TEACHER'S GUIDE - F1 in Schools

TEACHER’S GUIDERace Season 2011 -2012

TEACHERS GUIDE Race Season 2011/2012WHY HAS THE CHALLENGE BEEN INTRODUCED?The F1 in Schools Challenge project aims to help change inaccurate perceptions of engineering, scienceand technology by creating an exciting learning environment for young people to develop informedviews about careers in these disciplines. For junior cycle students the competition offers a fun andexciting introduction to many of the skills they could choose to develop at Leaving Cert level, whilesenior cycle students will have an opportunity to practice those skills in an integrated and challengingmanner.CAD/CAM, CNC and VR systems are now common place in the manufacturing industry, which is why it isso important for the engineers and designers of the future to get to grips with such software packagesearly on. Students using CAD/CAM, CNC and VR software are able to design, test and manufacture theirown creations using a computer.Primarily, the F1 in Schools Challenge provides students with an ideal opportunity to experience the verylatest developments in manufacturing technology:CAD (Computer Aided Design) encourages students to think, explore and visualise their ideasin three-dimensions, using features such as complex curve modelling and surface rendering,alongside more traditional orthographic presentations. Packages such as Solid Works includemany features developed around real industrial applications.CAM (Computer Aided Manufacturing) packages, such as QuickCAM and UGSCAM, create anenvironment where CAD designs can be developed and prepared for automatedmanufacturing processes. Most CAM packages include a wizard based interface that allowstoolpaths to easily be plotted over complex 3D shapes.CFD (Computational Fluid Dynamics) packages, such as SolidWork’s COSMOSFloXpresssoftware allow computer models of car designs to be analysed, with regard to aerodynamicefficiency, then modified to further increase performance.CNC (Computer Numerically Controlled) Machines, such as the Denford MicroRouter, allowprocessed CAD drawings to be manufactured to high degrees of accuracy, fit and finish.Through direct experience of the technology and processes required to complete this project, it ishoped that more students will be encouraged to explore and/or pursue a career in our design,engineering, manufacturing and technology sectors.F1 in Schools Challenge Teachers Guide 3

TEACHERS GUIDE Race Season 2011/2012KEY STEPSThe key steps of the Challenge are below. Later in the document there is further detail on the stages.01 / PLANStudents develop a plan with initial ideas that explain why their team should be selected to have theircar manufactured. If the teams bid is accepted, proceed to stage 2.02 / DESIGNUsing 3D CAD software, the team designs a model Formula One car.03 / ANALYSEThe team should analyse their design for drag in a virtual reality wind tunnel.04 / MAKEUsing 3D CAM (Computer Aided Manufacturing) software, the team gets their design manufactured.05 / FINISHEach team kits their car out with your team colours, logo and high-quality finish.06 / RACERace your car!! Teams should provide supporting evidence of their design, a verbal presentation anddisplay stand.HOW ARE THE TEAMS ORGANISED?Each team must have between three and six students.Each school can enter as many teams as they wish for the Qualifying Stage (five page plan), butonly a maximum of two from each category (Junior or Senior Cycle) will progress through to theRegional Final stage.Each team member should be assigned one or more of the following roles: team manager,resources manager, manufacturing engineer, design engineer, graphic designer or marketingand communications manager.Each team must have one teacher coordinator.There are two levels of entry, Junior and Senior Cycle.HOW ARE TEAMS JUDGED?Qualifying StageTeam’s five page plans are judged to select approximately 100 teams to progress toManufacturing and Regional Final.Regional and National Final Stage teams are judged on a range of criteria including.Speed of carQuality of engineeringTeam verbal presentationFull portfolio along with the team’s original five page plan.The portfolio should include elements of the following: engineering, graphic design marketing,P.R and team website.See Rules and Regulations documents for further details and marking criteria, further details onjudging are available from Judges Score Cards, available to download from www.f1inschools.ieF1 in Schools Challenge Teachers Guide 4

