UCMotorsport ManufacturingNewsletter

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Jens Schmidt
4 år siden
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1 UCMotorsport ManufacturingNewsletter

2 Overview UCMotorsportisastudentleadandrungroupwhose aim istodesignandbuildaformulastyleracecar.uc Motorsport has competed in the Australasian competitionsince2013,isoneoftheuniversity s premierengineeringprojectsandisundoubtedlya significantmotivatorforyoungstudentsconsideringan engineeringdegreeattheuniversityofcanterbury. The project produces experienced and talented graduates that have a great understanding and appreciation for vehicle technology, engineering design,andmanufacturingprocesesthattheytake withthem astheygointoindustry.thisyearuc Motorsporthassetthemselvesthegoalofproducing twocompetitionreadyvehiclestoraceintheformula StudentCompetitioninAustraliaattheendof2018. Thereisonecombustionclasentry,UCM18Candone electricclasentry,ucm18e. TheUCM18Cteam wasformedattheendof2017inoctober,andsincethen,thelevelofdedication,development, andprogresmadebytheteam hasbeenexceptional.whilethedificultdecisiontorevertbacktoacombustion vehiclehadtobemade-largelyduetothelackofelectricalstudents-itcertainlyhasn tmadeitanyleschalenging! Whilebuildinganentirecarinayearisamammothtaskforanygroup,Iam proudtosaythatasofthe31stofjuly, theucm18cvehicleissuccesfulydriving.fornow,theteam isahubofexcitementaswedelveintothetesting, tuning,andvalidationphaseinpreparationfortheformulastudentaustralasiacompetitionindecember. DuringtheNewYearIdecidedtoreturntouniversitytostartaMaster sdegree andagreedtotakeontheresponsibilityofleadingateam tofinishtheelectric car.althoughthechalengehaspushedeveryoneinvolvedfarmorethanwe couldhaveexpected,theelectricprojecthasfounditselfadedicatedgroupof studentswhoaremakingverygoodprogres.ibelievethattheteam hasthe competenceanddedicationthattogether,wilnotonlygettheelectriccartothe Australasiancompetitionthisyear,butthatwewiltakeoverapotentialy competitionwinningcarintheev category.sofarucm18e hasmade tremendousprogresandiam pleasedtoannouncethatonthe19thofaugustthe cardroveforthefirsttime.

to date,the powertrain team has been succesfulininstalingaworkingengineonthecarandhave now progresedtothevalidationandoptimisationstage. Primarily,theteam startedwitha3dscannedimageofthe engine.

3 Powertrain Thepowertrainteam exitedthesummerholidayshaving secured an unprecedented sponsorship from Triumph Motorcycles.Asaresult,thelastfew monthsofworkhas centeredaroundalteringthetriumphdaytona675rengine to ensure thatitissuitable forthe Formula Student competition.to date,the powertrain team has been succesfulininstalingaworkingengineonthecarandhave now progresedtothevalidationandoptimisationstage. Primarily,theteam startedwitha3dscannedimageofthe engine.thisalowedtheteam toaccuratelylocatethe positionoftheexhaustandinletports,enginemounts,front sprocket,andaloftheextremitiesforpackagingintherear subframe. Furthermore, the completion of the Dynamometer(Dyno)hasalowedtheteam tocolectdata andvalidatealmodificationsimplemented.thisalowsfor continualimprovementandeventualoptimisationofthe engine.inaddition,thedynowasusedtotunetheignition, characterisethewaterpumpforcoolingandtoensurethe modified oiling system is performing as expected. A LinkECU hasbeenusedtomonitor,controland subsequentlyoptimisetheenginesperformance.dueto the19mm inletrestrictions,theenginewilberunone85 fueltoaidintheperformanceandreliabilityoftheengine. Whatwehaveachievedsofarwouldnotbeposible withoutthesupportoftriumphmotorcycles,linkecu, AirandAlied,IHL,HighPerformanceAcademy,andal ofourothersponsors.

