FSG Workshop 2015

Mercedes Benz Sindelfingen

 All information, documents and advices published on the FSG website

(www.formulastudent.de) in the section Rules & Important documents
are OFFICIAL documents for the FS Germany events.
All advices given in this presentation are comparable to rule-announcements and
supersede the FSAE rules.

U.Steinfurth / Scrutineering FS Germany

fotolibra.com

U.Steinfurth / Scrutineering FS Germany

Driver Equipment Article 14 / 2016 Formula SAE Rules

Collected driver equipment during Formula Student Germany 2015

U.Steinfurth / Scrutineering FS Germany

Driver Equipment Article 14 / 2016 Formula SAE Rules

Why is the driver equipment so important?
All Formula Student cars are PROTOTYPES!
At any time anything can go wrong (fire, broken chassis components, accidents)!
The driver equipment is classified as fire resistant to protect the drivers skin!
The harness system protects the driver from severe injuries in case of an accident!

Please always remember:

It is your and your team members LIFE and HEALTH
U.Steinfurth / Scrutineering FS Germany

Scrutineering FSG 2016

For each team only 1 hour is planned for the first mechanical
scrutineering attempt

U.Steinfurth / Scrutineering FSG

Facts about SCRUTINEERING

Scrutineering is a SERVICE to the teams
to check if the car is safe and in racing condition
to verify the REQUIREMENTS given by the rules

The RESPONSIBILITY to comply with

the rules is always with the team.

Scrutineering is NOT a discussion event.

The technical inspection sticker ONLY shows that the car at the moment as presented at
the technical inspection meets the REQUIREMENTS given by the rules.
Scrutineers have the right to check the car during the event at any time.
If scrutineers find a deviation from the rules during a re-check (e.g. after a dynamic event),
the team will get a DNF for the last dynamic event and the team will lose the technical
inspection sticker!
U.Steinfurth / Scrutineering FS Germany

Visible Access (T2.5)

All items on the Inspection Form must be clearly visible to the technical inspectors without
using instruments such as endoscopes or mirrors. Visible access can be provided by
removing body panels or by providing removable access panels.
Question??
How can the fuel system checked by
scrutineers if the engine bay is
completely covered and not
removable??
Dynamics Regensburg

IN THIS CASE the team have to leave the scrutineering area, have to disassemble the car und the scrutineer will
check the item later on (if he will have time).

U.Steinfurth / Scrutineering FS Germany

Radii on Bodywork (T3.23.2) Clarification

All forward facing edges on the bodywork that could impact people, e.g. the nose, must have
forward facing radii of at least 38 mm (1.5 inches).

Picture 1: Left: Nose radii is more than 38mm

U.Steinfurth / Scrutineering FS Germany

Right: Nose radii is less than 38mm

Laminate Test (T3.30. + T 3.30.3) Clarification

Three Point Bending Test Test specimen with closed flanges are NOT accepted
for FS Germany

Picture 2: Test Specimen with closed flanges are NOT accepted for FS Germany
U.Steinfurth / Scrutineering FS Germany

Brake over travel switch (T7.3.) Clarification

A failure in the brake system is defined as one of both brake circuits is not working.
This will be tested by opening the brake bleeder nipple at the brake caliper at one of
both brake circuits. If the brake circuit is opened, the brake pedal must actuate the
BOT. For this test teams are allowed to adjust the brake balancer.

BOT must
be actuated
Open the brake bleeder nipple

Picture 3: Procedure for simulating a failure in the brake system

U.Steinfurth / Scrutineering FS Germany

ARTICLE 11: FASTENERS

T11.1.3
Any bolted joint in the primary
structure using either tabs or
brackets, must have an edge
distance ratio e/D of 2 or greater.
D equals the hole diameter.
e equals the distance from the
hole centerline to the nearest
free edge.

This also applies the driver harness

and AIP / IA attachment.
U.Steinfurth / Scrutineering FS Germany

ok

Design Example of 2015

Picture 4: Example of bracket design

Design requirement of 2016

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 5: Safety wire and wiring tool

U.Steinfurth / Scrutineering FSG

Safety wiring
o.k.

o.k.
o.k.

o.k.
Picture 6 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 7: Button head screws at attachment of the steering column or

suspension system NOT PERMITTED

U.Steinfurth / Scrutineering FSG

Self made fasteners Clarification

Self made fastener are NOT prohibited, BUT:
Formula Student is an Engineering Design Competition
The first question is: How can we proof it?
At the Technical Inspection a team has to be able to show that the design and
material of the fasteners is according to the FSAE requirements (T11).
How? (3 things)
Design documentation / material certification (calculations) and
Mechanical tests (test documentation + test samples) and
Delivery note / invoice of the manufacturer
U.Steinfurth / Scrutineering FS Germany

Fuel lines (IC 1.9.1) Clarification

NO plastic fittings in pressure fuel lines are permitted
NO plastic quick connectors on the fuel line are permitted (including sight tube)

U.S. Plastic Corp.