TEACHERS GUIDE Race Season 2011/2012KEY DATES | RACE SEASON 2011/2012Sep - NovTeam registration and preparation of 5-page planNov 18 thDeadline for Qualifying round submissionsNov - JanDesign and analysis stageJanManufacture of carsJan - FebFinishing of cars and portfoliosMarchTeams on the grid for Regional Finals26 th April Race for chequered flag at National FinalsTEAM PRIZESThere will be separate awards for:The Overall Winner of the ChallengeThe 1st, 2nd and 3rd Winners in each CategoryThe Fastest CarBest Engineered CarBest NewcomerBest Use of ICTBest Team WebsiteBest Digital MarketingBest Team Marketing and SponsorshipPrizes will be awarded at National final level.The Grand Prize winners receive:Opportunity to represent Ireland at the F1 in Schools World Finals€2000 for the winning school…and much more!The International TripThe overall winning team from the 2011/2012 season are eligible to represent Ireland at the F1 inSchools Technology Challenge World Finals in Autumn 2012, at a location yet to be decided. There,they will compete against teams from over 34 countries across the globe for the prestigious BernieEcclestone Trophy.F1 in Schools Challenge Teachers Guide 5

TEACHERS GUIDE Race Season 2011/2012STAGE ONE – SCHOOL REGISTRATIONRegister your school for the F1 in Schools Challenge on our website (www.f1inschools.ie). Youcan keep updated by viewing our blog on www.f1inschools.ie/blog for all the details anddeadlines you need to know about the Challenge.To complete the school registration you must complete the Challenge Agreement, whichcommits you to entering at least one team to the competition. In the registration process youwill be asked for your personal email address, this is so we can forward you updated informationon the competition. You will also be asked to enter the team managers email address, this is sowe can also forward them information on the competition and that they can have their ownlogin to the website to register the remaining team members.Teams must be registered by 28 th October 2011. Registration is online at www.F1inSchools.ieSTAGE TWO – CAD SOFTWARECheck your school has access to a suitable 3D CAD software package. Note that the softwaremust be able to meet the design and presentation criteria outlined in the Rules and Regulations.Many schools have received Solid Works software through the T4 subjects (Design &Communications Graphics, Architectural Technology, Engineering Technology and Technology),this software is suitable for the competition.If your schools does not have access to 3D CAD software for the Challenge, worldwide partnersof F1 in Schools, SolidWorks, have kindly given us copies of their fantasticsoftware to give to schools who participate in the challenge. Details on howto obtain your free copy of Solid Works software from F1 in Schools is availableon the website (www.f1inschools.ie).If you are unsure if your software is suitable for the Challenge contact f1@ics.ieSTAGE THREE – INTRODUCING THE CHALLENGEThere are a number of ways that the Challenge may be implemented in schools. In some schoolsgroups of students get together and ask the teacher to allow them to register for thecompetition in other cases the teacher picks the students most interested. Organise anyinterested students into teams of 3-6, positively encouraging mixed gender groups.If the teacher wishes to include the whole class we would recommend that multiple teams of 3-6are formed in class and work on designs in their own teams. Each school may enter as manyteams as they wish for the Qualifying Stage, but a maximum of two teams from each category(Junior / Senior Cycle) will be allowed to progress through to the Regional Finals.Teachers can use the videos and presentation supplied on the www.F1inSchools.ie website tointroduce the initiative and stimulate interest amongst students. Attention should be brought tothe relevant Rules and Regulations document.F1 in Schools Challenge Teachers Guide 6

TEACHERS GUIDE Race Season 2011/2012STAGE FOUR: DESIGNING THE CAR USING CAD SOFTWAREWhat kind of car do we design?There will be two categories of car in this year’s F1 in Schools Challenge:D-Type Car: The body of the standard D-Type car is made from a single block of balsawood. Junior Cycle teams must produce the D-Type car.D-Type CarFormula One Car: The more complex Formula One car body must also be made froma single block of balsa wood, although the wings can be made froma separate piece of material. Senior Cycle teams must produce the FormulaOne car.If you have any doubts about which car you should produce, please don’t hesitateto ask the F1 in Schools team by emailing: f1@ics.ie.Formula One CarYour team must use 3D CAD (Computer Aided Design) software to produce your ideas and modelthem in 3D. Hand drawn sketches are allowed at Qualifying Stage.CAD software templates for Solid Works/Solid Edge and dimensions for the balsa wood blocks aredownloadable from the F1 in Schools website (www.f1inschools.ie). When designing your F1racing car, bear in mind that the extreme ends of the block must be left clear for attachment ofthe manufacturing jig fixtures.STAGE 5 - QUALIFYING STAGEDue to the increasing numbers entering the competition and a limited number of manufacturingslots that are available it has been necessary to introduce a Qualifying Stage.Teams develop a 5 page plan which is judged to select approximately 100 teams to progress toManufacturing and Regional Final stage. Entry to this Qualifying Stage will be open to all schoolsand entry is free.The Qualifying Stage will be judged on the submission of a 5 page plan, by 18th November 2011.Further details for this stage can be found in the Qualifying Stage section of the Rules andRegulations documents.The teams that score highest in the Qualifying Stage will proceed through to the Regional Finals.All schools will be notified by email if they have/have not succeeded in progressing through tothe Regional Final stage. There is a fee of €80 per team for those who qualify for the RegionalFinal stage .Each plan should give details of team members, show some areas of teams research, displayteams initial design ideas and show some elements of their portfolio e.g. timeline, brandingetc…Team’s ideas and plan should be original; however there are exemplar plans downloadable fromwww.F1inSchools.ieF1 in Schools Challenge Teachers Guide 7

