1. Project Status Update R09220 – Competitive FSAE Autosports Systems
Aaron Heyman (IE)
Shijo George (ME)
Stephanie Malinowski (ME)
Alex Sandy (ME)
Greg Wall (ME)
Ken Mcloud (ME)

2. Project Status Update Project Number R09220 Project Family
Competitive FSAE Autosports Systems
Track
Vehicle Systems Technology
Start Term
2008-2
End Term
2012-3
Faculty Guide
Dr. Alan Nye (Mechanical Engineering)
Faculty Consultant
Dr. Martin Gordon, P.E. (Mechanical Engineering Technology)
Primary Customers
Formula SAE
Mini Baja SAE

3. Project Mission Statement
Product Description /Project Overview Developing a road map with a vision of where competitive auto-sports should be three years from now. Includes progressive innovation of senior design projects in the FSAE auto-sport discipline. Project Deliverables Competitive FSAE Autosports Roadmap Detailed project proposals beginning

4. Values and Norms Punctual Thorough Accurate Professional and Ethical
Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one team-mate prior to the expected absence. An absent team-member should confirm that a team-mate has received their message (in person, voice mail, , etc).
Thorough
Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person.
Accurate
Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow.
Professional and Ethical
Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers.
Demonstrates the core RIT values of SPIRIT.
Committed
Each team member will contribute an equal share to the success of the project.
Open source
All information and finding should be accessible to the RIT and public community

5. Preliminary Roadmap Functions AY 2008-09 AY 2009-10 AY 2010-11
Construct Composite Tubular Bridge
Construct Bridge with increased weight capacity
Construct carbon chassis with wheels
Integrate chassis on Formula Car
Composites
Develop Carbon Wheel
Integrate wheels on Formula car
Develop Composite flotation prototype
Develop full scale prototype
Integrate flotation on Baja Car
Water Propulsion
Develop propulsion system
Integrate system on Baja Vehicle
Aerodynamics
Develop prototype of Variable Air Intake
Scale Variable Air Intake to fit on Formula car
Integrate on to the Formula car
Suspension
Develop an actively controlled suspension
Develop 4 wheeled scaled prototype
Increase load capacity, improve performance and design
Integrate onto Formula and Baja Car
DAQ with Wireless Telemetry
Develop DAQ for Baja Vehicle
Add Wireless telemetry to DAQ
Implement on Formula and Baja Vehicles

6. Filament Winding Machine
Project Name
Filament Winding Machine
Project Number
P09226
Project Family
Competitive FSAE Autosports Systems
Project Leads
Shijo George (ME)
Alex Sandy (ME)
Start Term
planned academic quarter for MSD1
End Term
planned academic quarter for MSD2
Faculty Guide
Dr. Alan Nye (Mechanical Engineering)
Faculty Consultant
TBA (Dr. Ghoneim, Dr. Kempski)
Primary Customers
Formula SAE, Mini Baja SAE

7. Filament Winding Machine
Mission Statement:
To develop a low cost, first generation filament winding machine which produces simple composite tubing that can be further developed by future senior design teams
Roadmap Objective:
Fundamental step in developing carbon fiber tubing to be used in space frame of Formula Racing vehicles 7

8. Objectives and Project Deliverables
Design and build a filament winding machine
Failure analysis of composite design
Produce composite tubing
Test strength and stiffness of tubing

9. Filament Winding
The process by which a continuous strand of impregnated fibers is wound onto a mandrel with specific fibers’ orientation which is controlled by computer.
After the resin has cured, the mandrel is withdrawn
Components produced include pipe work, pressure vessels, storage tanks, and helicopter blades

10. Schematic of the wet filament winding process

11. Layout 11

12. Staffing 1 Computer Engineer 4 Mechanical Engineers Design Build Test
Develop program/controls for relative speed of mandrel to feed eye (determines fiber orientation)
Build
4 Mechanical Engineers
CAD Design
Determine speed, tension, machine layout
Determine fiber orientation, tube specifications (based on testing capabilities)
Build set-up based on design (new machine system or off of existing lathe)
Test
Determine strength of tubing in tension, bending, torsion 12

