FSAE_Specs_IC_PowertrainFSAE Design Spec Sheet2014Competitors: Please read the Instructions-Tips (tab below) prior to the completion and submission of this sheet.Car No.49SchoolDelhi Technological UniversityDimensionsFrontRearOverall Length, Width, Height2750 mm long, 1290 mm wide, 1270 mm highWheelbase1650 mmTrack Width1175 mm1130 mmMass with 68kg driver seated150 kg168 kgSuspension ParametersFrontRearSuspension TypePushrod actuated Unequal Double Wishbone SuspensionPushrod actuated Unequal Double Wishbone SuspensionTire Size, Compound and MakeHoosier R25B 20.5x6 -13Hoosier R25B 20.5x6 -13Wheels (width, construction)BBS 13" Aluminium Rims, 6" wideBBS 13" Aluminium Rims, 6" wideCenter of Gravity Design Height295 mm, confirmed via 'jacking rear axle' testSuspension design travel25-40 mm jounce/ 30 mm rebound25-40 mm jounce/ 30 mm reboundWheel rate (chassis to wheel center)20-29 N/mm27-39 N/mmRoll rate (chassis to wheel center)0.9-1.2 degrees per gSprung mass natural frequency2.6-3.2 Hz2.4-2.9 HzJounce Damping45-70% of critical damping at 34mm/sec40-60% of critical damping at 28mm/secRebound Damping40-60% of critical damping at 46mm/sec40-60% of critical damping at 36mm/secMotion ratio / type1.26 / linear1.12 / linearRate of Camber Change- Ride Camber (deg / m)56.9 deg / m50.7 deg / mRoll Camber (deg / deg)2.10 deg / deg1.85 deg /degStatic Toe+2deg to -2deg+2deg to -2degStatic camber and adjustment method-2.0 deg, adjustable via shims on upright-0.5 deg, adjustable via shims on uprightFront Caster and Kinematic Trail5.0 degrees, non-adjustable, 34 mm trailFront Kingpin Axis Inclination and Offset4.81 degrees non-adjustable, 2 mm offsetStatic Ackermann and adjustment method50%, adjustableAnti dive / Anti Squat0%-7 %0%-5 %Roll center position static68 mm above ground105 mm above groundRoll center position at 1g lateral acc65 mm above ground, 58 mm toward unladen side103 mm above ground, 45 mm toward laden sideSteer location, Gear ratio, Steer Arm LengthFront steer, 99 mm c-factor, 75 mm steer armBrake System / Hub & AxleFrontRearRotors4mm thick 230mm fixed steel discs, drilled4mm thick 230mm fixed steel discs, drilledMaster CylinderFront- 15mm bore Brembo, Rear 22mm bore NissinCalipersBrembo P32 Aluminium Fixed Dual PistonBrembo P32 Aluminium Fixed Dual PistonPedal Force and Line Pressure @ 1g decel165 N, 35 bar165 N, 25 barUpright AssemblyCNC milled steel uprightsCNC milled steel uprightsHub BearingsBack to back paired SKF tapered roller bearings, 35mm boreBack to back paired NTN tapered roller bearings, 65mm boreAxle type, size, and materialLive Spindle, Alloy steel hub with 35mm rotating shaftAlloy steel hub with 65mm diameter rotating shaft,tripod CV Joint HousingErgonomicsDriver Size AdjustmentsNoneSeat (materials, padding/damping)Foam padded thin aluminium sheet frame, mounted using velcro stripesDriver Visibility (angle of side view, mirrors?)125 degree side visibility, no mirrorsShift Actuator (type, location)Manual lever Shifter, mounted on left-hand side chassis structureClutch Actuator (type, location)Pull-cable Foot pedal clutch actuationInstrumentationVeypor V3 mounted on dashboardElectrical