| Newsletter 05/2015
may 2015
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Newsletter 05/2015
editorial >>
D
ear Ladies and Gentleman,
this season is special for us in every way. For the first time the team of joanneum racing graz consists of master students of Automotive Engineering of the U.A.S. FH JOANNEUM. After the change to the bologna system we are the ones who got the challenge to be the team and build a worthy successor of the ten jr-racecars that were made in the past. We began with the design and development already in 2014 and won the class 3 of FSAE Italy with a concept study. That made it possible to start the construction of the new car uncommonly early in respect to other years. But beacause of the FSAE rule changes and the realization of new ideas our departments had to face several new challenges. So we couldn’t feel bored during the winter either and got some grey hair during the construction period too. But as seen at the fabulous RollOut on the 24th of April 2015, everything worked out just as hoped and the jr15 is as great as imagined. Now we can say proudly that it became a worthy member of the weasel-family and will continue their legacy.
The jr13 and jr13evo set the bar very high. The 5th place in the world ranking we reached 2014 is the best result in our team’s history so far. But it’s still our goal to top this in the coming season, tough it won’t be easy. Therefor our next step is the testing period that also plays an important role in the preparation for the competitions. Another specialty of this year is the cooperation with the students of the following year groups. With that we were able to stretch the boarders of the project and guarantee a better exchange of knowledge. So here I want to thank them for their huge support they gave us during our manufacturing period! In the name of the whole team of joanneum racing graz I would like to thank all of our sponsors, manufacturers and suppliers who are supporting us during this season. Without their help we wouldn’t have been able to build this year’s race car on such a high level again. For you, dear reader, I wish a lot of fun browsing and reading through the following pages.
masthead Newsletter may 2015 >> Newsletter of joanneum racing graz from the FH JOANNEUM; may 2015 | Publisher>> joanneum racing graz represented by Marton Szabo-Kass, teamleader joanneum racing graz | Editors & Art directors>> Florian Born, Lisa Mayrhofer | Photo credits >> Lucas Kundigraber, Florian Born R.a.t.t.p.l. >> Lisa Mayrhofer | Address>> Alte Poststraße 149, 8020 Graz; E-Mail: office@joanneum-racing.at; Internet: www.joanneum-racing.at | Publication frequency>> 2 times a year Special thanks to>> FH JOANNEUM for funding
Marton Szabo-Kass teamleader jr15
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where‘s what >>
content editorial
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rollout
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department report
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season preview
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rollout >>
Newsletter 05/2015
Sponsored by chassis
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spec
hybrid-carbon fibre monocoque
®
crashbox crashelement and nose in one piece carbon fibre
rims 6 x 13 and 7 x 13 inch self-made, one piece carbonfibre rims
aerodynamics
CFD-optimised Front-, Rear- and Sidewings
Roll
Best Austrian team. Overall rank 4 at the FSAE in Michigan. Conclusion of the season 2014 with the 5th place of over 500 teams in the world rankings. Anyone who has seen this list will involuntarily ask how joanneum racing graz is going to beat this. The weasels are aiming high, but to achieve this they first need a car that can keep up with their plans. To design this, they had more time than usual during this season. Due to the change to the Bologna system in the study program Automotive Engineering at FH JOANNEUM they didn’t build a new car last season. Therefore, the weasels could start the design period during the © Lucas Kundigraber
| Newsletter 05/2015
sheet
engine
turbocharged 2-cylinder engine direct injection
wheels Continental C14 Slick (205 / 510 R13)
spec sheet >>
type monoposto conceived for Formula SAE 2015 dry weight 192 kg weight 199 kg wheelbase 1560 mm track width 1220 mm / 1180 mm (f/r) propulsion method sequentiell 4 speed gearbox electro-pneumatic actuation power transmission integrated differential clutch electro-pneumatic actuated multidisc clutch axle differential DREXLER limited slip differential engine displacement 595 ccm max engine speed 8.000 min-1 max output 69kW / 94PS max torque 125 Nm charging BorgWarner turbocharger and intercooling air-restrictor 20 mm in diameter CFK, regulation Formula SAE 2015 cockpit ergonomic carbon fibre seat & mulrifunctional steering wheel suspension double wishbone, pullrod actuated ÖHLINS spring-damper-units
Out
summer of 2014.
