FSG Workshop 2013 - Abstatt

Bosch Engineering GmbH

Abstatt 02.11.2013

 All information, documents and advices published on FSG

web page are OFFICIAL documents for the FSG events
All advices given in this presentation are comparable to rules
announcements and supersede the FSAE rules

U.Steinfurth / Scrutineering FSG

Read the rules ! Understand the rules! Follow the rules

If you do not understand a rule please send an inquiry to the FSG organization
according to the in FSG rule 3.2 given procedure!!

U.Steinfurth / Scrutineering FSG

Questions about FSG

Please do not use another email address than that specified in the FSC / FSE Rules
(otherwise your inquiry is classified as SPAM and you will get NO answer)

Uni Name_Rules Nr.

!! For technical questions
a picture or sketch for a
better understanding can
be helpful !!

Currently FSG is working on a web based FAQ system. FSG will make an announcement if the
web system is operational, until then please follow FSG rule 3.2

The maximum size for attachments is limited to 5MB / zip-files ore exe-files are not accepted
U.Steinfurth / Scrutineering FSG

SES (Structural Equivalency Spread sheet)

A new 2014 SES template will be available soon (in the mean time
reference the 2013 file)

For additional information to the reviewer you can add new TABS
and you can rename this new TABS with useful keyword

Cars with EV Powertrains must show all HV components (motor,

cables, accumulator) with a bright orange color.

U.Steinfurth / Scrutineering FSG

SES (Structural Equivalency Spread sheet)

For all cars please fill out the column for Design Description and/or
Material Used

???

For monocoque cars the different lay-ups should be identifiable at first

sight!
U.Steinfurth / Scrutineering FSG

SES (Structural Equivalency Spread sheet)

For monocoque cars it is strictly recommended that the teams
provides pictures, which show the different lay -up types

For this you can insert additional TABs

inside the Structural Equivalency Spread
ExcelSheet

Picture 1 Recommended view of different lay up types for monocoque cars

U.Steinfurth / Scrutineering FSG

Driver Harness Structural requirements

Orange marked tube must be made

of 25 x 1,75 mm or equivalent

Orange marked tube must be made

of 25 x 1,75 mm or equivalent

Picture 2 T5.2.1 / T5.4.1 shoulder harness bar support

U.Steinfurth / Scrutineering FSG

Red marked tube must be made of

25 x 2,5 mm or equivalent

Shoulder Harness Bar Support

By Rule T 5.4.2 this is necessary when the shoulder
harness bar is NOT straight

Picture 3 Examples of wrong designed shoulder harness bar (red lines show right support)
U.Steinfurth / Scrutineering FSG

EV4.2 Positioning of the Tractive System

Below 350mm above the ground, the
tractive system components must be
protected from impacts from the side and
rear by a triangulated structure with the
specified tubing sizes.
Above 350mm above the ground, the
tractive system components must be within
the frame envelope such that they are
protected from rollover (within the red line)
Note: the tractive system components
including the accumulator container must
be inside the structure and therefore
cannot also be the equivalent structure
U.Steinfurth / Scrutineering FSG

Picture 4 Positioning of the Tractive System

Fuel Line / Fuel System

IC1.9.1 Fuel Lines Flexible fuel lines must be either (i) metal
braided hose with either crimped-on or reusable, threaded
fittings, or (ii) reinforced rubber hose with some form of abrasion
resistant protection with fuel line clamps per IC1.8.2.
Note: Hose clamps over metal braided hose will not be accepted.

Picture 5 Fuel line attachment NOT o. k. ( wrong braided fuel line attachment)

U.Steinfurth / Scrutineering FSG

FUEL SYSTEM
Use ONLY the right fittings when using metal braided fuel lines
Right fitting

Picture 6 Fuel line attachment NOT o. k. ( wrong braided fuel line attachment, wrong clamps)

U.Steinfurth / Scrutineering FSG

DRIVETRAIN SHIELD AND GUARD (Rule T8.4)

Exposed high-speed final drivetrain equipment such as ..clutch drives and
electric motors, must be fitted with scatter shields in case of a failure.
The officials of FSG classify a external rotor motor or out runner motor (e.g.
EMRAX) as "Exposed high-speed final drivetrain equipment" !

Picture 7 EMRAX out runner motor and a typical application in an electric race car
U.Steinfurth / Scrutineering FSG

DRIVETRAIN SHIELD AND GUARD (Rule T8.4)

Picture 8 Examples of a typical application in an electric race car (red lines sows the scatter shield)
U.Steinfurth / Scrutineering FSG

DRIVETRAIN SHIELD AND GUARD (Rule T8.4)

The scatter shield must be at least 10mm wider on each side as

the motor itself.
The material is always steel and the attachment is just the same
as given in the rules (T8.4).

min 18mm

Dimension, Color, Shape of the car number

min. 152mm

min 24,5mm

min 24,5mm

Car Number (T 13.1)

min 24,5mm

min 24,5mm

min 18mm

Picture 9 Example of a car number according to the rules

U.Steinfurth / Scrutineering FSG

min 18mm

University Name (T 13.2 + FSG rule 4.8)

Right: Uni Trondheim

Right: Uni Padova

Picture 10 Examples of wrong university name decal

U.Steinfurth / Scrutineering FSG

H= min. 50,8 mm

2/3 of H

Correct dimensions and format of the university name decal

Right: Rochester IT

Steering-Brake-Suspension check
Positive locking of bolts of steering- / brake- / suspension System
No free play (steering mount, steering column, wheel pickup points etc.)
No grinding of parts (cables, tubes, A-arms to the wheel or rim, etc.)
Master cylinder
attachment

Rocker arm
attachment

Steering column attachment and Joint

attachment incl. movement of the column

Picture 11 Examples of a few technical inspection points

U.Steinfurth / Scrutineering FSG

Brake cylinder attachment, Steering system

attachment, A-Arm attachment

Safety wiring
Teams have to use a special lock wire AND a special tool for
safety wiring !

