
Formula Student.

Suspension Design w
ith
IPGKinematics.
Kinematics, Elastokinematics, S
teering Kinematics.

IPGKinematics.
Parameterisation

IPGKinematics.
Parameterisation

IPGKinematics.
Parameterisation

Vehicle
with
Virtual
optimisation
CarMaker.
Test Driving.

Tire model
CarMaker.
Driver model
Parameterisation
Virtual Testrun
Vehicle model
Race track
Maneuver

CarMaker.
Parameterisation

Results.

Formula
CarMaker.
Advantages of Using IPGKinematics und CarMaker
Static Events
Easier calculation of vehicle
dynamics and loads.
Well arranged diagrams present
the performed calculations.
Animated movies for
businessplan presentation.
Dynamic Events
Virtual testing of the car even
before completion.
Opportunity to test many
different settings.
Saving of costs and time.

Hockenheim
Results.
Best Newcomer Award
Second strongest engine
9th place Endurance
10th place overall (of 53)
Successes in 2007
Fiorano
Best first year team
2cnd place Skid Pad
6th place Endurance
6th place overall (of 20)

Silverstone
Results.
Most efficient use of
Eletronics Award
Successes in
6th place at Design Report
(best German team)
7th place overall (of 103)
Hockenheim
2008
Highest score ever reached
by Ka-RaceIng
Third strongest engine
13th position overall (of 87)

Thankyouverymuchforyourinterest!
Engineered
Excitement.