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    Racecar Engineering Aug 2019 PDF

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    Gregory Aguilera Lopes

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    — J Leading-Edge Motorsport Technology Since 1990 i iC Ly ae Seer ‘August 2019 + Vol 29 No 8 + wwv.racecar-engineering.com * UK £5.95 - US $14.50 Uae Why hypercars are the Peter Wright's vision for The inside story of how answer for the FIA WEC a sustainable Formuta 1 Toyota conquered Le Mans XRP ProPLUS Reusable Hose Ends The evolution in FLUID HORSEPOWER ™ pane! cao De ed ay of god rating be pane 8) but See en] Log on to www.xrp.com anytime for catalog downloads, ‘new product updates and tech ts. fe US XRP, Inc. sales@xrp.com tel 562 861 4765 fax 562 861 5503 EU PROTEC FUEL SYSTEMS LTD. info@protecfuelpumps.com tel 44 (0) 121 572 6533 AUGUST 2019 woewrcecrenginesingcom 3 ECR Engines Rely On BGG automotive joa ng produc Seen eee ered TOU Bae Lee Om ee ne en RO een me R MLO sed ee eee are the Mobil 1 12 Hours of Sebring in the DPI division of the IMSA Tee nemere Toe ARP fasteners provide strength and CCIE WAM am eaten) PRO OOK ec COM USECUL RS cutee Art ce IVETE] 218° fasteners are Ra ea ARP-bolts.com . Be RD RRS ESRD ey Pan beet te Pee IY er rey re ten en err STRAIGHT TALK — RICARDO DIVILA Back to the drawing boar Our columnist offers some hard-won advice on how to go about designing a racecar re ofthe things that do which ssi ing with acing cris ging ing anew problem, we exploit the knowledge about the world acquited utthe design buildand sofa, to quickly find an adequate solution that is tart of the presentation y 02s along the lines of it but ean sibilities that This derives from compiling all the mistake e ied. that Ihave commited 0 9 knowledge busines andis called experience, butt is realyoops Iw rake this mistake again And belew Grand designs main conceps of design should cate tothe sential rules: 1 There willbe acer init andit your responsiblity to mitigate the tokeepthemas ample, kerbs area af keeping diver inside the white lines but you know they will dive over renin search of faster lap time, accordingly. ou physics and mechani ct innate; _Ukelheed ofthis srt of chasis abuse into your racecar design and others experience through tial ant f he centuries stil the bs ther domains, perating method problem. of allthe technologies you wil ap you have leaned something new:The a complation of several treads of ye you do not master, but do understand tally and should have the coura corollary is aso being able to cisprove something you thought you knew.It shard to change: nd butt needs a general spring ce often, much ike ahard-sk ‘so, be open-minded, Technology ages en.also there the application ofa problem you simply don have, the ing for a problem. Engineers are the embodiment off itain broke, itdoesnt have enough features reason foradding feature does creativity gen decline with age? Well ge more. tean be an advantag lead to ignoring evidence that c ‘think we know: thas todo witha tension Keep it simple ein, The whole faster simp ind of thinking exploration and Drivers havea habit of using kerbs and you will eed to factor the Being realistic, every design's awed and incomplete in ight of further knowledge but can work ts valid '5 Pyramids, ship, and spacecraft are examples ‘ofwhat a group of people can do when working together Big complex projects that do on thelr own Modern rein nts roughly 80 per cent ofthe effects come 20 percent ofthe causes can atest it ceflec; that lst one percents ery very expensive, Mostindustril processes ae the: hy they ae specials; sk them what hey ecommend and vty. The prod willbe better and you will have a your knowledge base, ven puting dimensions on your drawing should cat method ofthe specialist as have todo the inputs But be aging the fame of referenc requires can introduc evaluable time, f courage to admitit not goin uldand then putit out of smi you taking anew tack or approach, 7 Group think can distort judgement. The biggest cock ups ha the desig office having a mistaken view butas hindsight flaws were ds So,armed with some painfully acquited precepts go out there and make your own mistakes fill be fun. Some Once you have invested a great deal of time, money and credibility into any project it will take a lot of courage to admit it is not going to work Full service testing and engineering facility spe + 487-post shaker vehicle testing + Data acquisition » Data analysis + Component performance & durability testing Engineers and operators experienced in testing and developing vehicles from IndyCar and NASCAR to OEMs and grassroots racers, From the earliest planning stages through validating results on the track, Zeta can provide all of the resources and knowledge required 804-690-8979 www.ZetaPVT.com SIDETRACK - MIKE BLANCHET Spoil sports Why top-level stewards need to learn to use a little bit of common sense debacle wl noc have fade fom its controversial postzace headlines by the time this columns printed, Regardless ofthe ights and wrongs of the incident (ifindeed there are any), Sebastian Vettels more measured later comments about his sllusionment