13. Preliminary Work Breakdown Structure
Team Member
Week 1
Week 2
Week 3
ME (Project Manager)
Establish team values and norms
Initiate brainstorming
Establish individual team member roles
Establish project direction and provide future WBS
ME (Chief Engineer)
Provide team with technical background information and design constraints
Analyze proposed designs for feasibility
Begin theoretical composite analysis ME
Develop understanding of project and consider possible designs
Determine feasibility of proposed designs
Determine machine criteria (rpm, fiber tension, etc.)
Determine machine design layout CE
Research applicable control components
Begin control system design

14. Concerns and Constraints
Project
Sponsor(s)
Advisor(s)
Build Space for filament winding machine
Finalize Budget
Raw Mat’l $800-$900
Motor and misc. $600-$700
Design
Fiber/Resin/Mandrel material
Control of fiber orientation angle
Existing lathe vs. build from scratch 14

15. Gregory Wall Stephanie Malinowski
Water Propulsion
Gregory Wall
Stephanie Malinowski

16. Background
Every year, the RIT club known as mini baja designs a water land vehicle to compete in competitions all over the nation. The vehicle is put through rigorous events that test the student's ability to engineer a fast, durable vehicle that meets certain specifications set forth by the SAE organization.

17. Customer Needs Water Propulsion system light weight and durable
Water proof
Able to be remanufactured
Ability to turn in water
Propelled forward quickly in water

18. Mission Statement
To design and develop a test stand for the water propulsion system that will measure the output force, durability and control of the system. The test stand must accommodate a full scale model of the propulsion system and be able to lift the tires in and out of the water as well as rotate freely. The stand must also and have a user friendly interface that displays quantitative information about the system. This will aid in the design of the water propulsion system that will be build later in the project.

19. Staffing Requirements
Name
Discipline
Role / Skills
TBD
Faculty Guide, Will work closely with the team on an on-going basis to facilitate success.
Faculty Consultant, Will provide discipline technical support on an intermittent basis.
Teaching Assistant
Stephanie Malinowski ME
Project Manager, Schedule meeting, book keeping, and keep team and project on track. Encourage team members.
Gregory Wall
Chef Engineer, Head the design and building of the test stand, and water propulsion system. Encourage team members.
TBD Student EE
Involved in the design and development of the sensor and wheel drive system of the test stand. Involved in any motorization of the water propulsion system that may be needed.
Assist with the chef engineer, and help develop an build the test system. Will do materials research for water resistance and protection of the motor. CE
Developing the interface for the test stand to display the information collected from the sensors, and to run the test stand. IE
Develop a way to remanufacture the system quickly and efficiently.

20. Work Breakdown Person Week 0->1 Tasks Week 1->2 Tasks
ME- Project Manager
Schedule team meetings and get group information, as well as get group caught up with background information of the project, and expectations. Team building exercises.
Make sure everyone from the group is on task, and is up to speed with each other. Update website, and schedule any needed meetings with Baja.
Update website, make sure everyone is on track. Help the other MEs with the design and fabrication of test stand.
ME- Chief Engineer
Research previous designs, and get group caught up with rule and regulations. Give group members starting goals.
Continue with R+D, look into materials to use on the test stand, and start collecting resources and planning design.
Start finalizing designs for the test stand, and make sure all the necessary recourses are lined up for building it. EE
Research sensors and suitable motors, for both the test stand and the water propulsion system.
Continue research, start looking into where we can get the resources needed for the project.
Start getting a hold of motors and sensors, and wiring and testing them to make sure they will work as needed. ME
Get together with the chef engineer, and help review and research designs.
Work with chef engineer in material research.
Continue working with chef engineer for finalizing the design of the test stand. CE
Get together with the EE and discuss sensors they will be used and make sure they can be implemented into a user interface.
Continue working with the EE, and possibly start developing a program for the user interface.
Continue developing a user interface. IE
Work with the two MEs with the initial research and development.
Continue working with the MEs in material research.
Continue working with MEs, making sure final design is manufacturable.