Picture 8: Examples of NOT accepted plastic quick connect fittings

U.Steinfurth / Scrutineering FS Germany

U.S. Plastic Corp.

Copyright 2015, Power & Performance News

Fuel Tank Filler Neck & Sight Tube (IC2.6)

IC 2.6.1 Clarification
"The inside diameter of the whole filler
neck length tube must be at least
38mm.
The opening of the cap must meet this
requirement.

ok
min 38mm

Copyright 2015, 2016 Formula SAE Rules

Picture 9: Dimensions of filler neck

U.Steinfurth / Scrutineering FS Germany

ADVICE -> Fans

Open rotors of fans have to be shielded

J. Falb / Scrutineering FSG

Design error of the year

Picture 10: Bad A-arm design

U.Steinfurth / Scrutineering FS Germany

General
Dont try to fool us. We are not your enemies but want to support you.
When we tell you This will only be allowed this year, but please change it for next
year we really mean it serious. Change it!
This was also okay last year is no good argument to convience a scrutineer.

M. Bonilla-Torres / Scrutineering FS Germany

ESF

Deadline for HV Accumulator form will be preponed

More time to review & earlier feedback in case change is needed

ESF will be downscaled to the bare minimum

Less redundancy & simplification

Important: Dont wait until end of deadline to submit your items and forms!

Forms will be reviewed in order of submission

The later you submit it the later you get a feedback!
M. Bonilla-Torres / Scrutineering FS Germany

Shutdown Circuit
Inertia Switch, BOTS, Shutdown Buttons and Master Switches must directly carry
the AIR current no relay/MOSFET
TSMS must be the last switch before the AIRs on the positive terminal.

M. Bonilla-Torres / Scrutineering FS Germany

iButton
No team exceeded the 60 degC limit at FSG15!
Please think about proper mounting and insulation of the iButton.
The iButton must be attached close to a cell terminal or on the bus bar and must
not be near to a fan.
Provide cooling simulation and CAD rendering in the ESF HV Accumulator form.

M. Bonilla-Torres / Scrutineering FS Germany

Energy Meter
We had some issues with reading out EM data due to the high number of WiFi
networks this year we will work on this!
Please attach the EM and its housing in a proper way into your car. (Velcro) tape
is not a proper mounting.

Its no good idea to place the EM at the bottom of your accumulator container. A
bad WiFi connection leads to long download times.
EMs will only be read once after each discipline (e.g. after all 4 Skid Pad runs). Its
your responsibility to have the EM checked initialy before you drive an event.

M. Bonilla-Torres / Scrutineering FS Germany

TSAL
TSAL must flash as soon as TS > 60V! This will be tested with an external power
supply please provide a possibility to connect the supply
The TSAL has to detect if one AIR is closed.
It is NOT sufficient to detect only the intermediate voltage.
New in FSAE 2016 rules: TSAL shouldnt be lower than 150mm from the highest
point of the main roll hoop (EV4.12).

M. Bonilla-Torres / Scrutineering FS Germany

E-Inspection
The time for E-Inspection will be limited to 2h.
Please prepare yourself for E-Inspection to save time!
Bring spare parts (PCBs etc.)
Provide relevant datasheets

Have your necessary tools on hand

Take a laptop or tablet with you. Dont show us datasheets on your mobile!

M. Bonilla-Torres / Scrutineering FS Germany

Accu Check
Sorry for the loss of time due to newly introduced Accu Check!
We will improve Accu Check for FSG16!
Also, please prepare yourself. You can speed up the process significantly by
having all relevant datasheets available.
Think about an intelligent accumulator container design! Also for maintenance
reasons its good to be able to reach parts (e.g. fuses) within short time.

Remember: professionally built no hot glue, no loose wires!

M. Bonilla-Torres / Scrutineering FS Germany

Structural Equivalency Spreadsheet

SES of Monocoques will be checked by structural specialists from DEKRA
Please first read the TAB Read_Me in the SES file
In general please read the comments given on each TAB
In general please fill out ALL the yellow marked cells on each TAB
and attach further important pictures to clarify the situation

For additional information to the reviewer please insert additional Tab's

Upload the revised version only if ALL the comments / questions of the
reviewer are answered

R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet general information

Use the right Template (last release)
When uploading a new version, please
write in the TAB Version History what
has been changed compared to the
previous version

R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Cover Sheet

Please fill out the
cells for contact
information
Please fill out this yellow marked cells
For standard materials use the international
material number (e.g. 25CrMo4 or 1.7218)
The Anti Intrusion Plate must be named too
For different parts of the monocoque the name of
the laminate incl. numbers of layers, the
orientation and the core must be inserted.
Providing a data sheet with all mechanical
properties is preferred. For this you can use e.g.
the TAB "Additional Info"

R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Chassis Pics

For monocoque cars it is strictly required that the teams provide pictures, which
show the different layups
For this you can insert
additional Tab's inside the
Structural Equivalency
Spreadsheet
Picture: Recommended view of different lay up types for monocoque cars

Please limit the colores to the major structure

(cover structures ect. can be difficult to understand)
R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Material Data