concerning curent FI have contained much which should belstened to, Most important ofall they shouldbe acted upon The FIA obsesion with safety and corectnessat all costshas bacome an Ancint Mariner‘albatoss circling over the sport. lam not signed-up to ‘the ules ae rules view rather respect the time-erved opinion that rules are forthe (strict) ‘obedience of fools and the guidance of wise men. Iffurther ammunition formy arguments required Le Mans provided it Previous ‘outright ace winner NckTandy had 10 take astop-and-go when his Porsche GTE crossed the pit-exting whiten byes than half atyre width. Clas leading Pro-Am plot Ben Keating sufered a similar penalty for slighty wheel-spining his Ford Tout ‘of his pit. Had Tandy joined the ack dangerously or Keating disappeared up proad ina tyresmoking, ‘ishtaling departure, then fair enough. ‘One assumes that there ae safety reasons behind these regulations, but neither incident could possibly have been described 2: creating ask noe ‘gaining an advantage. Against the rules These are only the examples sav: doubles there vere mere To me sch petfogging bureaucracy indicates tha stewards cannot be tstd wth making ntelignt assessments of cases such as these This cannot be so. Atel inte real word we entrust the fate of people charged with rave fences by sucha process governance of moor ‘acing more dc than this? The stead roomisno place for lawyers administrators unable to gasp that milseconds often decidea chive’ actions. Itshoul be only for stewards ith proven moor racing competence and experience. Racing is tough compatiton, ater than atest cies andteans adherence to every etal ofthe le book The concept ofa warning for minor ascrton but second stike and youie ou” | hope that the Canadian GPfve-second penalty ‘Atthe Canadian Grand Prix the Ft stewards should have been an epe dice forthe I - Pit Equipment - Impellers - Mixing Valves - Connection Systems - Pneumatic Systems - ‘han eve- anyone wo wants to entey, slong as they are Scart components But the ethos ofthe championship remained ‘the same proving ground forteams and ‘organisations wanting to get imolvedin electric racing, and therehas beena tof interest in particular from tuning companies. One of the key things about this series isthat we wantitto beaffordable inital because we were looking at unvestes but now mainly because somany small and medium sized companies haveshoun THe ERA series founder and technica decor itor Varswigenhovn pictured withthe Dome F11/EV monocoque very seriousinteres'Vanswiigenhoven sys ‘One market that the series founders had not considered was young dives, but almost as soon as this ne initiative was announce many were contacting them looking for dives Formula is Geatlya sucess, and the divers are well pad to acein it Vanswiigenhoven based around te same car, but one class would says’Butforayoung driver theres nat relly _bealmedatengineers and companies the ther MSAMailee lal UL anyoptiontoleamhowtoraceelecric ars, at rivers"Wewillhave wo lasses, thefistof ERE ‘Thereisjustelectric karting, and that’ really just themisthe Spor Class, where yourun our basic | EW HOS aero peueed 8) Dene Danpostes low performancerental stuff and then there's package, and thatincudes battery and motor, | gwereain Formula, afullon profesional championship, everycar willbe identical Vanswijgenhowen ‘Atelete, 120 she ms, 2k ia base ate ‘there wasnothingin the mile until we explains The second, which wil eventually be Supanson ‘came along Thatgave usthveediferentkey __thefasterlass.the Innovation Class Here we Doble wisone wi pustrodatne anpers ont and customers fr the series young engineers have createdafairamountof technical fieedom, _ Tansmision tuning businesses and young rivers Oncewe The eams willbe able to develop batteries, = understood hat trealyhad an impact cnalot__motorsandthel own bodywerkuithin some AN a rap gt Sm ‘ofthings,interms of what the series wouldbe, _liitations which illstep the costs geting out ack ss tort 420m not eastin tems of the car design cof control and alsokeep things sae war twas then decided thatthe series would While the ful technical regulations have yet). Roun 62a have wo classes acing together ontrack bath tobe nalsedit is xpacted tat there willbe a eee 7 seed 7 SAUDIA * SAUDI ony ee \\ aps Discover innovation at For race engineers and drivers hoping to workin Formula thee ar nol many opportunist lear about EV ecng The al-new ERA series nen fl is gap arrowprecision.com vownraccarengesingcom AUGUST 2019 INSIGHT - ELECTRIC RACING ACADEMY maximum power level forthe motor or motrs) and various safety requirements In tems of the racecar much ofthe cre package hasto be retained including the outboard suspension, ‘monocoque and front and rearimpact structures and some body parts ‘We created that tobe aitebitofan enginee’splayroune!Vanswigenhoven sys, ‘Geer novation Class entrant wll have to start off with a basic kit of parts from the Spor Class ‘at They then have the option of developing ‘the flowing pars-batery, motor inverter and cdver interface. We areloking at freeing up the rear bodywork, sidepods and some other parts, and weare aso considering making dampers feeinthe Innovation