21. Required Resources Old Baja Chassis
Light weight, durable, water resistant materials
Motors and sensors
Machine shop
Computer lab for user interface
Lab to build test stand
Wheels and tires
Lots of water

22. Issues and Risks
Currently do not have a sponsor, and therefore no funding.
Acquiring resources
Time in the machine shop

23. Budget Materials: $750 to $1250 + Motors and sensors: $1000 to $1500 =
Maximum approximate budget of $2750

24. Active Suspension P09227 Ken McLoud
Ken McLoud

25. Mission Statement
To Design and build an open source active suspension system based on a linear electric motor.
The system will be built on a small scale test stand that mimics a double wishbone suspension.
Serve as a proof of concept
Minimize Cost
The control system will be able to:
Minimize the effect of disturbances
Accept commands to effect dynamic load transfer

26. Staffing Requirements
Name
Discipline
Role / Skills
Ken McLoud ME
Project Manger / Controls Engineer
TBD EE
Power Systems (Actuator / Power Amp)
Controls Circuitry (Sensor / Compensator)
Linear Motor / Spring Design
Test Stand Design
Control System Design

27. Preliminary WBS Title Week 1 Task Week 2 Task Week 3 Task
Project Manager
Assemble and Organize Team
Research Available Parts and Technologies
Define and manage Interface Specs
Power Systems Engineer
Study Mission Statement and Customer needs
Begin Power Amp / Coil Design
Control Circuitry Engineer
Aid Controls Engineer in Sensor and Compensator design
Actuator Design Engineer
Begin Actuator Design (W/ Power Systems Engineer)
Test Stand Design Engineer
Coordinate with Formula Team and Begin Test Stand Design
Controls Engineer
Develop Plant Model and Begin Controls Design

28. Budget Item Very Approximate Cost N52 Neodymium Magnets ~$700
Control Circuitry
~$600
Power Amp
~$800
Test Stand
~$300
Total
~$2500

29. Data Acquisition System
Aaron Heyman

30. Project Status Update R09224 Competitive FSAE Autosports Systems
Project Number
R09224
Project Family
Competitive FSAE Autosports Systems
Track
Vehicle Systems Technology
Start Term
2008-2
End Term
2008-3
Faculty Guide
Dr. Alan Nye (Mechanical Engineering)
Faculty Consultant
TBD
Primary Customers
Mini Baja SAE

31. Purpose
Utilize electronic sensors to record vehicle performance and provide vital data to pit crew in order to enhance car’s performance
Design and test data acquisition system that will eventually be used on the Baja vehicle

32. Intellectual Property and SAE Regulation Concerns
Project must comply with all SAE Baja rules
No real time telemetry
All source code must be open source

33. Staffing Requirements
Faculty Guide: TBD
IE : Project Management
ME: Testing lead, Auto specialist (Baja member)
ME: Develop on car housing unit for DAQ
CE: Develop software interface for DAQ
EE: Program and develop sensor packages
EE: Design control unit to record data

34. Work Breakdown Structure
Person
Week 1
Week 2
Week 3
IE – Aaron
Present group to project
Establish goals for SD I and II
Understand team’s skills and weaknesses
Establish Values and Norms
Build consensus on prototype design
Build preliminary budget
Order necessary parts
Develop future WBS
Feasibility Assessment ME
Come up to speed on project purpose and scope
Meet with customer to identify needs
Begin brainstorming solutions
Work with EE to design control unit
Work with others to develop prototype
Develop draft of testing protocol
Brainstorm ideas for on-board housing
Begin designing housing prototype for housing unit CE
Research potential interface designs
Begin sensor design and programming EE
Identify necessary sensors
Begin sensor design and documentation of schematics
Develop prototype design for control unit
Develop documentation and schematics

35. Concept Development Customer Needs:
Joe Featherall – Meeting with E-Board Wednesday
RPM, Low Fuel, Wheel Speed, Crankshaft Speed
Robust Design
Quickly extract data from on-board device

36. Risks Lack of funding Ability to acquire old Baja vehicle
No sponsor at this time
Will speak with Baja about possible funding
Ability to acquire old Baja vehicle
Build space to work

37. Questions ?