FSAE_Specs_IC_PowertrainFSAE Design Spec Sheet2014Competitors:
Please read the Instructions-Tips (tab below) prior to the
completion and submission of this sheet.Car No.49SchoolDelhi
Technological UniversityDimensionsFrontRearOverall Length, Width,
Height2750 mm long, 1290 mm wide, 1270 mm highWheelbase1650 mmTrack
Width1175 mm1130 mmMass with 68kg driver seated150 kg168
kgSuspension ParametersFrontRearSuspension TypePushrod actuated
Unequal Double Wishbone SuspensionPushrod actuated Unequal Double
Wishbone SuspensionTire Size, Compound and MakeHoosier R25B 20.5x6
-13Hoosier R25B 20.5x6 -13Wheels (width, construction)BBS 13"
Aluminium Rims, 6" wideBBS 13" Aluminium Rims, 6" wideCenter of
Gravity Design Height295 mm, confirmed via 'jacking rear axle'
testSuspension design travel25-40 mm jounce/ 30 mm rebound25-40 mm
jounce/ 30 mm reboundWheel rate (chassis to wheel center)20-29
N/mm27-39 N/mmRoll rate (chassis to wheel center)0.9-1.2 degrees
per gSprung mass natural frequency2.6-3.2 Hz2.4-2.9 HzJounce
Damping45-70% of critical damping at 34mm/sec40-60% of critical
damping at 28mm/secRebound Damping40-60% of critical damping at
46mm/sec40-60% of critical damping at 36mm/secMotion ratio /
type1.26 / linear1.12 / linearRate of Camber Change- Ride Camber
(deg / m)56.9 deg / m50.7 deg / mRoll Camber (deg / deg)2.10 deg /
deg1.85 deg /degStatic Toe+2deg to -2deg+2deg to -2degStatic camber
and adjustment method-2.0 deg, adjustable via shims on upright-0.5
deg, adjustable via shims on uprightFront Caster and Kinematic
Trail5.0 degrees, non-adjustable, 34 mm trailFront Kingpin Axis
Inclination and Offset4.81 degrees non-adjustable, 2 mm
offsetStatic Ackermann and adjustment method50%, adjustableAnti
dive / Anti Squat0%-7 %0%-5 %Roll center position static68 mm above
ground105 mm above groundRoll center position at 1g lateral acc65
mm above ground, 58 mm toward unladen side103 mm above ground, 45
mm toward laden sideSteer location, Gear ratio, Steer Arm
LengthFront steer, 99 mm c-factor, 75 mm steer armBrake System /
Hub & AxleFrontRearRotors4mm thick 230mm fixed steel discs,
drilled4mm thick 230mm fixed steel discs, drilledMaster
CylinderFront- 15mm bore Brembo, Rear 22mm bore
NissinCalipersBrembo P32 Aluminium Fixed Dual PistonBrembo P32
Aluminium Fixed Dual PistonPedal Force and Line Pressure @ 1g
decel165 N, 35 bar165 N, 25 barUpright AssemblyCNC milled steel
uprightsCNC milled steel uprightsHub BearingsBack to back paired
SKF tapered roller bearings, 35mm boreBack to back paired NTN
tapered roller bearings, 65mm boreAxle type, size, and materialLive
Spindle, Alloy steel hub with 35mm rotating shaftAlloy steel hub
with 65mm diameter rotating shaft,tripod CV Joint
HousingErgonomicsDriver Size AdjustmentsNoneSeat (materials,
padding/damping)Foam padded thin aluminium sheet frame, mounted
using velcro stripesDriver Visibility (angle of side view,
mirrors?)125 degree side visibility, no mirrorsShift Actuator
(type, location)Manual lever Shifter, mounted on left-hand side
chassis structureClutch Actuator (type, location)Pull-cable Foot
pedal clutch actuationInstrumentationVeypor V3 mounted on
dashboardElectrical Power/Control/Systems ManagementPower
Distribution Management / ControlElectronic, Aftermarket Electronic
Control ModuleWiring / Loom / ECM mountingIn-House fabricated
wiring harness, ECM inside right-side sidepodBattery / Charging
SystemVRLA 10.5A-hour 13V Battery, Stock 3-phase
alternator-rectifier circuit for chargingGroundingNegative terminal
grounded on space-frameDriver Assist SystemsN/ALogging /
TelemetryN/ASpecial Sensing TechnologyN/AFrameFrame
ConstructionTubular Space-frameMaterialMild-SteelJoining method and
materialMIG WeldedTargets (Torsional Stiffness or other)1200 N-m /