Clas too, ‘But wehave toretainal he safety citcal parts Vansnjgenhoven ads. thinkit vl ‘give young engineers alot to work o, and will akohelp divers ean natonly how to dive an ‘ect carbut aso how to develop one. But we are taking care to ensureit doesnot become spending war. Torace inthe Sport Class you simply have to buy carand enteritinto the series but there are enough common pats that ifa team wanted to step upto the Innovation Chass then it would be totally achievable Component i imle l=) == 9 For Professional Motorsport THE BEST JUST GOT BIGGER With the clases and overall objective ofthe series defined Venswijgenhoven had to finda racecar to use But while the open whee! single seater markets crowdedin Europe, there were ‘no obvious solutions for an electric powered cardi se the pointin creating something entirely from scratch, there are plenty of good chassis out there 0 we looked around tsee which one ogo for he says. We considered intial opening it up tallow ny F3tub cr horelogtedin hela 10 ens tobe used but qui became cla that costs could get Manage the entire Se aera as teal oof conto tat ay Sowe decided component lifecycle in one that we would ave to goforaone-make chassis and realistically that would have tobe acurent Formula, F2-Ror Fa chassis We id think bout the old DallaraSF14o Sift Super Formulacas but that was over, "We met with mst ofthe major European manufacturers ofcourse buta chance meeting lead us to Dome in Japan Vanswijgenhoven ads. Mey alkeadyhad wo efferent Fa cas ‘acing, onein the JAF seties and onein the FIA series anda Formula 3 Regional chasis under development (see RCEV2GNE).The team there really understood what we were tying to do and boughtinto it and when we visited ther facltyin Japan we were blown away they had everthing we needed (ne ofthe questions thatthe series had totackle was whethertoutiiseaHaloon the ETE by reaper nota tinastdornamees haf tyumioune sigur eheany = as www.gems.co.uk vownraccarengesingcom AUGUST 2019 AUGUST 2019 wewracaareninengcon clear intuitive system > 9 tri-colour shift lights Drives improved reliability, better Sr A performance and lower costs ee (i Pra INSIGHT - ELECTRIC RACING ACADEMY isnot mandatory outside of FA lasses. We lap times are nt necessarily there Hert was er engineers who had fares including ct electronics allowing i . byaineritvasabigstepandthe drives st developing puncture anda hybrid system faire cost reportedthat the corwas much better temwasalso Toyota the win Porsche tok third victory on Butthe euphoria wasnottoltforlong. _intaducedfothsseaton while Toyota _—_the bounce an then etd rom he dine ‘ioulortetntnccyeseeseying —nveicedcsupenson sndvnths—toleasenisneFomantpoganme E> » AUGUST 2019 LE MANS - TOYOTA Seer escent) one ey DST Petree) vwnracarengesingcom AUGUST 2019 CO ee ES Seneca ee ey Incidemally Toyotas battery development ‘meant thatthe temperature operating window as higher, and te compulsory air contoning system was no longer required fr the battery ‘The batery therefore reverted to 8 more traditional water-cooing system, ‘None asa manufacture forthe super season which an fom Spain 2018 to Le Mans, 2019, Toyota had to find ways to race against the privateers The tam acknowedged that t ‘Would have to give up performance toallow theron hybrids to compete, and reduced its ‘maximum stntlength increased its weight ane aso reduced the amount of fuel that it Up to 100 display pages G Dorr www.gems.co.uk Think Automotive are specialists in oil cooling systems and all aspects of vehicle plumbing. We are the manufacturers and distributors of Mocal® and Laminova products. Ous We stock and distribute the finest automobile products, such as ol coolers, hosing, hose fittings, filler caps, water pumps, oll pumps, heater, gauges and more. Buf AUGUST 2019 wrsucecarengineeingcam Get the latest product TECHNOLOGY - THE CONSULTANT Anti-roll bars, pinion angles and differing differentials This month we're looking at how sway bar size affects handling, the myths surrounding pinion angles, and road course versus oval diffs P ) Leading-Edge Motorsport Technology Since 1990 developments, technical F insight and performance , ! i L jae analysis from the leading | im | § | Ly ri | y r) motorsport technology en ime: =o publication every month. a 3g aa enng Le Mans 2019 MTree ery ei *Unrivalled analysis of major events including Formula One, the World Rally Championship and the World Endurance Championship * Detailed racecar design and innovation * Features from leading industry engineers = Print or and the latest product ——Twotattsvepowerlent —_Indyar ao igital itinues its CFD development ETO hint ribleer sues io waiepatens baie, ACCESS DIGITAL EDITION ALSO AVAILABLE WORLDWIDE ome eecletueneceut nec wre p. x Pres eee een eee al Tes 1 How does thesize ofthe sway bar affect racecars? know you ‘canrun softer or harder springs when you change the boar size, but whyis that? And how doesit affect the caster and camber? ‘Asway bar antl bar. isan interconnectve spring almost always inthe form of torsion bat It connects front or ear ‘wheel pac nitssimples fortress only ‘oppositional motion ofthe two wheels: when they movein the same direction, the bar just, ‘umsin