Please enter the
material name

Picture: Recommended material properties

All material parameters must be inserted

For metals at least values corresponding to the given material properties
For different laminates all material properties must be determined experimentally
Material names should be used uniformely for the whole SES
(design description, material data sheet, laminate tests)
R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Major Structure tabs

For all major structure tabs it is strictly recommended
that the team shows pictures of the specific frame or
monocoque part in the yellow marked cells
For monocoques, all measurements used for the
calculation should be visible in the section picture
(e.g. panel heigth ect.)
If the neutral axis calculation (as flat panel) is not
suffucient, CAD-picture of the cross section and the
parallel axis theorem calculation must be placed here

?
Picture: Fill the yellow marked cells with pictures

R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Front Hoop Bracing / Bulkhead Support

Attachment of Front Hoop to monocoque should not be lower than
50.8 mm from its top (rule T3.13.4)
FHB laminate in this area + at least 2 attachment points (bolted)
For fully laminated Front Hoops calculation of bonding area
can only referred to area which is made from FHB-laminate structure

Picture: FHB-structure

Front Bulkhead Support must extend - not lower than 50.8 mm from
the top of the bulkhead - back to the front hoop (rule T3.19.2)

no interruptions allowed
Picture: FBHS-structure
R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Front Bulkhead (Cutout)

Cutout dimensions in SES define the panel heigth
If the core thickness is reduced towards the cutout edges,
the Front Bulkhead structure has no uniform stiffness
cutout dimensions must meet the area where the actually
installed laminate has the same structure like the tested
layup
This problem is noticed usually at first at the technical
inspection the bulkhead must be strengthen up at event!!!

- Laminate strucutre with core

- Laminate structure without core
Picture: Front Bulkhead cutout

R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Side Impact Structure

Side Impact Structure requires three physical tests:
Monocoque (side up to 350 mm above the ground + floor)
between Main Hoop and Front Hoop must have EI of 3 tubes

FSAE

SIS between upper surface of the floor and 350 mm above

the ground must have an EI of 2 tubes (without floor) and the
floor itself must have an EI of at least 1 tube
SIS up to a heigth of 350 mm above the ground (without
floor) must absorb the energy of at least 2 tubes
R. Pfeiffer / DEKRA Automobil GmbH

Picture: Definition of SIS for monocoques

Structural Equivalency Spreadsheet 3 Point bending test

Definition about different layups
If structures have the same ply schedule (number of
plies, orientation, fibre material, skin thickness) and
same core material, but only the core thickness is
different, the layup with the thickest core must be
included in the test and the properties can derived for
the layups with thinner cores
If structures have different ply schedules even
only more or less plies of the same layup than each
structure requires a new bending test!!!

OK

not OK

not OK

Picture: Definition Different layup

R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet 3 Point bending test

Energy absorption
The calculation of absorbed energy for the
baseline steel tubes ends at a displacement
of 12.7 mm
For the SIS test panel, the energy calculation
must be stopped, either:
at the point where the test panel failes or
at a displacement of 12.7 mm

Failure of laminate significant drop of force

Picture: typical force characteristic for laminates
R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Perimeter shear test

Test samples for perimeter shear tests must have the identical layup to those used in the
actual monocoque (Rule T3.31.5)

Every deviation in the laminate layup require a new shear test!!!

Shear tests must be done at least for:
Side Impact Structure / Front Bulkhead Support / Front Bulkhead
+ every different layup where a calculation for an attachment point is required
ATTENTION ! ! !
Many teams leave out the core or use extra plies for local reinforcements at attachment
points deviation from baseline layup further perimeter shear test is necessary
R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Laminate tests

Names of the tested structures
Laminate structures should be called equal
over the whole SES

Material name

Please enter the material name

(name of test specismen)
Rename the tabs
Material name

Pictures: Test setups with appropriate material designation

R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Monocoque Attachment Points

All measurements which are used in the
calculation must be visible in the pictures
Please choose the actual used laminate
(SES Version 2015 only SIS and FBHS available)
Fully laminated Front Hoops 2 calculations:
Shear strength of the adhessive
Shear strength of skin

Picture: Exemplarly Monocoque attachment point / Note T11.1.3 of FSAE rules

Please ensure that you have determined perimeter shear strength for each laminate with an
attachment point.
Assumptions or estimates can not be accepted
R. Pfeiffer / DEKRA Automobil GmbH

Structural Equivalency Spreadsheet Harness attachment points

Test samples for harness attachment points must have the identical layup to those used in
the actual monocoque (check would be done at technical inspection)

Supported edges of test sample must be at least 125 mm appart from the load application
point
If the panel height of shoulder harness bar is smaller, the test sample must represent the
form to show equivalency
If the design in the actual car has free edges, the test sample must not be fixed at these
edges
The load application angles must be nearly the same like the belt routings
worst case angles described in rules T5.3.5 and T5.4.5
R. Pfeiffer / DEKRA Automobil GmbH

See you at the Hockenheimring

August 9th - August 14th 2016