degTorsional stiffness and validation method1142 N-m/deg CAE beam
model, N/A N-m/deg physical testBare frame mass with brackets and
paint40.9kgsImpact Attenuator material2mm Aluminium SheetImpact
Attenuator dimensions200mmImpact Attenuator energy capacityFEA --
8.10 kJ, physical test - 7.50kJPowertrainManufacturer / ModelHonda
CBR600 F4iBore / Stroke / Cylinders / Displacement67 mm bore / 42.5
mm stroke / 4 cylinder(s) / 599 ccCompression ratio12.0:1Induction
(natural or forced, intercooled)NaturalThrottle Body /
Mechanism38mm bore single barrel butterfly valve, linear ratio pull
cableFuel Type98 RON Unleaded PetrolMax Power design RPM70PS at
7400Max Torque design RPM50Nm at 5500Min RPM for 80% max
torque4800Fuel Injection System (manf'r, and type)Stock, Honda
PGM-Fi (programmed Fuel Injection)Fuel System Sensors (used in fuel
mapping)Mass Air, MAP, TPS, Air Temperature sensorsFuel
Pressure5.0barInjector location65 mm before end and directed
towards intake valveIntake Plenum volume and runner length(s)2500
cc, 235 mm runnersExhaust header design4-2-1, equal length (+/-
20mm), 50mm collectorEffective Exhaust runner length410 mmIgnition
SystemComputer-controlled digital transistorized with electric
advanceIgnition Timing3-D map, RPM and Throttle position, 22 deg
BTDC advancedOiling System (wet/dry sump, mods)Crank driven wet
sumpCoolant System and Radiator locationDemineralized water based,
single core, aluminium finned radiator, located on left hand side
of main hoop ,cfm fan mounted to 12 V motorFuel Tank Location,
Type1.5mm Aluminium sheet in-house welded, placed between firewall
and engineMufflerAkrapovic Carbon Fibre Free-flow mufflerOther
significant engine modificationsNoneDrivetrainDrive
TypeChain-Sprocket DrivenDifferential TypeTorsenFinal Drive
Ratio3.5:1Vehicle Speed @ max power (design) rpm74001st gear, 2nd
gear50kph72kph3rd gear, 4th gear95kph115kph5th gear, 6th
gear120kphN/AHalf shaft size and materialSolid Hardened Alloy Steel
(EN24), Unequal length, SplinedAxle Joint typeTripod Constant
Velocity BearingsAerodynamics (if applicable)Type /
ConfigurationN/ATotal Downforce and Drag ( scale using incl. note
)N/ACoefficients of Lift & Drag , and Reference AreaN/AAero
Balance (% Front at v=80 kph)N/ANoteable Features (active,
etc)N/AOther InformationBody Work (material, process)0.7mm
Aluminium Sheet/ 1mm Polypropylene sheet- manually formedOptional
InformationValues of all parameters of Suspension represent range
in which they could be altered/tuned or set-up during further
testing of vehicle.
&L&F V1&C&P &R&D-Speed in each gear.-If
CVT or other drive system, provide maximum speed at designed max
power RPM as well as effective gear ratio bandwidthCalculation
should include chassis roll appropriate for 1g of lateral
accelerationSuspension Roll rate, does not factor in the tire but
you should know the tire contribution.Suspension wheel rate-
Does not include tire rate although you should know the tire
contribution to net ride and roll rates.When writing Design report,
expand upon these parameters and discuss testing used to confirm
targetsDue to common wheel sizing, wheel widths typically given in
inches.
If you are using a metric wheel size (diameter) feel free in
input in the manufacturers units.
Include wheel offset.
Describe wheel materials and manufacturing method (spin cast,
machined, stamped, composite).Focus of tire information shall be
for the dry tires.
Tire sizing can be in inches, metric or other manufacturers
units.
Tire sizing should reflect mounted wheel diameter, tire width,
and outer tire diamter or aspect ratio. (example: 22 x 6.5 - 15, or
P215/40R12).
Tread compound should be identified.
Example: 18 x 6.5-10 R24A GripmaxBe as descriptive as you can
within this small space. Describe in detail within your Design
Report.