its bushings and offers ne resistance; when one goes upandthe other goes down, ‘that wists the bar anditressts the motion The bar and the two springs both ress ol Together they create the elastic component ‘ofthe roll esitance. The geometry ofthe suspension genealy ls creates some roll resistance. So, for a given amount fol resistance, a silfer bar dictates softer springs. ‘Atagivenspeedina given turn the car willhave an amount of lateral load transfer determined almost entirely bys track width andg height The front and rear wheel pars have to absorb this load transfer, and they spit itn proportion to theirrespectiv total elastic and geometric oll esitances Assuming equal tack width at both ends fone end of the carhas 60 per cent of the roll resistance it ‘experiences 60 percent of the load transfer So increasing therollesitance atone lend ofthe car, whether with the ati-olba, the springs or the geometry increases load transfer at that end and decreases load transfer atthe opposite end. Load transfer hurts lateral acceleration capability (se bit), so increasing rollesitance at one end ofthe car makes the ‘opposite end ofthe car stick beter. ‘The se ofthe bar dramaticaly affects its stfoess The stiffness varies directly with the fourth power ofthe diameter. it als varies inversly wit the square of lever arm length, inversely wit the square of lever arm end to. ‘contact patch motion rato, and inversely with the fist power ofbar length (On oval track cars, sometimes the ar and its associated hardware can be markedly asymmetial.In such cases the bar can create (sve ato baron a Formula Ford 1600s asta by sing the veral ads on eer sie ang the bar Increasing the roll resistance at one end of the racecar makes the opposite end stick better roll momentsin response to vertical forces onthe ar. In extreme cases the barcan even Pick the left front wheel up off the ground ‘when the front end ofthe cars pulled straight down and the carisnotallowed toro Changing the bac does notin itself change camber o caster. Using a big ba/sft spring setupon an oval rackar wil cause the front end torun lower through the turns, and that wil afect camber and caster nthat case, as genera ule the car will require more static postive camber ontheleft font, ess static negative camber on the ight font, and ess static asteron both font wheels Some sayrollbars create more load transfer than other means of resisting rll Tha'snot trv, Rall esisance ha the same effect on load transfer distsbution, no matter where it comes from. The suspension hasto act through the ‘resto essa and iinescapably changes theirloads in tect proportion to the ol resisting moment generated Another mythisthat atoll bars cannot or should not be used wth beam axles They are less needed with beam axles because these can safely have mare geometric rolresitance than independent suspensions andi some classes in stock car racing they are prohibited ‘onthe ear axle, However they workjust fine with beam axes, and are used with them very succesfull onal sors of racecars and road vehicles. They are particularly useful on road racing cars with Iverearases in conjunction with low roll centres, This combination reduces torque wedge the change in diagonal percentage that results fram driveshatt torque acting through the suspension Whatis pinion angle and how doesitaffect a car? How would youcaleulateitand around what angle would be ideal? Pinion anesthe side view inclination ofthe ear axles pinion shaft Horzontalis .generaly taken as zero. Over the years there has beena lat of mythology among ‘oval racers about pinion angle According to Some, the cr puts power down better when the pinion shaft has anose-down attitude, AUGUST 2019 winaccarengineengcam TECHNOLOGY - THE CONSULTANT "ANASCAR stock car ona oad course (Watkins Glen), Dero lockers are much ei ule to oval racing applatons An abrupt increase in thrust from the outside wheel adds oversteer and creates the ‘locker twitch’ Some others say having itnose-up does the same thing do not subscribe to any ofthat rmyset | actually think the main effec of ‘oddball pinion angles isto increase Uoint fiction, reducing power tothe wheels and ‘giving theillusion of more traction, ‘There may also bea small tendency for the driveshaft try tostraighten itself ‘outwhen tis eunning with ots of joint angular, but fundamentally the driveshaft is designed to transmit rotational force only. Ikisnot an axle locating member. For smoothest operation and good Uoint le the usual recommendation isto have ‘the pinion shaft statically at the same side view inclination asthe cank centerine, For reduction cas this ill generally be around four degrees nose-up.Thisis usually measured with an angle finder on the companion ange For best joint if, we want small joint angulaty, butt quite zre. We want the parts ta move enough so the needles inthe ‘cups dont Brine indent the surfaces they run on, but that usualy nota problem. How we adjust pinion angle depends on the "ype of suspension. n some cases, we get changesin the geometry of things that do locate the axle when we change pinion angle, and these wil aflect the handling With track rms or leaf springs we can adjust