Successful FSC Participation Global Formula Racing FSG Workshop

Successful FSC Participation Global Formula Racing FSG Workshop 2014 Continental AG in Hanover

About Us Trevor Takaro Tim Fritz Masters student @ OSU 3 rd year @ DHBW Ravensburg Mechanical Engineering Vehicle Systems Engineering 8 th year in Formula Student 3 rd year in Formula Student c. Car Technical Director e. Powertrain Mechanical Lead

Presentation Outline ▪ About GFR 14 c ▪ GFR History + Team structure ▪ GFR Goals and Philosophy ▪ Decision making processes ▪ Manufacturing and supply chain ▪ Vehicle development

About GFR 14 c ▪ Full carbon fiber monocoque ▪ Honda CFR 450 X - 52 hp ▪ Front and rear wings, undertray ▪ 170 kg ▪ German - American heritage Photo credit: FSG Grams

Global Formula Racing - Two schools - 8800 km

Global Formula Racing - Two schools - 8800 km ▪ State university ▪ Duale Hochschule ▪ 28, 000 students ▪ 1, 400 students ▪ Multidisciplinary ▪ Engineering focus ▪ Student machine shop ▪ Strong company connections

History of GFR - 10 years in the making ▪ 2005: DHBW Ravensburg students at OSU ▪ 2006 - 2009: Two separate vehicle concepts ▪ 2010: Two identical combustion cars ▪ 2011 - present: One combustion, one electric

Team Structure - Advisors ▪ OSU - Graduate students ▪ DHBW - Graduates ▪ Provide advice and direction

Team Structure - Tech leads ▪ Most experienced current team members ▪ Leaders in each area

Team Goal ▪ Win every competition we enter ▪ Philosophy of ▪ Simplicity ▪ Reliability ▪ Simulation validated by physical testing Photo: Schwarz (FSA) Photo: Kroeger (FSG)

GFR Attitude ▪ Nothing is good enough: continuous improvement ▪ Decisions based on engineering merit ▪ You’re only as good as your last event ▪ Be cautious but not afraid to “go your own way” Image: FS Total

Team building ▪ Team members are people, not robots ▪ Recreation as a team ▪ Have a team hangout space

Team culture and communication ▪ Open processes ▪ Easy access to information ▪ Look for positive intent, not exact words ▪ Don’t assume tone or attitude ▪ Respect teammates ▪ Get to the actual issue ▪ Find compromises #GFRiends

American - German cultural differences Americans Germans More big picture oriented More “shoot from the hip” More work / relaxation mixing Trust reasoning more Focus on passion More risk seeking More detail oriented More planning More work / relaxation separation Trust experience more Make sure everything gets done More risk averse

Read Know the rules ▪ “Customer” requirements ▪ Read between the lines ▪ submit rules questions early

Tradeoffs and compromise ▪ “Unfortunately, there is no free lunch” - Carroll Smith ▪ Everything has a tradeoff ▪ ▪ Cost ▪ Performance ▪ ▪ Time etc. Was this presentation worth the time we put into it?

e. Car and c. Car tradeoffs ▪ e. Car and c. Car priorities are similar…. ▪ but not identical ▪ Rules ▪ Cooling requirements ▪ power - efficiency tradeoff ▪ part similarity - performance tradeoff

Drivability ▪ ▪ Linear input - output relationships ▪ Flat torque curve ▪ Stable vehicle behavior (especially at limits) ▪ Supportive, comfortable ergonomics ▪ Stiff suspension - responsive ▪ Give the driver what they expect Soft suspension - tires and car not physically jarred

Lap time simulation ▪ Steady state lap time simulation ▪ Lateral or longitudinal acceleration ▪ Point mass ▪ Models ▪ Tire ▪ Load transfer ▪ Engine ▪ Aerodynamics “Remember that all models are wrong; the practical question is how wrong do they have to be to not be useful” - George E. P. Box

Lap time simulation ▪ Establish input - output relationships ▪ Build trends and characterize system ▪ Simulate competitors’ vehicles ▪ Understand simulation limitations Photos: FSG Almonat, Kroeger, Hirvonen, Reichmann

Using data acquisition from old cars ▪ Identify problem areas ▪ Determine strengths ▪ Driver / vehicle issues

Documentation ▪ If you didn’t document it, it didn’t happen ▪ Career of formula student is short ▪ Project is bigger than any one person

Documentation ▪ If you didn’t document it, it didn’t happen ▪ Transfer all knowledge ▪ ▪ Management ▪ ▪ Engineering Dealing with people Minimize risk of fall off as team members graduate

Supply chain management ▪ Manufacturer options ▪ OSU Machine Shop ▪ GER sponsor ▪ US sponsor ▪ Maybe = no ▪ Serial processes ▪ ▪ plating ▪ ▪ heat treating assembly Minimize risk - “stack the odds”

Supply chain management ▪ Manufacturer options ▪ ▪ GER sponsor ▪ ▪ OSU Machine Shop US sponsor Consider ▪ timeline ▪ part quality ▪ effort / workload

Manufacturing ▪ Tolerances and fits ▪ Material grades ▪ Quality control

Shipments ▪ Plan ahead ▪ ▪ Customs issues + tariff codes ▪ ▪ Shipping lists All parts of process planned Understand shipping limitations ▪ ▪ ▪ physical dimensions limitations on products over airfreight Start on sponsorship early

Testing ▪ Most expensive and highest effort per hour ▪ Make it count! ▪ Have a plan before you leave ▪ More than “drive the car and see what breaks” ▪ Types of testing ▪ Reliability and problem fixing ▪ Driver training and development ▪ Vehicle tuning and development ▪ Fun/team drive days -> teambuilding

Testing ▪ Have priorities ▪ Use checklists ▪ Rehearse where appropriate

Testing ▪ Have priorities! ▪ Plan for the unexpected ▪ Additional tests ▪ Spare parts / cars

Testing ▪ Test location is critical! ▪ Weather ▪ Access dates and times ▪ Pavement differences ▪ Safety ▪ Resources ▪ power / electricity ▪ bathrooms ▪ water ▪ internet ▪ camping?

Statistical Analysis ▪ Motorsports data is very noisy ▪ ▪ Non-professional drivers ▪ ▪ Changing conditions Generally poor control of other variables Be careful of making the “wrong” conclusion

Competition ▪ Sorry about the 6: 00 am wake up calls ▪ We’re not going to stop : ) ▪ The most important 120 hours of the year ▪ Drivers (and engineers) are athletes ▪ Sleep ▪ Meals

Competition ▪ Avoid stupid mistakes ▪ checklists ▪ communication ▪ regular vehicle inspections

Sweeping ▪ Keep the roll around area clean ▪ ▪ safety wire ▪ ▪ bolts nails (!) Tone muscles : )

In conclusion ▪ Be ambitious (Like an American) ▪ Be organized (Like a German) ▪ Make your own path (Like an American) ▪ Be the technical expert (Like a German) ▪ Be OK with Formula Student being your life ▪ Be #GFReady

See you at the Hockenheimring July 28 th - August 2 nd 2015