This year i would like to post the building process of our second car in Cairo Uni FSAE team. i want to go forward to the core of the topic without typing too much as an intro, but what i would like to say that: i'am sure that in this topic our team will gain many things.
This year we modify 2015 car with the main goals of:
- Building a car complies with the rules(seems stupid, every team should do so) but unfortunately we didn't join the dynamic events last competition .
- Finishing the car 4 month prior to the competition date (This year we are planing to join UK competition)
- We don't have high goals regarding the dynamic events. joining the dynamic event with the main goal to finish the endurance is perfect for the team. But we do have some goals on the static events.
Moving to every single system (Our goals regarding this system, and what we have finished so far).
The power train:
- Engine: in 2015 we have used KTM 450 EXC engine we do not have any plan to change it this year.
- The intake system: this year some modification regarding to the material of the intake system and its integration on the car.
- The exhaust system: Some modifications related to it's packing in the car.
- The radiator: we will design another radiator with the main goal to finish the endurance.
- The fuel system: we are still using the motorbike pump and we will modify the fuel tank.
- For the differential and for financial reasons we will use Torsen differential, with some modification on its fixation.
The suspension
- Last year we have spent a lot of time on the suspension kinematics. but we ended with a complex suspension with some errors in the manufacturing and many deviations from the designed points. although we are working to increase the team understanding level of the suspension. but with the main target to finish the car very early we will do it simple, no time to spend to optimize the dynamics, no anti features , direct acting . . . if i want to set the suspension goals this year:
1 - A simple suspension (Less time in designing and manufacturing)
2 - well mechanical designed wheel assembly.
- Although Mr Pat has advised us to use 13" wheels, but we do have 2 sets of tires + rims that are ready to be used. so this year we will go for 10" wheels.
The brakes
- We went very fine in braking system last year (we have some braking testing) this year we are planing to go for angled M/C pedal box (Decision matrix).
- last yea we faced some problems in the brakes lines as we used local lines but this year we are planing to buy them from an international supplier.
The chassis.
- Unfortunately the main reason for not joining the dynamic events in FSG15 was the chassis , so we will focus more on the chassis rules.
- Simple and minimum required tubes chassis is considered enough (Removing extra tubes, planar tubes, easy to be jigged during the welding process)
- In Egypt we don't have the minimum required tubes stated in FSAE rules we have thicker and larger tubes. this year we want to deal with an international supplier to supply for our chassis tube (It's not a final decision) but this will reduce the chassis weight 20 kGs (As if you designed based on the minimum available tubes size in Egypt you will be lucky to end with a 50Kgs chassis).
- The electric team
we have switched from using the stock KTM ECU to megasquirt, so the team is now working with the engine team to run the engine .
we want to do the minimum requirements from the competition regarding the electric system although we have received some negative feedbacks from the design judges in FSG15 as we have to use more sensors. but i think this year a running car 4 month before the competition is our main priority.
In the next comments i will add what we have finished in the car CAD model.