Pinion angle by changing the angle of the armor springs with respect to the fame, or \wecan change itwith shims or mounting pad ‘magifcations where the springs or arms attach tothe carsanle- Changing the position ‘ofthe springs ortruckarms with respec tothe frame changes ant-squat With lea springs it nsoeca-engnesngcam AUGUST 2019 changes bump ster. Changing the angle of the axle housing wit respect tothe springs or armshas no such effect ‘Sometimes, particulary with Late Model ir wack stock cars, a Panhard bar ataches to thenose ofthe centre section The height of this attachment point wll change I we aise or lower the font ofthe centre section Lowering itwalleduce rear geometrierol resistance. This ‘may add understeer, although notifthe car comers wth the left rar suspension topped ‘outand the lft front wheel off the ground regardless ofthis adjustment (ne effect of changing pinion angle thats often unrecognised isthatit also changes the heightof theo filer plug onthe differen Assuming we fillto the plug tataffects the cillevel inthe dif. This is one reason that otherwise identical dif when used in diferent vehicles, willsometimes have diferent filer pluglocations. Running too much ortoo litle cilinthe unit adversely affects ts efficiency and operating temperature. ‘Will you please explain the differences between the rear end differentials of road course and circle (oval) trackracecars and why they are each designed the way they are? Stock cars masty use Detroit lockers. These ae not quite true lfferential but they are use for the same purpove:to drive two ‘output shafts froma common input shaft whi allowing speed differences between the output shafts. A tue diff maintains a designed torque distribution between two output shafts and ets their relative speed vary rely. Atrue aitferential with imitd slip add some sort of friction mechanism thatin some manner limits how rely te relative speed can vary Alackeisitferet it drives both output salts atthe same speed ordinary but wil let cone whee! overrun ifitreceives a bit of reverse torque from its wheel. In most lockers ether vwiheel can overun (but not both at once; there issill engine power or engine braking tothe slower wheel, Thismeans that there's not fixed torque spl. stead the torque split can ay freely but the speed split cannot, up tothe point where the torque atone wheel goes negative. Beyond that point, the slower whe! gets essentially all the torque and the fasterone has just enough reverse torque to ‘overcome light spring and unlock When comerin, the outside whee! ‘overruns and the inside wheel drives This holds tre uti the river applies enough power to spinthe inside whee. Then the nit locks and the drives then shared by the two rear wheels in proportion tothe action they have, Theceis an abruptincrease inthrust fom the ouside wheel This adds overseer, creating the locke witch Thereisalsoa special version ofthis device that isused only on oval tacks where only the left whee! can overun. One might suppose that thisis backwards Doesnt the right wheel ‘eed to overrun in alefhand comer? It would except that these unitsare used with ‘enough tye stagger to make the right wheel tur slower than the lft one ina left turn of the radius tat trackhas So the outside wheel www.WOODFORDTRAILERS.com Woodford Trailers Limited 14 Great Central Way Daventry + Woodford Halse Northants * N11 3PZ Telephone: 01327 263379 Email: sales@woodfordtrailers.com AUGUST 2019 yowcecrengneeingcn mall TECHNOLOGY - EV COOLING Eco telpaCnahsoo eco oP CASCADIA 26: MOTION and no diferent toszingany system where we inverter canbe asmuchas20ftes per minute” arenow commercially availabe = a hvebeengvenasetofboundaycondtensMarinsya‘Apkspontsthatyouwoudtw Thegeea pelo oolng emis 5 pee = from the customer. We use these specific through the inverter ist, then through the the same for IC hybrid and electric powered Prof I M Coumioutpcdeesndacrcnewthins mre ndimrsndbectotepumyso means bebat ae bomen ‘essional Motorsport aiahtewcoecciouge! sieeihenacwWines peter Motors and Inverters grometisoetberalcinpefomane, pena pele esi Steg wich eredeshet he ple UNLEASH YOUR CURRENT POTENTIAL Asfor inverter cooing, wel that's open and an s1ea of development for many custome fenoa TOOL nS The soltionsiplerented depend hey onthe manufatuersintegaton,butour nce coolant often wate has extracted the eat rom the et source, be tha the experience wth igh complex vacuum engine, battery motor orinerte then owsino thereat though aes of hin brand coll plates lps us withhese nelr tbe! inwren theses ional cited shaped ikea Propulsion systems from 50kW to 1MW and beyond chalenges hat wespecalienis working iti ith li than tensed toh theta alan ati wich th Inpanielwtheurctomerstoachievetie __sptesthshestothe oncoming and cooler a that fos tough the orf the adr coolngrecuremerswtcomplesgeometic | _“Outubesate ether older exe tuber andsome have was thinas 2. Whee -the- in si Sapestomamseperomance andminnse ous canbe as thins 6mm expan And Sct senor engineer a PUR-Once we Inverters, motors, off-the-shelf or custom, in single or dual packages the paclaging spac required worked outthe speciation ofthe cre, we wil the tube and manufacture