TEACHERS GUIDE Race Season 2011/2012Plan –maximum 5 pages (A4)All team plans must be submitted by 5pm 18 th November 2011Plans should be submitted by email to f1@ics.ie or by post to:ICS, Crescent Hall, Mount Street Crescent, Dublin 2The plan should consist of the following:Introduction (1 page)Research (1 page)o A look at the different ideas behind making your car the Fastest.Design (1-2 pages)o Pencil sketch will suffice, but 3D CAD more advantageous (so long as it links withthe ideas of your design through your research!)Resources planning (1-2 pages)o Outline plan to include, for example: timeline, budget, marketing etc..Winning teams innovate!!Formula One is constantly innovating in all areas of the Formula One business i.e. design,research, marketing. Each team has the option of an additional 10% of their overall marks for theplan, for an innovative idea. For further breakdown of marks for the plan view the QualifyingStage section of Rules and Regulations document.STAGE 6 - ANALYSE / TESTTeams may also wish to evaluate a variety of car designs, or car parts, using computational fluiddynamics (CFD) software.Included in your copy of Solid Works is COSMOS, Solid Works design analysis software.COSMOSFloXpress can be used to quickly analyze the Race Car Block part which is used in theRace Car Assembly. COSMOSFloXpress is a fluid dynamics application that calculates how fluid,(air or water) flows through a part or assembly model. Based on the calculated velocity field, youcan find problem areas in your design and improve them before you manufacture any parts.Details of how to obtain your **free** copy of Solid Works is available on the Resources page ofwww.F1inSchools.ie. Information on analysis of the car using SolidWorks is available by viewingthe SolidWorks F1 in Schools Tutorial Document available on the Resources page also.STAGE SEVEN - COMPUTER AIDED MANUFACTUREJAN**This step is completed by Make Centres (Colleges), if your school does not have access to a CNCrouter.When your students have completed their F1 racing car designs, the CAD drawings must beconverted into a CNC program. The CNC program is formatted using standard G and M codelanguage, used by CNC machines for plotting all their movement and cutting operations. CAMsoftware packages can be used to help automate this process.Many schools do not have the machinery to manufacture their own cars and for this purpose wehave teamed up with ‘Make Centres’, these are third level institutions who have agreed toparticipate and convert your teams designs to a CNC (Computer Numerical Control) program andmanufacture them using CAM (Computer Aided Manufacture).CAM software turns 3D designs into X, Y and Z coordinates, the tool path that controls themovements of the 3-Dimensional routing machines cutting tool. You may wish to contact thecollege whom we team you with if you wish to know more about the process. For example, willtwo separate CNC programmes need to be created – one for cutting the right side elevation ofthe F1 racing car, the second for cutting the left side elevation or will a ‘mirror’ command suffice.F1 in Schools Challenge Teachers Guide 8

