An SAE International newsletter for Sponsors, Faculty, and Students @ SJSU
Left FSAE class of 2009. Randy Roque, Douglas Tse, Gary Ta, David Sam, Calvin Chin, Arturo Quintero, and Ken Lau. Right FSAE class of 2010 and beyond. Joey Penniman, Ruben Delgadillo, Chris Lau, Fortune Fresquez, and David Voth.
The 2010 SAE International SJSU Officers Congratulations to the newly elected 2010 SAE International SJSU Student Officers. President – Randy Floresca Vice President – David Voth Executive Director – Alan Cheng Treasurer – Tony Lee Public Relations/Marketing – Marissa Dayton Members/Receptions – Jeff Yan Events Director – Anish Ramrakhyani Graphics/Artist – Fortune Fresquez
Con GRADUATIONS What do you want to be when you grow up? Where do you see yourself in 5 years? 10 years? When will you be done? A few of our members along with the San Jose State University Class of 2009 can now answer these questions. For some, this journey took longer than expected. For others, it only seemed like yesterday they were just freshman. Goals were accomplished, dreams became reality, and friendships were created that will continue for years to come. Congratulations to the graduating class of 2009. May your future endeavors lead you to prosperous, successful, and wonderful lives. Special thanks and congratulations to our graduating Formula SAE team members.
With projects like Formula Hybrid, Formula SAE, Baja SAE, and BE UNITED we have a busy schedule ahead of us. Our SAE International student chapter is looking forward to the 2010 academic year and can’t wait to make more positive differences in and around campus. For more information please visit: http://www.engr.sjsu.edu/sae
Club Auto Sport allowed our team to use their facilities to set up and test our car. We were able to set up short autocross style tracks with a series of slaloms, straights, hairpins, and chicanes. This was the perfect opportunity to get our drivers trained and gave us the chance to see how well our car could handle.
We tested our car for more than twelve hours
Formula SAE Testing Testing students by having a finals week is always fun. But what can be better than celebrating the end of a semester by a series of tests? How about testing our very own student designed and built formula style racecar. During finals week, we didn’t just challenge ourselves by studying for our classes, we made sure that our car would be ready for some serious driving. It wasn’t easy.
After more than 32 hours of troubleshooting electrical
over a two‐day period at Club Auto Sport. We made suspension adjustments, measured tire pressures, made driver changes, and most importantly, we worked as team to understand how our car handles and performs.
These next few weeks we will be fine tuning our car, getting our drivers prepared, and practicing for the design, cost analysis, and business proposal presentations. Check out the videos of our team testing the car on youtube: http://www.youtube.com/sjsuformulasae
gremlins we found out that our car wasn’t running properly due to a pinched fuel pump line. Once we replaced the line our FSAE team was able to get valuable time testing our racecar. Initial testing was done on campus at places like the engineering courtyard and driveway behind room E123.
After some discussion, driving, and noise polluting it was clear that our car was too fast and too loud for these small areas. So our next stop was at the top of a parking garage that was right across the street. We were able to do a few short acceleration and skid pad runs. This gave our potential drivers a chance to get a feel for the car and also made them realize that this was the fastest car they have ever driven.
While testing the car our team noticed a few things: fasteners vibrating loose, charging system not charging, cooling system not cooling, and a pedal assembly that was making more noise than the exhaust. All these problems were solved by simple solutions: replace the fasteners and use locknuts, replace the regulator rectifier with one from a 2007 CBR600RR, and use nuts and bolts to prevent the pedal assembly from rattling. Once these solutions were implemented, we were off to the Club Auto Sport testing grounds.