thea nto Safety first ee eae Ui From the Dakar Rally to hill climb, drag-racing, endurance, InFormalsftyhasremined the main Stackthe sandwich layers of ue andfn ontop ofeach oterto mest rei face area tha, Dron fichastewos frei | ad in nl ist alt “ motorcycle, Formula E and Formula1 Category of eecticacing understandable efor the components are tacked and brazed together hey wl gothoughaclening Thiseiplnsay the btery coved thon pres Fash they are washed reduce any contanation onthe component going int the indirect cooking system using dielectric fu furnace, The coreis then faxed, which Supercars/Hypercars ‘0 avoid any potential leaks and consequent isa procedure where aflux and water intention nm) short cicuts within the battery, despite the ‘mixtures applied tothe complete core. — loveratesothetvansechoweve, ava —Tisthen eso powdertat MAUR near and ghcolmiisusedtcolthe motorand_eneapsustesthe whole core proving a inverter on te grounds thatashr cuit Alayerof protection etre braang, Pomme Le pee) fromaleskcan bemvtigtedby opeingthe __Thssesental Because any oxygen RANT MTT battery contactors Thetefore wit erent haters upinthe face through Ta rai fhidswsedtocooithebateryandthe motors lhe theenvrnment or evaporated and inverters the cooing stem onfybridand _romwaterthathas been ton the tlecticrcearschanconiscftwosepante | caeuilinhttha basing proce cheutsassthe case informa “Theis the basing procedure, youhaveamoterandinvertrwhichare which cons of sever stages usnga wate cold sterandyreguicion | astet reseed bt aise? youneed tows dlecticfuid onthe baton, _Scttays‘Depending onthe se and Aspen of Rew range et KR a sOU0OT Jouhavenechoicebuttosptthe systems’ massofthe core each wireatferenty_ vlped by waFinevn arse PR, Marinsays'Whatve a seeninthe pasts becuse ots thermalietia so we veto thatyoutendtofow more fuidtroughthe _pckabespote recto gtthatcoreupto the ital braze temperate: . bateysoasarestyouneedadifeentpump. _ Thebrazng process stars of witha dying stage to ensure that any ofthe remaing fx ‘ ‘overdo presets Duh” sbewn ede Tematfal there model fam 00 ees PROPELLING INNOVATION in ELECTRIC PROPULSION flyer the ater cooing cra Depanding onthe cor concn either the tubes eis wil have an adtonalacrfical Forthemotorandvertecoolngcicut _lyerwhichly makesup anal portion ofthe total mater hchness. PES | wcascanianorion.com thereat several schoo of thought onthe “Thesacrifiialcading ners slighty lowering pinthan the parent mater ee insteffectveconiguatonTypealy ning _sowhanthe furnace ast to theca temperate the cladding layer lly est ‘to make a cooling circuit with a very high heat and it will start to use capillary action to work towards any joints in the core itself; Scott a een LAA tranfercoefcentoftenrezutsinalatofback explains Those ae the jit between the fran th tbe andl the joint between the presure onthe motor whichmakesitdifiat ender lateandthe tue. tlcete alt in those its and once the part drops below tocool bot the motor and theinverrin thecal braze temperate itil oii. Therefore weend up with one piece uit SeiesThecombined pressure losislicyto_whichiscompltel sealed without any aks 86 wnsacear-angnosingcom AUGUST 2019 mill TECHNOLOGY - CHASSIS SIMULATION Playing with dyno mights While dyno results should be treated with some caution, when they’re combined with simulation data it all adds up to one very powerful set-up tool, argues Racecar’s maths guru By DANNY NOWLAN ne ofthe most disturbing trends have sen over the ast couple of years has ben the emerging view that dyn results whether they're for engine tyre or aerodynamics, might be afox sent from God Almighty himsel Thisis particularly apparent with ecent ‘graduate engineers uta supsngly effects alotof enor engineers as wel ste principal ‘of ChassisSim one ofmy main activites i getting ‘correlation on a daly basis and thisputs mein unique position to discus this After al have to deal wth the fallout from this every day Tobegin dynos whether they be engine, ‘tyre or aero ~are primary comparative too, Dont get me wrong, they wil ge you a good idea on where the absolute numbers ae but they arenever the nal wor. leant this ist hand when worked foran aftermarket engine management compary. We used to derive alt ‘of amusement atthe keyboard warriors who ‘would oloatinly pos thr dyno resus. Butif yout involved inthe engine tuning game you recognise very quickly that the absolute results ‘ofan engine dyno wl vary. tl depend on your ambient conditions and how lang the ‘engine/carhas been onthe dyna, becauseit gets eal warm real quick This doesrt mean the rumbers you get from the dyno are bad. Asa ‘comparative too they are lant, and having been involved inthe experince of tuning engines on the road, know that once you tune ‘ona dyno you wil never go back ‘eth hisis al wel and good for the engine what about tyes and aero? Wel frst. fal hate to bust alot of engineers bubbles here, but wind tunnel esuts arent the panacea that everyone seems to thinkthey are. Tounderstandthis you need to knora tle bit about how wind tunnels work and what you are trying to model in them. As canbe seen in the picture above, the wind tunnel hasa certain ‘oss sectional atea and you have ascale