CAR DESIGN PROBLEMS ANALYSIS SOURCE OF POSSIBLE SOLUTIONS PROBLEMS TO BE SOLVED

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2 PROBLEMS TO BE SOLVED 1) How to design the fastest possible car What are the forces acting against the car? How can these forces be minimised? What tests may need to be carried out? 2) How to design a car according to specifications? Car will have to satisfy all specifications while minimising forces acting against it. For example: Car length between 170mm-210mm Body height above track between 3mm-10mm Body width at side pods between 50mm-65mm Total body width between 60mm-85mm Minimum body weight without CO2 canisters55g Lowest point of chamber to race surface between 22.5mm-30mm Wheel diametres between 26mm-34mm Wheel width between 15mm-19mm Wing width between 40mm-65mm Wing Depth between 15mm-25mm Front wing thickness between 1mm-12mm (which means minimum fillet of 0.5mm) Rear wing thickness between 3mm-12mm(which means minimum fillet of 1.5mm) 3) How to design a car that is compatible with a CNC router? Find the capacity of the CNC Router to be used no. Of axes, diameter of cutter CAR DESIGN PROBLEMS ANALYSIS Internet: SOURCE OF POSSIBLE SOLUTIONS Formula 1 car designs Existing fastest F1 in Schools car designs Aerodynamics Principals Study fastest F1 in Schools cars and learn what makes them fast Use Wind Tunnel software (Cosmos) to preform various tests on parts and cars to to see what is faster. Design engineer and manufacturing engineer to collaborate on CNC machine capacity

3 INVESTIGATION What forces are acting against the car? Internet sites on aerodynamics like m or Forces acting on car are CAR DESIGN - INVESTIGATION RESULTS Wind Resistance: results in drag. This is the biggest force acting against the car. The most aerodynamic shape is a teardrop shape which only has 5% resistance. CONCLUSIONS Drag slows the car down Use of aerodynamic shapes essential. Design must minimise drag and turbulence. Car should contain as few corners as possible Corners facing into the wind and away from wind should be curved and sloped. No square corners if possible. Teardrop shapes should be use used where possible. Turbulance: air split by the car not flowing smoothly together again as with the teardrop shape. This causes drag. The picture on the left is an example of turbulance. Rolling Resistance: which is friction between Wheels and Road, and between the wheels and the Axles.

4 CAR DESIGN - INVESTIGATION 1) What forces are acting on the car?(continued) 1) Road: I. The greater the weight of the car, the greater the Friction between the Wheels and the Road. II. The more surface area on the wheel the more friction. CONCLUSIONS Preferable to have narrower (within specification) wheels: less drag and rolling resisitance. 2) Axel: Bearings used to prevent resistance between the wheels and axels. Radial Bearings Radial roller bearings likely to be the best solution. Roller Bearings Ball Bearings Closed Bearing Density of Balsa Wood Test: measured mass and volume of Balsa Wood result: average density = g/mm^3 Problem : similar sized pieces of Balsa Wood can vary in density up to 100% Will need to test if open or closed bearings are best. Take average value of density of balsa wood when calculating weight of designs

5 INVESTIGATION What made previous f1 in schools cars a success? Look up record times Look at pictures of fastest cars from the teams homepages Study cars from F1 in Schools Uk Final. 1) FUGA, current world record holder. CAR DESIGN - INVESTIGATION RESULTS CONCLUSIONS Choosen car should incorporate the aerodynamic design features. The way the side pods are up high to carry air from wheel to the next is very clever. The back wing in each car eases the air back together to prevent turbulance. This feature should definetly be included. Team trip to F1 in schools UK Final Designs should contain no square corners facing the wind which, after testing, turns out to be more aerodynamic. Bearings are being used to reduce rolling resistance.

6 IDEAS CONCEPT 1 3D CAD MODEL SKETCHES TESTING IN THE VIRTUAL WIND TUNNEL MOVED BACK CAUSES LESS DRAG Wind Tunnel Test Results newtons of drag when 20m/s of air is flowing past it.