./0/* Our FormulaHybrid team kicks it into a higher gear and begins the design phase. A month of organization has done a lot for the Hybrid team, which is now driving full speed into the design stage. Members have been organized into three categories: Chassis Team which is responsible for suspension, frame, steering and braking; Powertrain Team which is responsible for drivetrain, engine, transmission, and throttle; and Electronics Team which is responsible for all electrical circuitry, servo‐ controls, and fusing. Now that we are organized, we have begun to tackle the all important design stage. Our Chassis Team has been running initial iterations of suspension design, while the Electronics and Powertrain Teams have been discussing which motors to use. Meetings are happening regularly, so please don’t wait to join the team. The team’s website is now up and running at: www.engr.sjsu.edu/sae/formulahybrid. Check it out for the latest news, events, and info surrounding the Formula‐Hybrid@SJSU. The Team is taking a trip to California Polytechnic University on Monday, June 8th. CalPoly took 1st Place Overall among rookie entries at this year’s Formula‐ Hybrid competition. During the visit we will get a feel for the electrical circuitry involved as well as the suspension involved in an electric powered racecar. More info to come soon! Joshua Hogan F‐H@SJSU Team Captain Josh.firstname.lastname@example.org (408) 807‐4272
Sponsorship Packages Our San Jose State University Formula‐Hybrid race team welcomes and appreciates sponsorship in many ways. Direct funding will help purchase materials, parts, tools, and equipment to make this project a success. Contributions of parts or services will also aid in creating a competitive vehicle. All monetary donations are tax deductible and greatly appreciated. Lithium Ion Spartan Package ($7,500) Lithium Ion package benefits plus: • Access to team member resumes • Additional logo on the nose of vehicle • Company logo featured on all team helmets Lithium Ion Package ($5,000+) Nickel Metal Hydride package benefits plus: • Upgrade to largest possible logo in highly visible location on vehicle • Company mention in all press releases and newsletters • Company logo featured on team banners at all public events Nickel Metal Hydride Package ($2,500+) Nickel Cadmium package benefits plus: • Upgrade to large company logo featured on the side fairing • Company logo featured on all team apparel Nickel Cadmium Package ($1,000+) Alkaline package benefits plus: • Upgrade to a medium size company logo on vehicle • Team photo with member’s signatures Alkaline Package ($500+) • Small company logo on vehicle • Company logo and link on team website • DVD photo album documenting the vehicle’s design and construction 3
As we close in on finishing our first Formula SAE car, we realize that along the way we tend to overlook small aspects of racecar engineering that many would deem secondary or unimportant. We take certain design elements for granted until it actually becomes time to design the parts. Aspects like how body panels are fastened onto a chassis, or how the seat of a race car is incorporated into the firewall or even something as uninteresting as how teams incorporate a brake light switch into the pedal assembly are design problems that have many solutions but many people don’t give them a second look. Perhaps even more pervasive is how little attention is given to the bracketry designed into a racecar. When it comes time to install a perfectly good component into the chassis, frequent attention is paid to where the component will go, but not necessarily how it will be attached. It may very well end up being bolted or riveted to an overly heavy, improperly loaded, ill‐“designed” bracket that has no place on a race car. In my opinion just as much attention should be given to both where and how a component is installed! Carroll Smith says in chapter 4 of Prepare to Win that the main reason why brackets fail (and the resulting race lost) is due to the fact that brackets are oftentimes an afterthought. An example of this is when a fabricator ignores the fact that any sort of tank for fluid (fuel, oil or water) will be much heavier when full and be even heavier when the car sees any sort of g loading. The difference between a properly designed bracket and that of the “home and garden” type is usually fairly small. The worst type of bracket is one that loaded in the direction most likely to cause failure (usually bending) and is overly heavy, and almost always one often compliments the other. In order to keep the bracket from failing, its mass is increased so much that it is laughable. Below are two bracket designs meant to be welded to a tube: Bracket A