model corinthiscasea carin there, andiealy a oling ‘oad. The ist problem comes with blockage elects that wl effec the low aound the mode ‘orcar Thanks to Bemoul’ equation we know ‘the alrspeed wll increase around the cr Also, ‘when modeling in subsonic flow you match the Reynolds numbers and in supersonic ow yyoumatch the Mach number The problem with racecar aerodynamics is that thanks to thecars proximity tothe ground we have high subsonich ‘tansonic flow coming together There are ‘certain things we can do to mitigate this and as _acomparative tol and something tohep get you int the bal parka wind tunnels invaluable, However to claim twillgive you absolute numbers to within one to two per cents foolish, Irthiswas the case why mould FI teams employ ‘engineers tovalidate their ontrack ero? Taking on fluid sit now CFDs ioimmatre to give you an aroma thatiswihin ve er cet! the absolute velues The cod bssnumeta procsing powers spy not there where (isworth ts waghtingotisin png ou undesiandwhathe ow sutures as el asilstating the pitch sensi Butthere awesome xcptons. At acate Inpont. Toman ToalsimUSAdo great ‘ork wl Andrew iat om AME ‘ero Butthey areexcepional at wath do Rob Lewis Ray Letoand Andrew Brillant and their respective teams have been doing this forsolong they have an instinctive felfor the numbers, while they have fallen in love with thei oun publicity ether. The next thing to seus istyre testrig results and what you get from Pacejka results, because tissomething weneed tohave 2 serious chat about had five dolls fom every Formula tudent/FSAE team that thinks that Pacejka result from tyre test gests ae thelast word on tyre performance then | would have retired avery longtime ago as avery wealthy ‘man. The thing they are wrong. One ofthe worst kept secrets ishow unreliable Pacejta results actualy are Figure 1 isaPaceka result fram aigh downforce category was involed in, which a particularly egregious example of Something going pear shaped Dueto confidentiality cant say where thiscame from and have hadto blockout the scalings but what thi tye model shows is thatas yu apply laa the peakslip angle wil Increase significantly So what this means for vehicle performance’ you would have to be applying 10 degres of tering lock Given ny Dynos will certainly give you a very good idea on where the absolute numbers are but they are never the final word 188 wsacecatengresingcam AUGUST 2019 customers atthe time where reporting about ‘wot three degree of tering through high speed comers an the racecars were gluedto the trackthey gured out eally quickly that ‘these results lefa lot tobe desired, ‘The eason these results can go wrong is ‘down totwo factors and the ist of theses the inadequacies ofthe Paceka mode self This «ould be anartlein its ov ight. The other reasonisthat tre test machines are very hard essed todeal with the thermal conditions you willencounter onthe ace track Thisis motto say they are bad onthe contrary they are very useulanda a asin point would jump at thechanceto use the Sova Motion igin Alton, Virginia inthe US, for instance Asa comparative ‘ool they are very useful and have their pace. However you alvayshave to treat tyre test results sa rough stating point ony Dyno sore Nowat ths pointin the game know afew of you reading this wl be iting the rev inite suffering from extreme cognitive cssonance, But ‘alm down forthe way you deal with this is actually quite simple, and | wl break this down ‘rom the easiest method tothe hardest. Fist, dealing with the engine isactaly very simple, because of al the measurements were looting at thisis actually very close. What you do hereis fix the engine power and use your lap time simulation tools ike Chass, to tune the engineeficency and global A values. In Table’ there are some ugh rules of thumb thathave worked fr us ove the years Do treat these as rough rules ofthumb, ‘though. You typically employ tis when your end of staightisa +-delta of 20kmvh. Once you are ‘down under thislimit you tuneby scaling the CRE ee ny Lateral force (N) Normal force (N) Slipangle (Rad) nee ed Transmission type ‘Open wheelerprototype GTear/mid-engine ring canfront engine total QA map or in Chassis speak you play with the C,Aon therear wing. The gal here Istomatch the speed at the end of the fastest straight. This ilusteated in Figure 2 InFigure2 actuals coloured data and simlatedis black. You play with the maximum CAvalues until you are within 05to tanh This Figure 2: Matching the speed at the end of the fastest straight and thats representative environment Net taken thelsts dealing wth downforce. your wind tunnelis any good itwillgive you very good baseline on pitch eh see ———— = |s good enough. Artis pointinthe game sty speaking you may not have an absolute value bbutyou have something much more powerul, & AUGUST 2019 wonnaecrengnesingcon 99 TECHNOLOGY - CHASSIS SIMULATION sensitivity. Your st pot of cll. hen istoscale the global A and apply 2glbal aero offset. ‘The great thing about Chasissim isthatifyou clickon the rear wing by adjusting the Cand aero balance offset valves then ths willbe done for you.The goal here is tomatch the damper postions front and ear atthe end ofthe longest