The result was a victory in class 3 at the FSI in Varano de Melegari. During winter the real fun began. From dawn to dusk, the Weasels sat in the garage and in front of their PCs and design programs in order to make the concept of jr14 reality. The birth of the jr15. How many hours of work are really gone ultimately in the new car even the Weasels themselves cannot answer. The term „countless“ seems to be accurate.On April 24, 2015, it was finally done. While some team members were still in the garage to put the last finishing touches on the jr15, a large part of joanneum
© Lucas Kundigraber
racing graz arrive at the Dom im Berg in Graz. That was the place where in the evening the great moment was about to happen and the jr15 to be unveiled in front of the watchful of sponsors and fans. Until this very moment a lot of work had to be done. Build up the bar. Technology, projector and sound set up. The live stream program so that weasel fans around the globe could witness the great moment. During the afternoon the prominence of the evening arrived. No, not the technicians, but their works. The jr07 and jr11 took place at the entrance of the Dom im Berg and receive the visitors allurement in black and red. A few hours later, the big star arrived. With united Weasel Power the jr15 was brought into the mountain and put onto his place of honor on the stage. After the last polish it was covered so that no one could catch a glimpse before the big moment. After all they didn’t want to ruin the surprise. At the rehearsal nervousness was all around. But everything went smoothly and not even an hour later, 7 o’clock to the minute, the mountain opened its doors and the guests poured in. Within minutes the room was filled with proud weasel relatives, sponsors and supporters. 8 o’clock: The hosts Benjamin Barteder and Sara Griesbacher took the stage, welcomed the guests of honor and said a few words of thanks to all who came. First the program director of engineering department Kurt Steiner was called on stage, followed by the management of FH JOANNEUM Karl Peter Pfeiffer and Günter Riegler. Thereafter, the Federal State Council of Research, Christopher Drexler came, and was soon replaced by Lena Haas of the öh joanneum and the Faculty Advisor of the weasels, Michael Trzesniowski. At last the team leaders, Marton Szabo-Kass and Matthias Zingerle, came on stage and thanked their colleagues for the great work of the past year. When finally the whole team had gathered on the stage, it was time. After a great video the team leaders took the cover that veiled the car. And then the moment came. Ladies and Gentlemen: The jr15! © Lucas Kundigraber
Newsletter 05/2015
department
report
The engine department also had a lot of work this year. Although the basic engine is the same, the periphery is completely different. Whether in the field of control, clutch, intake system, cooling, fuel and oil system or motor housing, all components were revised or completely redesigned. Once again weight reduction and performance improvement were most important to us, but the changed Formula Student regulations didn’t make it easy for us. It was therefore necessary to make profound changes to the approved design of the previous years. The result is a completely changed appearance of the entire unit. The first thing to see are the self-developed motor housing parts made of carbon fiber. They guarantee a huge weight advantage over the conventional versions of the already very light aluminum. Of course, our mascot the Weasel couldn’t be missing, that’s why they are integrated into the management structure during the manufacturing process. Due to the significant changes in the rules of the Formula Student Series, the concept
powertrain
© Lucas Kundigraber
of the charge air route had to be changed fundamentally since the throttle valve has to be installed after of the compressor of the turbo now. The proven turbocharging components are also used at the jr15 so the throttle valve and intercooler had to be adapted to the new stresses. The new intake system was equipped with a flowoptimized and also handcrafted carbon air restrictor. The oil tank is of the same material which is just like the cooling system a completely new development. The dynamic characteristics of the vehicle in operation were optimized by a clutch switch and a throttle valve actuator. The overall packaging of the engine produces a harmonious design that harmoniously integrated into the overall vehicle without compromises in the technical functionality. The upcoming testing phase will demonstrate how the creative ideas of young engineers in the design phase match with the physical findings of vehicle testing. Never stop pushing.