Chassis SinceOctober2017,thechasisteam hasworkedtireleslytomeetucm18c smostaggresivetimeline.the chasiswascompletedonthe19thofjune2018.

4 Chassis SinceOctober2017,thechasisteam hasworkedtireleslytomeetucm18c smostaggresivetimeline.the chasiswascompletedonthe19thofjune2018.thisyear,theteam optedforathreequartercarbonfibre monocoquechasisduetotheheatcomplicationsasociatedwithacombustionengine. Theteam initialyworkedonthedesignofthemonocoqueusingan iterativedesignproces.thisproducedthegeometryforthemdfplugs, whichinturn,enabledtheproductionofthemouldsandfinaly,the chasis.thiswasahugeefortthatincludedmanylatenightsofsanding andpainting,butultimatelyresultedintheproductionofucmsmost refinedchasistodate. Additionaly,atthebeginningoftheyearthechasisteam decidedto dramaticalyalterthewaytheyoptimisethecarbonfibrelay-upofthe monocoquechasisbyutilisingafiniteelementanalysis(fea)program caledhyperworks.hyperworksisanadvancedfea softwarewith extensivecompositemodelingcapabilitiesandassuch,alowedtheteam toutiliseathreestage,iterativeoptimisationprocestodeterminethe lay-upofthecar. Newfor2018istheadditionofa¾ 4130chromolyrearsubframe.The designandmanufactureoftherearsub-frameprovidedthechasisteam withanopportunitytodeveloptheirunderstandingofstructuralfea,jig designandwelding.utilizingautobendstubenotchingmachinetheteam wereabletoreducethemanufacturingperioddowntojusttwoweeks. More recently,the the chasisteam hasoverseen the design and manufactureoftherearsubframe,thelocationanddrilingofhard-points, andtheatachmentofmostparts.whilethemostworkintensiveperiodhas pasedforthechasisteam,wearestilworkingonaddingthefinishing touchestothecarsuchastheimpactatenuator,seat,andheadrest. ThankstoAutobend,Daiken,AltairHyperworks,SmithsCNCPaternsandmanymorewehavebeenabletoproduce bothacarbonmonocoqueandsteelspaceframeinrecordtime.

5 Suspension Thisyearthesuspensionteam hasfocusedondesigningareliable,easytoworkon,highperformancesuspension system forucm18c. Overthelastfewmonthstheteam havebeeninvestigatinga newmanufacturingmethodforthesuspensionarms.thanksto RodinCar smetallasersinteredtitanium printer,bearing housings(pictured)wereprintedandbondedtocarbonfibre tubes.initialtestdatavastlyexceededourexpectationsinterms ofstrengthandweightandasaresultweproceededwiththe implementationofthedesign. AshifttoanoftheshelfOZracingrim hasopenedthedoor toacentrallockingwheelretainingsystem,thisalsobringsthe addedbenefitofminimizingthecarsun-sprungmas.thisis pairedtoacncmiledaluminium uprightcourtesyofmetco Engineering, which takes advantage of topological optimisationperformedinansys.thisoptimizationmethod usestheresultsofafiniteelementanalysistodeterminethe volumesofapartwhichtransmittheleastamountofload,and hencewheremascanberemoved. WewilcontinuetouseOhlinsdampersforUCM18asthe team hassignificantexperiencewiththem andtheyhave provenreliableforalofourcars.theyarealsooneofvery fewmodelstunedspecificalyforuseintheformulastudent competition.therockers,whichactivatethedampers,usea threepiecedesignmadefrom 7075-T6Al.Thishighstrength materialalowsustousealightweightdesignwhichhasbeen CNCmiled. Completelyredesigningandmanufacturingthesuspensionsystem insuchashorttimeperiodwouldnothavebeen posiblewithoutthegeneroussupportofmetcoengineering,rodincars,ansys,johnbrooksandmanyothers.