Power/Control/Systems ManagementPower Distribution Management / ControlElectronic, Aftermarket Electronic Control ModuleWiring / Loom / ECM mountingIn-House fabricated wiring harness, ECM inside right-side sidepodBattery / Charging SystemVRLA 10.5A-hour 13V Battery, Stock 3-phase alternator-rectifier circuit for chargingGroundingNegative terminal grounded on space-frameDriver Assist SystemsN/ALogging / TelemetryN/ASpecial Sensing TechnologyN/AFrameFrame ConstructionTubular Space-frameMaterialMild-SteelJoining method and materialMIG WeldedTargets (Torsional Stiffness or other)1200 N-m / degTorsional stiffness and validation method1142 N-m/deg CAE beam model, N/A N-m/deg physical testBare frame mass with brackets and paint40.9kgsImpact Attenuator material2mm Aluminium SheetImpact Attenuator dimensions200mmImpact Attenuator energy capacityFEA -- 8.10 kJ, physical test - 7.50kJPowertrainManufacturer / ModelHonda CBR600 F4iBore / Stroke / Cylinders / Displacement67 mm bore / 42.5 mm stroke / 4 cylinder(s) / 599 ccCompression ratio12.0:1Induction (natural or forced, intercooled)NaturalThrottle Body / Mechanism38mm bore single barrel butterfly valve, linear ratio pull cableFuel Type98 RON Unleaded PetrolMax Power design RPM70PS at 7400Max Torque design RPM50Nm at 5500Min RPM for 80% max torque4800Fuel Injection System (manf'r, and type)Stock, Honda PGM-Fi (programmed Fuel Injection)Fuel System Sensors (used in fuel mapping)Mass Air, MAP, TPS, Air Temperature sensorsFuel Pressure5.0barInjector location65 mm before end and directed towards intake valveIntake Plenum volume and runner length(s)2500 cc, 235 mm runnersExhaust header design4-2-1, equal length (+/- 20mm), 50mm collectorEffective Exhaust runner length410 mmIgnition SystemComputer-controlled digital transistorized with electric advanceIgnition Timing3-D map, RPM and Throttle position, 22 deg BTDC advancedOiling System (wet/dry sump, mods)Crank driven wet sumpCoolant System and Radiator locationDemineralized water based, single core, aluminium finned radiator, located on left hand side of main hoop ,cfm fan mounted to 12 V motorFuel Tank Location, Type1.5mm Aluminium sheet in-house welded, placed between firewall and engineMufflerAkrapovic Carbon Fibre Free-flow mufflerOther significant engine modificationsNoneDrivetrainDrive TypeChain-Sprocket DrivenDifferential TypeTorsenFinal Drive Ratio3.5:1Vehicle Speed @ max power (design) rpm74001st gear, 2nd gear50kph72kph3rd gear, 4th gear95kph115kph5th gear, 6th gear120kphN/AHalf shaft size and materialSolid Hardened Alloy Steel (EN24), Unequal length, SplinedAxle Joint typeTripod Constant Velocity BearingsAerodynamics (if applicable)Type / ConfigurationN/ATotal Downforce and Drag ( scale using incl. note )N/ACoefficients of Lift & Drag , and Reference AreaN/AAero Balance (% Front at v=80 kph)N/ANoteable Features (active, etc)N/AOther InformationBody Work (material, process)0.7mm Aluminium Sheet/ 1mm Polypropylene sheet- manually formedOptional InformationValues of all parameters of Suspension represent range in which they could be altered/tuned or set-up during further testing of vehicle.