7 IDEAS CONCEPT 2 SKETCH 3D CAD MODEL TESTING IN VIRTUAL WIND TUNNEL Wind Tunnel Results newtons of drag when 20 m/s of air is flowing past it.

8 IDEAS CONCEPT 3 SKETCH 3D CAD MODEL After Regional s Design Wind Tunnel Test Results newtons of drag when 20 m/s of air flows past it. After Regionals Modification drag was newtons. DEFLECTORS TO SEND AIR OVER WHEELS

9 IDEAS CONCEPT 4 SKETCH 3D CAD MODEL TESTING IN THE VIRTUAL WIND TUNNEL LOTS OF DRAG HERE Wind Tunnel Test Results newtons of drag when 20 m/s of air flows past it

10 WHEEL CONCEPTS CONCEPT 1 NYLON WHEEL (SOLID) CONCEPT 2 CONCEPT 2 IN VIRTUAL WIND TUNNEL CONCEPT 3 IN THE VIRTUAL WIND TUNNEL SOLID NYLON WITH RADIAL BEARING CONCEPT 3 HOLLOW NYLON WHEEL WITH RADIAL BEARING

11 SELECTION OF FINAL SOLUTION- CONCEPT 3

12 MANUFACTURE

13 WOOD FINSIHING, BEARINGS AND WHEELS Wheels The wheels were made on a lathe in the metalwork room. A 9.65 mm hole was made to produce an interference fit for the bearing to fit into. Bearings were pressed into the hole. Bearings Manufacturing the wheels After the regional s we wanted to re-investigate the bearings as our bearings locked up reducing our speed greatly, We changed how we spun our bearings after being washed out, We now spun it by hand to be more gentle, rather than the lathe. Tests: Original Bearings: 8 Seconds Lubricated with oil bearings: 6 Seconds Graphite Bearings: 7 Seconds Dry run-in Bearings (lathe): 40 Seconds Dry run-in bearings (hand): 60 Seconds Conclusion: The fastest bearings are ones that have been run-in by hand after oiling and then washed out with methylated spirits and dried. Getting Graphite for Tests

14 Testing and Evaluation Fastest Car Possible? Ideal: To manufacture some concepts and test on the race track To race cars with different wheels solid or hollow Car satisfies the stated Specifications? Car Specifications as per Specifications sheet. Actual: Only testing possiblity was using the Virtual Wind Tunnel Result: Concept producing the least drag was chosen as final design Hollow and Solid wheels tested in wind tunnel - Solid wheels produce less drag. But Hollow wheels turned towards the car body reduced the drag while still allowing a reduction in weight. Finishing Process Paint is excellent colour and has excellent gloss shine Surface could be smoother better primer preparation more coats of primer sanded to remove all wood grain from painted surface.

15 GRAPHICS DESIGN PROBLEMS ANALYSIS PROBLEMS TO BE SOLVED INVESTIGATION How to make graphics aesthetically pleasing? What colours? (Associated with speed) -Fit with main sponsor colours? Graphic Identity suitable to use in all aspects of projects? What media can be used? For example; printing, painting, textile printing on team kit. Ferrari and McLaren have simple colour schemes, e.g. Ferrari is red. Honda s colour scheme is very complex. Easily recognisable brands don t use complex colour schemes. Slogans of car brands: The Power Of Dreams (HONDA) Driven By Passion (FIAT) The Passionate Pursuit Of Perfection (LEXUS CARS) SOURCE OF POSSIBLE SOLUTIONS Formula One Cars Graphic Identity they use: -Logos -Slogans Commercial Cars - Graphic identity the use -Logos -Slogans Colour scheme of Main Sponsors Printers (Printing companies) Wood Finishers CONCLUSIONS A simple elegant design should be used so our car is instantly recognisable - like successful Formula one cars e.g. Lewis Hamilton s car. The overall colour scheme will be red with black as this matches our main sponsors logo. The car will be red with the logo in black. It was decided on the slogan Power Passion Performance because the words reflect the teams passion, the power of the race and the performance of the car. Also alliteration of the letter p sounds very good. This is the team logo. This logo is simple, dynamic and instantly recognisable

