1. Validation through Instrumentation
Formula SAE Performance Enhancement
Validation through Instrumentation
Walter Thorn – 12/7/2007

2. What is Formula SAE? Collegiate design competition
Small formula-style racing cars
1 year project time span
FSAE Design Competition: Students design, fabricate, test, race cars.
Fairly loose regulations, designed to challenge knowledge, creativity and innovation of students
Open wheel = similar to Indy or F1, except smaller
Relatively short project, rules released in October, competition season from May through July
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

3. FSAE Car Requirements 610 cc max engine displacement 20 mm air intake
Independent 4 wheel suspension
Structural safety req’mts
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

4. The Formula SAE Competition
120 International teams
10 international competitions sponsored by Society of Automotive Engineers
1000 total points
Static events
Dynamic events
Main events held in Michigan, California, England, Japan and Australia
Competition designed to evaluate design, cost and manufacturing, business viability, and car performance in various areas
Performance weighted much higher
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

5. Static Events – 325 points
Main events held in Michigan, California, England, Japan and Australia
Competition designed to evaluate design, cost and manufacturing, business viability, and car performance in various areas
Performance weighted much higher
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

6. Dynamic Events – 675 points
Main events held in Michigan, California, England, Japan and Australia
Competition designed to evaluate design, cost and manufacturing, business viability, and car performance in various areas
Performance weighted much higher
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

7. Quantitative Performance Tuning
Currently, performance tuning requirements developed from driver feedback
No quantitative performance measurements
As production limited year, testing/improving/development = 6 weeks
Traditional testing through driving and basic tuning
No data collected to verify designed performance parameters
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

8. Commercial Off-the-Shelf Solution
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

9. Project Approach National Instruments CompactRIO LabVIEW FPGA software
Commercial Sensors
Steering
Suspension
Engine
Acceleration
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

10. Acceleration Measurement Example
2-Axis accelerometer mounted on car
Measure lateral and longitudinal acceleration
Generate lateral vs longitudinal (g-g) diagram
Braking
Right Turn
Left Turn
Accelerating
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

11. Theoretical Vehicle Performance
Theoretical performance envelope generated using:
-Tire grip
-Vehicle weight
-Engine power
-Brake force
Source: Race Car Vehicle Dynamics
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

12. Actual Vehicle Performance
Look at how well we can fill the theoretical performance envelope on-track
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

13. Driver Performance Comparison
Driver A
Driver B
Side by side comparison of two driver’s abilities to exploit total vehicle performance
12/7/2007
Walter Thorn - National Instruments On-Site Presentation

14. Summary of Benefits Maximal vehicle performance
Enhanced driver training/evaluation
Validation of vehicle design
Improved competition results
12/7/2007
Walter Thorn - National Instruments On-Site Presentation