Bracket A shows a tangential tab with a hole in it, while Bracket B is also a tab, but with triangular gusseting folded into it. Both were designed in SolidWorks to have the same length and weight and then analyzed in Cosmos as 4130 chromoly. Bracket A had a resulting thickness of 0.125in while bracket B had a thickness of 0.065, about half of bracket A. A 50lb load was applied 3 inches out from the fixed end of the brackets. Element size was held constant for both brackets. The corresponding data for the brackets can be found in table 1. Table 1 Weight (lb) Thickness (in) Deflection at end (in) FOS (to yielding)
Bracket A 0.0136 0.125 0.0758 1.3
Bracket B 0.0136 0.065 0.0035 4.7
Although physical testing should be done to validate these numbers, the increase in rigidity and strength by putting a little extra thought into brackets is hard to ignore. It’s hard to argue with a factor of safety increase of over 3.5 and an increase in stiffness of over 200 percent. The point of all this is that it’s not very hard to design a bracket that will be light and strong as long as you put a little thought into it. I like to think that the reason people glaze over bracket design so often is due to the fact that when they see a properly designed bracket, they simply write it off. When people see something designed properly they don’t analyze it, they simply think it looks “right” and move on. Hopefully with a little thought and ingenuity, we can make the world a better place one bracket at a time. Joey Penniman Chief Engineer – SJSU FSAE
Baja SAE at SJSU
June 6, 2009 Engineering Room E114B Hotel and Shirt payments due June 89, 2009 San Luis Obispo Formula Hybrid Collaboration June 10, 2009 Engineering Room E114B 2010 Formula SAE Kick Off Meeting
Several of the Formula SAE team members managed to find the time to design and complete a Baja vehicle for the 2009 Baja West competition whilst still playing vital roles in Formula SAE and keeping up with school. The 2009 Baja SAE competition took place in Portland Oregon and Washougal Washington from May 6 ‐ 10th. Our vehicle featured 4‐link rear suspension, an extremely lightweight and comfortable custom seat, and character that can only be developed here at San Jose State University. This year’s vehicle was also significantly lighter than the vehicle from last year.
The highlight of the endurance was the so‐called “log drops.” These large drops were separated by telephone poles across the muddy track. Many teams rolled their vehicles here and some were removed from the competition for cracks in the roll hoops. We talked with many teams about their experiences in endurance. Our favorite teams were: Ecole de Technologie Superieure (ETS), Oregon State, and Michigan Tech. However, most impressive was Nebraska State’s team and their first year vehicle. They made it through all but the last ten minutes of endurance when a broken axle put them out of the race. At the end of the race, everyone looked the same: completely covered in mud.
June 13, 2009 Active Auto Body Painting of our FSAE car June 116, 2009 Engineering Room E123 Preparing for FSAE West
June 1621, 2009 Fontana, CA Formula SAE West June 21, 2009 San Jose State University 2010 Formula SAE Design Begins July 35 2009 Volunteering for Moto GP Mazda Laguna Seca Raceway
The competition also gave our team a chance to see firsthand which features helped and hindered vehicles in different events. For example, if a team wanted to be competitive in the rock crawl they would need to have a gearbox with reverse and neutral. Cutting brakes or differential braking would also be advantageous. However, if light weight, simplicity, and reliability for endurance were top priorities then a single‐speed gearbox with a CVT might be the best choice. Overall, participating in the competition was very motivational. There were many talented and creative teams out there. We have been inspired more than ever to bring a winning car to competition. For more information please visit: Newsletter Staff: http://www.engr.sjsu.edu/sae/minibaja/
Editor/Writer: Randy Floresca Writer: Joey Penniman Writer: Johanna Knudsen Writer: Josh Hogan
Thank You to our Sponsors
gp BIKE PARTS
At San Jose State University
Randy Floresca President (510) 206 3229 email@example.com
Baja SAE Captain ‐ Darren Schwald – firstname.lastname@example.org Formula Hybrid Captain – Josh Hogan ‐ email@example.com Formula SAE Captain ‐ Ruben Delgadillo ‐ firstname.lastname@example.org
Published on Nov 11, 2011