Include the basic suspension configuration (examples:
(Short-Long Arm, MacPherson strut, 5-link, etc)
also include a description of sprung mass load path (examples:
direct acting, pull rod, push rod, etc...).
Optional (if space allows): discuss spring type, stab bars,
other relevant features.Travels from Design Position w/ 68kg
driverAnthony L Lyscio:
scale using = 1.162 Kg/m^3 and v= 80 kphAnthony L Lyscio:
RC=wheel camber/chassis roll angle (both relative to ground),
ref. SAE J670e or Milliken- Race Car Vehicle Dynamics Ch 17.Ride
Camber = change in wheel camber/vertical displacement of the wheel
(relative to ground the body)The term Upright refers to the
component also sometimes referred to as the knuckle, hub, or
corner.
Basic materials and construction: ie. Aluminum weldment, cast
Ti, machined steel.
Add relevant features for uprights.
While not detailed in the spec sheet, be prepared to discuss the
stiffness of the uprightsand their contribution to the overall
camber and toe stiffness.Front or Rear steer referring to location
of tie rod relative to wheel center (assumption is Front wheels are
the only steered wheels, if different, please describe).
Gear Ratio or C-Factor = rack travel per revolution of steering
input shaft
Steer Arm Length = effective distance from kingpin axis to outer
tie rod joint.Unless you have two brake pedals, the pedal Force
should be the same for front and rear.Describe methods and strategy
for monitoring and controlling electrical activity on vehicle.
PDM (Power Distribution Management), Fuseblocks, Relays,
Auto-switching systems, Safety Power-OFF?Detail: Wire sizing, type,
identity, wire protection, safety factors, standardization,
vibration isolation
Judges will observe wiring integrity and question whether the
wiring loom was an early design consideration, or an
afterthought?Main chassis power. What battery type? Rating? How
will battery maintain charge throughout dynamic events?
On-board charging control? Alternator / Generator
capacity?Ground locations and strategy? Isolation?
Have proper grounding paths been employed?Note any special
driver assistance/control systems. Note this may or many not be
electrical in nature!
Systems may include: HUD, _____-by-wire, Traction control, Shift
without Lift, etcData logger designed by team, or purchased? Type?
Special characteristics?
Channel count/type?
Data radio-transmission typeUnique sensor use or technology?
Wireless network/sensors? State and event monitoring, and
special physical/chemical sensing?Lateral measurement from wheel
center to wheel center.Exterior Dimensions: If you were to put the
car in a box, how big would the box have to be?Longitudinal
Measurement from wheel center to wheel center.Specified 'with
driver' to assess fore / aft weight distribution.Provide values per
side. Ie. Not Sum Toe.
Sign Convention: Positive Toe = Toe In Negative Toe = Toe
OutProvide as much information as possible in the space available.
Useful information: caliper material, model, make, piston diameter,
configuration.Often referred to as kingpin offset or caster offset,
Offset here refers to fore/aft distance of spindle relative to
kingpin axis. If zero, state as such.Anthony L. Lyscio
While not included in this specification, You should know and
understand "pneumatic trail" at the competition as well.Be as
descriptive as possible in the space provided.
Include: fixed/floating, sizing (diameter and thickness),
materials, vented?, coatings (if applicable)Include type, sizing
and proportioning method.Motion ratio: provide for laden vehicle
(with driver) at normal trim height.
By type, comment on motion ratio linearity. For exmple: linear
MR, progressive rate (give MR range (ie. X.x - x.x : 1)Describe the
bearing type, sizing, and configuration.
Like the Upright assembly, you should understand the impact of
bearing stiffness on suspension compliance.Include relevant
adjustement mechanisms such as adjustable pedals, seats, seat
inserts, column adjustments, etc
Provide range of adjustments (ie. Seat adjustable +/- xx
mm).
Remember: the judges expect the vehicle to accommodate a range
of driver sizes.Angle of view refering to unobstructed view from
straight ahead at typical seated driver eye level.Detail actuation
method (ie. Linkage, Cable, Hydraulic, etc).
If an assisted shifter, include assist mechanism (air, electric
solenoid, etc).
Include shifter location. Gear selection indicator?For welded
structure, include welding method and filler material.