straight. Thisislustratedin Figure 3. ‘Again actuals coloured and simulateds black. The ist channels speed the seconds steering, The tied trace the fron pitch which istheaveraged leftand ight front dampers, and the last races the rear pitch, which isthe averaged lft and ght reat dampers Allyou are doing i playing withthe global A and aero balance to match up the fastest end of ‘straight condition You can also do this with ther lap time o track epay simulation. At this stage ofthe game it doesnt matter. The next step inthe process sto refine the pitch sensitivity map. This is actual rally simple and as much a would ike to take the ence engpetngcom AUGUST 2019 EQUATION 1 Trip =ky(l—ky “F,)F Were: Tyo =o hs 0) il eter fon top el oe ith nt dente creditor ths haveto give ito a colleague of min. JP Sarin, ho came up ith the idea of sing the Chasssim track repay to compare simulated to actual datas shown in Figure 4, Here youneed tolook t where the dampers don'tmatch up Then look at what the simulated rie heights are and that ls you what you need Parameter Value | 2 | sestN) | toadjustin the aeromap inthis case what this telngusis that we need to decease the CAin thisateaandincrease forward aero balance. The ast thing we need totalkabout ishow to ea withthe tyres and to this we needto cap a technique ve discussed before, which involves tyre modeling frm scratch To recap, we are sing the form ofthe traction crc radius that isshownin Equation 1, and some typical values forthisae shown in Table2. What sally seul about thisis that any 'yre canbe broken down into a peak oad and DOCKING ea Ea en TELE Wg ¢ Cen aa ET EY << ras EUR ASS CDs PEM pac Peete Prete Cee Dre eye Soy oO ReeeCglet +44(0) 1327 858011 Ps ecu acy OM ‘Welding Standards Unit 15 Siverstone Circuit’ Silverstone, Northants NNI26T, United Kingdom Ren Rod crane erro earn in motorsport transmissions covering rebuilds, PUSeiecro on ates agcetonl types of gearboxes and axles. Supporting teamsin the Worid Endurance Championship, pteoey Cie neeeeeats tas Eee ee cee aes Eien natant as wellas input erates MJTech Limited peer cs a ee ee eee ort) eee od eNeeeet ey ss te sero oo a) >: www.m-)-tech.com + @ MJ Tech Limited. 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Hope to hear fom you soon. ~ = oOo o> AUGUST 2019 yowacecrengneeingcmn TECHNOLOGY - CHASSIS SIMULATION cabernet = she HA ee Mn nici 4 pet me nly addition to ths fyouare sing something The bottomline is that awel-alibrateddatalog ke Chassis, isthatfortransient simulation _villalway hae the final word you add 20 per cent scaling font and rea, In closing, while engine, wind tunnel and because you need that offset the bumps. tyre testi results are valuable points of _ Tosumup.whatwehavedonehere suse reference they are never the final word on the both dyno results and data together Inthecase numbers you apply othe acecar T subscribe ofengine and aero we tookourenginedyno_tothisvewisnaively optimistic at best and and wind tunnel essa ourbaseline We then downright dangerous at worst But you sed the data to ine tune the resis use these numbers asa start point and cross Lastly, with the tyre results because tyre reference this withthe data usin the methods testrigresutstendtobelessrelablewe had wehave discussed then they wll become a force asilustatedin Figures (where, isthe _tobealitleceativehere. However asalways vty powerful ool that will provide you with load atvhich thetyregeneratesitsmaximum everythings crosreferenced backtothedata. _amodelthat srepresetatve, force). There are two ingredients tothe magic sauce that makesal this work AS canbe seen from Figure 6, the fist method is youneed to determine the peak load of the traction cirle - eee om ‘adius You cn do this by runing a track replay simulation or 2 ough cut time simulation, ‘ether using ChasssSim or something sito determine what the tye lands look ke during ‘the lap Thisislstrated in Figure Allyouthen need todo isto take the peak ‘yreloods and add 1000 200kg and this gives you your peak load For Formula Student cars, which ate so mach ightes,add50 to 100k ‘The final piece ofthe purses figuring out the intial co-efficient offction.Allyou are doing isa stat force balance oragivencuvatue, Speed and setup. Then you change the k tems or initia co-efficient of fiction tomatch the corner speeds The eally grat thing about this isitcanbe combined nan Excel spreadsheet suchas the one illustrated in Figure 7. (Once youhavealthisyouhaveatyremodel | #f you can putinto your simulation package.The + #Astem ACR! venue engpetngcom AUGUST 2019 0 ee DISCOVER NEW TECHNOLOGY. ES BUSINESS. P14 1a Ua PD UT ca) Se VR ee eRe Lee Cell (c} SU amie eas TM eee Miya Ra AZ Le PCS CO SCL LL Learn more at pri2019.com lll BUSINESS - PEOPLE Interview —- Hugh Chambers At your service The CEO of Motorsport UK explains how the recent shake-up in the national governing body in Britain amounts to much more than just a name change By MIKE BRESLIN ‘The very clear evidence is that unless we make ‘some changes the future of motorsport, not just in this country but | think worldwide, is threatened’ betes. an expression Hugh Chambers kes to use to

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