Please read a user manual for creating perfect safety wiring !

YouTube movie: www.youtube.com/watch?v=OwFjUX6SaY8

Picture 12: Safety wire and wiring tool

U.Steinfurth / Scrutineering FSG

Safety wiring
o.k.

o.k.
o.k.

o.k.
Picture 13 Examples of safety wiring
U.Steinfurth / Scrutineering FSG

Safety wiring
FS Germany Scrutineers will NOT accept improper
safety wiring

Make sure that your wiring is of high quality and done

with the right tools

U.Steinfurth / Scrutineering FSG

FASTENERS (Rule T 11)

The use of button head cap, pan head, flat head or round head
screws or bolts in critical locations is prohibited.

NOT PERMITTED: Button Head Cap Screws (a) pan, (b) button, (c) round, (d) truss

DIN 912 (ISO 4762)

PERMITTED: Hexagonal recessed drive screws or bolts
U.Steinfurth / Scrutineering FSG

FASTENERS (Rule T 11)

Securing Fasteners
. on the steering, braking, drivers harness, and suspension.
Pins and lock plates or snap rings are NOT permitted.

NOT PERMITTED: pins, bajonettclip or rotorclip. Because they have no positive locking mechanisms
U.Steinfurth / Scrutineering FSG

FASTENERS (Rule T 11)

Picture 14 Button head screws at attachment of the

steering column or suspension system NOT
PERMITTED
U.Steinfurth / Scrutineering FSG

FASTENERS (Rule T 11)

Picture 15 Hexagon socket Countersunk head

screws are NOT PERMITTED as fasteners named in
T 11
U.Steinfurth / Scrutineering FSG

T 5.6 Head Restraint

Must have a minimum width of 150 mm
Must have a minimum area of 235 cm (36 sq. ins) AND have a
minimum height adjustment of 175 mm (7 inches), OR have a
minimum height of 280 mm

OR
Picture 16 Definition of head restraint dimensions

Please note: The width can be more than 150 mm but in this case the
contact point of the helmet can not be less than 50 mm (2 inch) away from
any edge of the head restraint
U.Steinfurth / Scrutineering FSG

CAMERA MOUNTING (T14.15)

For any dynamic event an attachment

of a camera to the drivers helmet is
NOT PERMITTED

U.Steinfurth / Scrutineering FSG

Additional FS Germany camera rules

The camera has to be lie within the surface defined

by the top of the roll bar and the outside edge
of the four tires.

The camera can be placed inside the main hoop if the

distance to the helmet of the (tallest) driver is at least 50 mm.

The camera has to be attached with a proper holder

and the housing has to be secured additionally with
wiring or cable ties.

The attachment of the camera has to be checked by a scrutineer and he/she will mark
the right attachment with a sticker on the camera housing.

The camera should not obstruct the driver during an emergency egress (i.e. the camera
should not be mounted on to cockpit side tubes).

Should not obstruct the drivers view.

U.Steinfurth / Scrutineering FSG

Shoulder harness attachment (e.g. wrap around)

Picture 17: Wrong shoulder belt
attachment

Please inform yourself

about the installation in the
user manual!!

Picture 18: Belt Weave with 3 Bar Slide

Schroth
U.Steinfurth / Scrutineering FSG

Jacking Point
Access from the rear of the tube must be unobstructed for at least 300mm of
its length.

min. 280mm

U.Steinfurth / Scrutineering FSG

Picture 19 Example of jacking point

Wrong Design Examples T 3.19.2

Red line
marks the
rearward
position of
front
bulkhead

Picture 20: Examples of wrong design

U.Steinfurth / Scrutineering FSG

Firewall

U.Steinfurth / Scrutineering FSG

Firewall

Picture 21: Examples of the fire damage

U.Steinfurth / Scrutineering FSG

Firewall
At FS Germany aluminium tape shown below is only accepted to close
small gaps (3mm).

PLEASE use high quality products only (not flammable by itself)

U.Steinfurth / Scrutineering FSG

Firewall / Heat shield

Please use for the firewall and all components of fuel and exhaust
system ONLY appropriate isolation material

Heat mat hose ISA Racing

Heat sheet ISA Racing

Heat mat ISA Racing

Gold reflect folie ISA Racing

Exhaust heat mat ISA Racing

U.Steinfurth / Scrutineering FSG

Firewall / Heat shield -> E-Cars

For E-Cars the firewall must be able to fulfill two minimum
requirements:

First: Protection from flames and fire as in a combustion car

Second: Electric insulation for the driver.

That means the firewall has to be electric insulated on the drivers

side.
It is allowed to be electrically conducting on the NON-driver side,
but it has to be connected to the chassis ground in that case.
The firewall has to be rigid and puncture resistant

Firewall / Heat shield -> E-Cars

NOT PERMITTED AS A FIREWALL : flammable materials

ADVICE -> Energy Meter Attachment

The attachment of the energy meter must be safe and rigid.
Velcro tape is classified as a NOT safe attachment method
The energy meter itself must be enclosed with a rigid housing

ADVICE -> Fans

Open rotors of fans have to be shielded

U.Steinfurth / Scrutineering FSG

ADVICE -> PUSH BAR

Please make sure that the attachment of the push bar to the car is
rigid and safe for the pushed people (and the driver).
A slipping to the side of the push bar from the car must be
impossible in order to prevent injury.
For the FS Germany Event 2014 the Scrutineers will keep a special
eye on this.

U.Steinfurth / Scrutineering FSG