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Knowing the consumption of the device is very important, since there is no light generator at this vehicle. The alternator was inefficient and heavy. You also save fuel because the power no longer needs to be generated by the engine. The energy comes from LiFePo powerful batteries, which – thanks to high-end chargers from Graupner– can be recharged very quickly. Another big change took place on the steering wheel. The two-line LCD display was replaced by a 4.3“ color display. As space in the steering wheel is very limited, we had circuit boards factured, whereby there is only cable between the switch and board in the steering wheel. It
is therefore easy to disassemble and can be repaired quickly.
electrics
The electronics department was very busy in the last months. Some parts of the jr13 are used in the jr15, but there are also many changes. The previous analog fuse box, which supplies the individual components with power has been replaced by a digital power distribution box. This allows us to monitor the consumption of all electronic components accurately. The safety fuses are left off which has the advantage that the fuse doesn’t have to be replaced immediately if there‘s an error.
In addition, the shift actuator was revised and the launch control was vigorously programmed. The extensive functions of the vehicle control device can be tested quickly and easily now. We built a testing environment to perform software-in-the-loop tests, hardware-inthe-loop tests and bus simulations. Using this test environment, we are able to test and optimize the functions of the steering wheel quickly and easily. Our cable harness was not built in our own laboratory this year. For the first time the companies EPlan and Raytech supported us in the manufacture of the harness. The wiring harness has thus become the strongest in the history of joanneum racing graz. This season, we also use a Motorsport ABS by Bosch. As all drivers must be students and thus have no experience, this should achieve the optimum braking and relieve the driver. This can be perfectly adapted to the prevailing road conditions.
Core field of the department are the testing units during which the care car is moved. Everything from time management of the testing days to the reservation of the proving grounds is done be the twoman-crew. So they can ensure a efficient handling of the setup work. Due to the small time windows in the beginning of the season it is of very high importance to make up chronological setup plans to be able to adjust the race car in the best was possible. So it is possible to ensure that the jr15 can take advantage of its full potential and is able to bring in top positions during the competitions. Also the regular maintenance of the car is part
We started the season with a tire test, so we were able to gather data and decided to change the tire manufacturers. We were able to use the test data to re-interpret the kinematics, it differs fundamentally from the old one, because our aim was to exploit the tires as much as possible. We worked with the chassis team to interpret the points on the chassis correctly. For the interpretation of the points on the chassis, we worked closely with the chassis team, with the new monocoque and the new rear frame and the mounting points could be changed. The parameters that influence driving behaviour result in an iterative process. The next step was the design of the parts in CAD, where new ideas could be realized. In order to achieve the optimum balance between weight and stiffness we worked closely with the calculation department. Changes also were made in our developed and manufactured carbon rims. They were widened to adapt to the tires, they are characterized by their lightness. The technology of the rim went smoothly and
Newsletter 05/2015
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As the name suggests another duty of the department is the newly implemented driver training. During that the drivers are prepared ideally for the challenges they have to face in the cockpit. Several times a week complete specifical training units during which the strains in the competitions are simulated with a combination of strength and stamina practices. It’s the goal to bring the drivers’ bodies in form so they will be able to concentrate on steering the car during the competition without suffering from output losses from their own fitness. It will reveal itself if the founding of a whole new department – a whole new step in the Formula Student – in these fields is going to bear fruits.
at the end of several weeks we could almost go into series production. Shortly before our rollout we began the assembly of the vehicle. It was glued, screwed and turned to finish the jr15 in time. After the RollOut one of the most important phases began: the testing phase. To make the best of our car, the suspension has to be perfectly adjusted. A device for wheel alignment, which will be manufactured of a bachelor thesis, will be a relief when adjusting various parameters. The whole team is looking forward to fully exploit the potential of our jr15 on this year‘s competitions and burn the fastest lap times into the tarmac.
testing
Experiences from the past showed that it’s very important to have a close look on this topic because it is essential for the driver’s and also the car’s performances during the competitions.
of the department’s duties to ensure operational capability in all times.
suspension
Due to the huge efforts made in adjusting and testing, which first came up in the season 2014 for jr13evo, the team around the jr15 brought the new department „Testing & Driver Training“ into being.