&L&F V1&C&P &R&D-Speed in each gear.-If CVT or other drive system, provide maximum speed at designed max power RPM as well as effective gear ratio bandwidthCalculation should include chassis roll appropriate for 1g of lateral accelerationSuspension Roll rate, does not factor in the tire but you should know the tire contribution.Suspension wheel rate-

Does not include tire rate although you should know the tire contribution to net ride and roll rates.When writing Design report, expand upon these parameters and discuss testing used to confirm targetsDue to common wheel sizing, wheel widths typically given in inches.

If you are using a metric wheel size (diameter) feel free in input in the manufacturers units.

Include wheel offset.

Describe wheel materials and manufacturing method (spin cast, machined, stamped, composite).Focus of tire information shall be for the dry tires.

Tire sizing can be in inches, metric or other manufacturers units.

Tire sizing should reflect mounted wheel diameter, tire width, and outer tire diamter or aspect ratio. (example: 22 x 6.5 - 15, or P215/40R12).

Tread compound should be identified.

Example: 18 x 6.5-10 R24A GripmaxBe as descriptive as you can within this small space. Describe in detail within your Design Report.

Include the basic suspension configuration (examples: (Short-Long Arm, MacPherson strut, 5-link, etc)

also include a description of sprung mass load path (examples: direct acting, pull rod, push rod, etc...).

Optional (if space allows): discuss spring type, stab bars, other relevant features.Travels from Design Position w/ 68kg driverAnthony L Lyscio:

scale using = 1.162 Kg/m^3 and v= 80 kphAnthony L Lyscio:

RC=wheel camber/chassis roll angle (both relative to ground), ref. SAE J670e or Milliken- Race Car Vehicle Dynamics Ch 17.Ride Camber = change in wheel camber/vertical displacement of the wheel (relative to ground the body)The term Upright refers to the component also sometimes referred to as the knuckle, hub, or corner.

Basic materials and construction: ie. Aluminum weldment, cast Ti, machined steel.

Add relevant features for uprights.

While not detailed in the spec sheet, be prepared to discuss the stiffness of the uprightsand their contribution to the overall camber and toe stiffness.Front or Rear steer referring to location of tie rod relative to wheel center (assumption is Front wheels are the only steered wheels, if different, please describe).

Gear Ratio or C-Factor = rack travel per revolution of steering input shaft

Steer Arm Length = effective distance from kingpin axis to outer tie rod joint.Unless you have two brake pedals, the pedal Force should be the same for front and rear.Describe methods and strategy for monitoring and controlling electrical activity on vehicle.

PDM (Power Distribution Management), Fuseblocks, Relays, Auto-switching systems, Safety Power-OFF?Detail: Wire sizing, type, identity, wire protection, safety factors, standardization, vibration isolation

Judges will observe wiring integrity and question whether the wiring loom was an early design consideration, or an afterthought?Main chassis power. What battery type? Rating? How will battery maintain charge throughout dynamic events?

On-board charging control? Alternator / Generator capacity?Ground locations and strategy? Isolation?

Have proper grounding paths been employed?Note any special driver assistance/control systems. Note this may or many not be electrical in nature!

Systems may include: HUD, _____-by-wire, Traction control, Shift without Lift, etcData logger designed by team, or purchased? Type? Special characteristics?

Channel count/type?

Data radio-transmission typeUnique sensor use or technology?

Wireless network/sensors? State and event monitoring, and special physical/chemical sensing?Lateral measurement from wheel center to wheel center.Exterior Dimensions: If you were to put the car in a box, how big would the box have to be?Longitudinal Measurement from wheel center to wheel center.Specified 'with driver' to assess fore / aft weight distribution.Provide values per side. Ie. Not Sum Toe.

Sign Convention: Positive Toe = Toe In Negative Toe = Toe OutProvide as much information as possible in the space available. Useful information: caliper material, model, make, piston diameter, configuration.Often referred to as kingpin offset or caster offset, Offset here refers to fore/aft distance of spindle relative to kingpin axis. If zero, state as such.Anthony L. Lyscio

While not included in this specification, You should know and understand "pneumatic trail" at the competition as well.Be as descriptive as possible in the space provided.

Include: fixed/floating, sizing (diameter and thickness), materials, vented?, coatings (if applicable)Include type, sizing and proportioning method.Motion ratio: provide for laden vehicle (with driver) at normal trim height.

By type, comment on motion ratio linearity. For exmple: linear MR, progressive rate (give MR range (ie. X.x - x.x : 1)Describe the bearing type, sizing, and configuration.

Like the Upright assembly, you should understand the impact of bearing stiffness on suspension compliance.Include relevant adjustement mechanisms such as adjustable pedals, seats, seat inserts, column adjustments, etc

Provide range of adjustments (ie. Seat adjustable +/- xx mm).

Remember: the judges expect the vehicle to accommodate a range of driver sizes.Angle of view refering to unobstructed view from straight ahead at typical seated driver eye level.Detail actuation method (ie. Linkage, Cable, Hydraulic, etc).

If an assisted shifter, include assist mechanism (air, electric solenoid, etc).

Include shifter location. Gear selection indicator?For welded structure, include welding method and filler material.