TEACHERS GUIDE Race Season 2011/2012Manufacture will occur in an F1 in Schools approved Make Centre. You will receive notice from F1in Schools as to the location of your local Make Centre. If your school has a CNC machinery toproduce the car body, you can create your own car, but please let F1 in Schools know (f1@ics.ie).The 3D design files should be sent to a Make Centre electronically. F1 in Schools will send you ondetails of the person to contact in your relevant Make Centre to agree a time frame and file typefor design to be submitted to Make Centre. The CNC programmes produced by your MakeCentre will then be manufactured at the Make Centre. You may wish to book a visit to thecollege to see your designs being manufactured.If you intend to manufacture at your school, ensure your CNC machine meets the specificationrequired for construction. Check against items such as your machine working envelope,maximum spindle speeds, available router bits etc. by referring to both your original CADdrawings and the parameters defined in your CNC program.You will also need to purchase or construct a jig fixture, to hold the balsa wood block duringmachining. This will also make it much easier to configure any offsets, since the block can beaccurately replaced in the machine working area. Remember, you will probably have to load andrun a CNC program that machines one side of the car, then remove, revolve and replace theblock, before loading and running the second CNC program that machines the opposite side.Offset configuration is the MOST important time to be accurate, since any mistakes at this pointcould easily damage your material or equipment.STAGE EIGHT – FINISHINGFinishing should involve the following steps:JAN - MAR• Smooth down the balsa wood car body with rough / medium grade glass paper.• Finish using a fine grade glass paper.• Apply a coat of sanding sealer if available. Sand lightly when dry.• Apply several coats of paint (you may want to undercoat it first).• Decorate the car bodyOnly a limited amount of hand finishing of the body is allowed. Any major hand finishing mayresult in team disqualification. This will be at the Judge’s discretion. We expect all F1 racing carsto be completed with a high quality paint finish, including the application of any graphics,sponsorship or liveries, where deemed appropriate.STAGE NINE – PRODUCTION OF MODEL CARJAN - MARThe plastic tubing enclosed in your F1 Car Kit, can be cut and installed as the bearing for thewheels.*Axles should be inserted.*Washers placed on axles.*Add the wide wheels to the back axle. Add the narrow wheels on the front axles.*Mark out positions for the screw eyes, making sure they are centred. Screw into position.Your model should be then ready to run!*Note: A school may manufacture their own wheels/axles as long as they fit the set specification,as per Rules and Regulations document. Ball bearings are permitted and wheel material isunrestricted.F1 in Schools Challenge Teachers Guide 9

TEACHERS GUIDE Race Season 2011/2012STAGE TEN – RACING EVENTSMARCH AND APRILThe top teams will proceed through from the Qualifying Stage to the Regional Final stage. Youwill be informed by email when and where your Regional Final will take place, together with anyspecific requirements and arrangements for the event. Please ensure you confirm your intentionto attend the Final at least 2 weeks before the date of the final.Information regarding any race event will also be posted on the F1 in Schools website(www.f1inschools.ie) and emailed to the registered email address.REGIONAL AND NATIONAL FINAL STAGEFor teams successfully getting through to the Regional final stage the following should becompiled:At regional and national final stages each team must produce a design portfolio whichdetails the design, production and evaluation process including, initial ideas, designdevelopment, manufacture and evidence of testing and evaluation. Max 20 pages (A3).At regional and national final stages each team must supply a 1 st or 3 rd angleorthographic projection and a graphic rendering of their final design, both producedusing a 3D CAD package.At regional and national final stages teams must prepare a verbal presentation on theirwork about the design and development of their final F1 racing car design. 5 minuteswill be allocated to present to the judges.Time TrialsQuality of ManufactureUse of CAD & ICTReaction TimesSpecification of CarDesign PortfolioTeam Design for F1 CarVerbal PresentationF1 in Schools Challenge Teachers Guide 10

TEACHERS GUIDE Race Season 2011/2012EDUCATIONAL CONTENTThe F1 in Schools Technology Challenge is specifically aimed at secondary level schools.The Challenge offers the perfect opportunity for teachers and students to explore the world ofCAD/CAM/CNC and allows students to experience the entire design process from beginning toend.HOW TO OBTAIN SOFTWARE, HARDWARE AND CONSUMABLESIf you would like to purchase any equipment for the challenge please contact:Sureweld Educational Division, Fonthill, Lucan, Co. DublinTel: 01 6266 242Or contact T4 (Technology Subjects Support Service) for a list of approved equipmentTel: 091 745 650Details on how to obtain your free copy of Solid Works software from F1 in Schools is availableon the website (www.f1inschools.ie).MANUFACTURING CENTRESTeams will be paired with a Manufacturing Centre (3rd level institution) by F1 in Schools, if you donot have facilities in your school.ENQUIRIES AND QUESTIONSAll questions and queries about the F1 in Schools Technology Challenge should be e-mailed to: f1@ics.ieFor the very latest information, visit the F1 in Schools Technology Challenge Website(www.f1inschools.ie).F1 in Schools Challenge Teachers Guide 11

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