© Lucas Kundigraber
department report >>
STUDY YOUR DREAM.
department report >>
| Newsletter 05/2015
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APPLIED COMPUTER SCIENCES ENGINEERING HEALTH STUDIES BUILDING, ENERGY & SOCIETY MEDIA & DESIGN MANAGEMENT
www.fh-joanneum.at Austria | Styria FH JOANNEUM Graz | Kapfenberg | Bad Gleichenberg Alte PoststraĂ&#x;e 149 8020 Graz, AUSTRIA, Tel.: +43 (0)316 5453-0 info@fh-joanneum.at www.facebook.com/fhjoanneum
chassis calculation
R
With preparations starting during summer 2014 the chassis department was able to complete their needed tools in the last year. As in the past seasons the milling works were done at SFK Tischler and wouldn‘t have been possible without them. A small group of workaholic weasels stayed in Graz during the christmas holidays to laminate the CFK tools and prepare everything for the production of the monocoque.
obserbed by the crash nose to protect the driver druing a worst case scenario.
Monocoque, steering wheel, seat, crashbox and many other carbon components were manufactured in january at Mubea Carbo Tech in Salzburg. The crashbox has to comply with very strict rules. Therefore a testing car was filled with a weight of 300 kliograms at the test field of the MSF AG and driven into a rigid barrier. The whole impact of the crash has to be
We simulated and refined the complex aerodynamics of the jr15 with CFD. We primarily focused on the efficient ratio between downforce and drag. The production of the aerodynamics package was done wholly on the FH JOANNEUM.
The main task of the calculation department of joanneum racing graz is to make structural-mechanical calculations and to optimize the design in order to reduce weight and increase stiffness of several parts of the car. The department consists of three members an works with the FE-program Abaqus. Therefore we got licences from SIMULIA.
structure with purposefully inserted carbon layers and adjusted thickness.
During the design period the calculators had much to do because many parts had to go through iterations of design and calcuation. The main focus was laid on the undercarriage and the suspension. Another main task of us was to completely redesign the monocoque with composite materials including the sandwich-construction of outer carbon layer, core and inner carbon layer. The result was an optmized layer
Simultaneously to the development and production of the frame parts of the car we started to develop a whole new aerodymics package for the jr15. The rules limit the room for the front and back spoiler. To still generate enough downforce we created an innovative concept with additional wings to the site of the car. The air is led from the front wing alongside the inner wheel to provide enough airstream on the side of the race car.
The chassis of the jr15 is stiffer, lighter and more service friendly than those of any before coming car. Combined with the other departments and parts this leads to a car which will lead joanneum racing graz into a successful season 2015.
Because of the newly integrated topology optimizing tool TSOCA in Abaqus many parts of the jr15 could be optimized that way and afterward constructed with result of the calculations. But not only FE calculations were part of the duties of the calculation departement. All material testings are part of that. Due to a change in the rules for this season we had a way higher number of trials under stricter defined trial requirements. These tests are necessary to prove the equivalence of the monocoque to a tubular steel framing. For that there is a template, the so called Structural Equivalency Spreadsheet (SES), that has to be done and checked by a techincal committee for every competition. Currently we are waiting for a feedback of this committee concerning the SES and simultaneously work on the documents that are needed so we are well prepared for the design competition.
season preview >>
Newsletter 05/2015
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season preview >>
| Newsletter 05/2015
Last placement (season 2013): 12th place
FSG Hockenheim Circuit
Last Winner Overall (season 2014): AMZ Racing competitors last competition (season 2014): 74
Last placement (season 2013): 8th place
FSA Spielberg Circuit
Last Winner Overall (season 2014): AMZ Racing competitors last competition (season 2014): 40
FSH Gyรถr
Last placement (season 2013): 5th place
Circuit
Last Winner Overall (season 2014): TUfast Racing Team competitors last competition (season 2014): 38
FSI Varano de Melegari
Last placement (season 2013): 3rd place Last Winner Overall (season 2014): TU Graz competitors last competition (season 2014): 44
Circuit
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Newsletter 05/2015
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