For bonded structures, include adhesives and joint details

For composite structures, use the space to add overflow information from Material specFrame mass applies to the complete vehicle structure and all structural / stiffening braces.Space provided for optional engine content or notable features.

Potential items could include: titanium connecting rods, student built crankshaft, student design cam profiles, hydraulic crank dampener, pneumatic valve actuation, etc...Belt (type, width), chain (size?), gearbox, direct.Provide as much information as possible for configuration and tuning of differentiation.

Include both drive and decel bias ratios.

If clutch type, include preload.Be as descriptive as possible in space provided.List all relevant sensors / inputs into fuel control system.Include size, configuration (butterfly style, barrel valve, flapper, etc), and actuation method.

If possible, include information on throttle pedal to throttle body design (linear, special profile, etc..).Normal running pressure. If using a variable pressure design, define pressure range and actuation method.Basic configuration: ie. 4-2-1, 4-1, 3-2-1

Also include relevant diameters ( ie. primary, secondary, collectors, etc).Include tank / bladder material type, manufacturer.Be as descriptive as space allows.Define spark mapping control method,

Include: base timing, max advance timingIf dry sump, define sump configuration, volume, pressure control

Drive mechanism? (electric, crank driven, chain driven, cam driven, etc)Describe induction method and details.

If forced induction, note max boost pressures and intercooling information.Detail of primary structural tubing / sheet / composite material for frame and support structures.Frame / Structure type: Steel spaceframe, Aluminum or composite monocoque, others??

If a hybrid structure or mixed materials describe.Anthony L Lyscio:

Detail material, sizing, and relevant material processes / treatments.Describe material and basic construction of seat.

Include type of padding.

Include heat support / padding detail.Detail actuation method (ie. linkage, Cable (Pull? Push?), Hydraulic, etc).

If an assisted clutch, include assist mechanism (air, electric solenoid, etc).

Include clutch location (if other than typical pedal location).Detail instrumentation including: tachometer, gages, indicators, warning lights, noise level, shift lights, etcAnthony L Lyscio:

Include size, solid or hollow, material, hardness, and other relevant processing information.Items of interest and optional space for your use.

Describe special bits such as: autodarkening windscreens, automatic driver detection, and curb feelers.Anthony L Lyscio:

scale using = 1.162 Kg/m^3 and v= 80 kph

Instructions-TipsInstructions / Tips for Design Specification SheetCompleteness: Please complete the spec sheet in its entirety. The judges expect that there will be a value or description entered for each and every line item contained within. If by chance, the particular item does not apply to your vehicle / design, please enter "N/A" in the space provided. N/A in this case meaning: Not Applicable.Range of Values: In cases where you have yet to determine a specific value for a parameter, please input the range that you anticipate the values to fall within. Please make the noted range as tight (ie. narrow bandwidth) as you feel comfortable.Units: For the majority of the specifications requiring a numerical input, an example of the desired unit of measure has been provided. Please be consistent with the units as specified on this sheet.Formatting: Please do not modify the formating of the spec sheet. It has been laid out to print on a single sheet of 8.5 x 11 paper (double sided). While we acknowledge that there is little space in the cells, we ask that you be brief and include longer descriptive information within the Design Report.Comments / Clue Tabs: For many line items, there is additional descriptive information provided if you hover your cursor over the specification cell. Please use this information to guide your entry.Understanding: The sample values in the template are fictional and should not be used as the baseline for your designs. Note that the specifications identified within the spec sheet contain the type of information the judges will expect you to know, understand, and be capable of discussing during the Design Event. Key factors during the discussion shall be the engineering rationale behind each decision and resulting specification.Consistency: All values contained within this spec sheet are expected to align with your Design report and your vehicle at competition. It should be expected that inconsistencies will be discussed during the Design event. Without adequate reasoning for the discrepancies, a negative impact on your design score may result.Timliness: Please submit the Spec Sheet and Design Report ON TIME. Late submission penalties can be significant and there is little excuse for points lost due to late submissions.Data Entry Issues: If you are having issues with Excel not taking a value (especially if a negative sign is used) please try beginning the entry with a " ' " as the first character.File naming: Please adhere to the specific file naming convention as stated in the rules. This greatly simplifies file management for the judges and event organizers.