For bonded structures, include adhesives and joint details
For composite structures, use the space to add overflow
information from Material specFrame mass applies to the complete
vehicle structure and all structural / stiffening braces.Space
provided for optional engine content or notable features.
Potential items could include: titanium connecting rods, student
built crankshaft, student design cam profiles, hydraulic crank
dampener, pneumatic valve actuation, etc...Belt (type, width),
chain (size?), gearbox, direct.Provide as much information as
possible for configuration and tuning of differentiation.
Include both drive and decel bias ratios.
If clutch type, include preload.Be as descriptive as possible in
space provided.List all relevant sensors / inputs into fuel control
system.Include size, configuration (butterfly style, barrel valve,
flapper, etc), and actuation method.
If possible, include information on throttle pedal to throttle
body design (linear, special profile, etc..).Normal running
pressure. If using a variable pressure design, define pressure
range and actuation method.Basic configuration: ie. 4-2-1, 4-1,
3-2-1
Also include relevant diameters ( ie. primary, secondary,
collectors, etc).Include tank / bladder material type,
manufacturer.Be as descriptive as space allows.Define spark mapping
control method,
Include: base timing, max advance timingIf dry sump, define sump
configuration, volume, pressure control
Drive mechanism? (electric, crank driven, chain driven, cam
driven, etc)Describe induction method and details.
If forced induction, note max boost pressures and intercooling
information.Detail of primary structural tubing / sheet / composite
material for frame and support structures.Frame / Structure type:
Steel spaceframe, Aluminum or composite monocoque, others??
If a hybrid structure or mixed materials describe.Anthony L
Lyscio:
Detail material, sizing, and relevant material processes /
treatments.Describe material and basic construction of seat.
Include type of padding.
Include heat support / padding detail.Detail actuation method
(ie. linkage, Cable (Pull? Push?), Hydraulic, etc).
If an assisted clutch, include assist mechanism (air, electric
solenoid, etc).
Include clutch location (if other than typical pedal
location).Detail instrumentation including: tachometer, gages,
indicators, warning lights, noise level, shift lights, etcAnthony L
Lyscio:
Include size, solid or hollow, material, hardness, and other
relevant processing information.Items of interest and optional
space for your use.
Describe special bits such as: autodarkening windscreens,
automatic driver detection, and curb feelers.Anthony L Lyscio:
scale using = 1.162 Kg/m^3 and v= 80 kph
Instructions-TipsInstructions / Tips for Design Specification
SheetCompleteness: Please complete the spec sheet in its entirety.
The judges expect that there will be a value or description entered
for each and every line item contained within. If by chance, the
particular item does not apply to your vehicle / design, please
enter "N/A" in the space provided. N/A in this case meaning: Not
Applicable.Range of Values: In cases where you have yet to
determine a specific value for a parameter, please input the range
that you anticipate the values to fall within. Please make the
noted range as tight (ie. narrow bandwidth) as you feel
comfortable.Units: For the majority of the specifications requiring
a numerical input, an example of the desired unit of measure has
been provided. Please be consistent with the units as specified on
this sheet.Formatting: Please do not modify the formating of the
spec sheet. It has been laid out to print on a single sheet of 8.5
x 11 paper (double sided). While we acknowledge that there is
little space in the cells, we ask that you be brief and include
longer descriptive information within the Design Report.Comments /
Clue Tabs: For many line items, there is additional descriptive
information provided if you hover your cursor over the
specification cell. Please use this information to guide your
entry.Understanding: The sample values in the template are
fictional and should not be used as the baseline for your designs.
Note that the specifications identified within the spec sheet
contain the type of information the judges will expect you to know,
understand, and be capable of discussing during the Design Event.
Key factors during the discussion shall be the engineering
rationale behind each decision and resulting
specification.Consistency: All values contained within this spec
sheet are expected to align with your Design report and your
vehicle at competition. It should be expected that inconsistencies
will be discussed during the Design event. Without adequate
reasoning for the discrepancies, a negative impact on your design
score may result.Timliness: Please submit the Spec Sheet and Design
Report ON TIME. Late submission penalties can be significant and
there is little excuse for points lost due to late submissions.Data
Entry Issues: If you are having issues with Excel not taking a
value (especially if a negative sign is used) please try beginning
the entry with a " ' " as the first character.File naming: Please
adhere to the specific file naming convention as stated in the
rules. This greatly simplifies file management for the judges and
event organizers.