Aerodynamics ThisyeartheAerodynamicsteam hasfocusedonoptimisinghowthecarperformsthroughoutacornerasthisiswhere mosttimeislostonthetrack.

asaresult,theteam developedacomprehensiveunderstandingofhow thecarwil perform inacornerbydistinguishingthecentreofpresuremigration inrelationtothecentreofgravityandassuch,theyhavedesignedthe

6 Aerodynamics ThisyeartheAerodynamicsteam hasfocusedonoptimisinghowthecarperformsthroughoutacornerasthisiswhere mosttimeislostonthetrack.emphasiswasalsoputoninvestigatingnew manufacturingmethodstoproducea stronger,lighteraerodynamicpackage. Inrecentmonthstheteam usedansystoproducefulcarcornering simulationswith diferentcaratitudes.asaresult,theteam developedacomprehensiveunderstandingofhow thecarwil perform inacornerbydistinguishingthecentreofpresuremigration inrelationtothecentreofgravityandassuch,theyhavedesignedthe aerodynamicpackageaccordingly.theteam arehopingtovalidate theresultsgainedfrom ANSYSinthecomingmonthsviascalewind tunneltestinganddevelopingapresuretappedwingtouseonthecar itselfduringthetestingphase.inrecentmonthstheteam used ANSYStoproducefulcarcorneringsimulationswithdiferentcar atitudes.as a result,the team developed a comprehensive understanding ofhow the carwilperform in a cornerby thecentreofpresuremigrationinrelationtothecentreofgravityandassuch,theyhavedesignedtheaerodynamic packageaccordingly.theteam arehopingtovalidatetheresultsgainedfrom ANSYSinthecomingmonthsviascale windtunneltestinganddevelopingapresuretappedwingtouseonthecaritselfduringthetestingphase. Now,withthedesignofalAerodynamicelementsonthe carfinalised,atentionhasbeguntoturntomanufacturing the package.throughoutthe yearnew manufacturing methodshavebeenexplored,whichhasresultedinthe ability to make more complex element shapes. Thenew holowwings methodhasencouragedashiftaway from thetraditionalfoam basedmethods,leadingtostronger andlighteraerodynamicelements.theteam anticipatesthat thefulaerofoilpackagewilbecompletedbyseptember.

ElectricTeam Update Atthebeginningof2018theUniversityofCanterbury decidedtogiveucm17asecondchancetogetitswheels turning aftera series ofunfortunate events leftit uncompletedattheendof2017.

7 ElectricTeam Update Atthebeginningof2018theUniversityofCanterbury decidedtogiveucm17asecondchancetogetitswheels turning aftera series ofunfortunate events leftit uncompletedattheendof2017.assuch,ucm17was transformedintotheucmotorsportelectricvehiclefor 2018(UCM18E).Theprojectplannedtohavethecar runningonthebenchbytheendofthefirstholidays. Unfortunately,thisplanwasderailedbytheaccumulator, whichrequiredafulnewsetofbateries.however,this providedthemechanicalteam withagreatopportunityto stripeverythingofthecarandadministersomewel deserved maintenance, and apply a ful-body of conductivepaint-aspertheformulastudentrules.the Electricalteam hasbeenkeptbusyre-coding,debugging andrewiringtheentirecartooptimisealthecontrolsand avoidmistakesmadepreviouslyinucm16.theteam was abletogetthecarrunningonthebenchwithapower supplyattheendofapril2018. Inmorerecentmonthstheteam hasreceiveda new batery pack and Batery Management System forthecar.aftermuchanticipation,anda plethoraofsafetyprecautionstaken,thebatery waschargedtocapacityandtheteam wasableto getthemotorrunningfrom theaccumulator. Additionaly,the steering system has been completelyre-designedandinstaled,andthe coolingsystem hasbeenmovedtooutsideofthe car. Withalthechangessuccesfulyimplementedwecanannouncethatthecarranforthefirsttimeonthe19thofAugust. Whiletheteam hasmadeamazingprogresonthevehiclethusfarthereisstilabusy4monthsaheadastheteam preparesforthecompetition.

8 Events competitionareunderway. Greengridpowerconference. 2018partsdiscusingalthingsengineering.

9 Sponsors

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