16 MARKETING Problem Analysis 1. How to design/formulate an excellent marketing/ sponsorship strategy 2. How to publicise project locally and nationally. 3. How to efficiently gain sponsorship and raise enough money to fund the project. 4. How to communicate with business men and women with far greater marketing experience Media Packs should include: 1. Contact Details at top of page. 2. Paragraph of information about the competition. Sources of Possible Solution 1. Marketing Expert. 2. Put together list of local/ national media sources and their contact details. 3. Marketing Expert. 3. A suggestion that the media source should interview the team 4. Talk to marketing expert who has experince of dealing with sponsorship proposals on a regular basis. To Do: 1. Search locally for marketing expert who can help us. 2. Research marketing ideas on net. 3. Find contact details for media outlets Investigation Receive commitment from media source(s) to help promote the project Found Marketing expert-mr Finnian Murphy: Worked with Finn and came up with an excellent marketing/ sponsorship campaign strategy. From meeting with Finn every week for a month, the following was learned: Dealing with Marketing Managers: How to deal with experienced business men and women involved in distributing sponsorship on behalf of their companys: Be precise/ factual Never Hesitate State your goal from the word go Be persuasive but in an encouraging way State the benefits of sponsoring the project, and what these benefits could result in (increase in sales due to media exposure) Follow up media packs 2 days after sending. Process for securing Media Commitment Get right contcat details for all media sources i.e. find out contact details of the media outlets marketing manager, not a helpdesk. Send media packs to media sources 4. Paragraph listing the benefits ( Unique selling points) to the media Process for securing sponsorship commitment: Find the right contact details for marketing managers of various local, national and international companies who may be possible sponsors Based on media pack results ( what you can offer companies in terms of media exposure) send out sponsorship packs to various different companies after finding right contact Follow up sponsorship packs 2 days after their sending. Receive commitment from sponsors Work on media exposure/ posters/ radio interviews etc Receive funding from sponsors

17 MARKETING CONTINUED Sponsorship Packs should include: 1. Contact details at top of page. 3. State the aims of the team i.e. World champions Paragraph stating the benefits of sponsoring our project. 4. Paragraph of information about the competition Sample media pack sent to Spin Sample Sponsorship Pack sent to Koni Sample Sponsorship Pack Sent to Koni continued During the Team s Media and Sponsorship Campaign a total of: 15 media packs were sent to local and national media outlets 18 Corporate Sponsorship Packs to companies such as Quinn Direct, Vodafone and Koni Ireland. 50 Local Sponsorship Packs to local businesses such as The Happy Pear and Super Valu

18 MARKETING CONTINUED After Regional Finals Media Exposure Bray People Interview: This is the picture which appeared in the Bray People after our regional final success, The most read local paper in Wicklow Greystones News Article We have also appeared in the new local paper the Greystones News since our regional finals Sponsorship Structure: It was decided to organise the sponsorship campaign in the following grades/tiers: Corporate Sponsorship: 1000 euro Gold Sponsorship: 500 euro Silver Sponsorship: 250 euro Bronze Sponsorship: 125 euro Sponsor: Amount Koni Ireland 1000 PM Group 500 Gregory s Garage 250 Fenton Fires 250 ECR Tyres 250 Jim Rock 250 Finnegan Buses 125 Mary O Doherty As well as receiving monetary sponsorship, the team also received the following use of services for free: Digiprint Scoil Dara ICA Finnian Murphy Aishling Conroy Lutterworth College Free Printing Free Use of Laser Printer Free use of Car Spraying Facilities Free Marketing Advice Free Design Advice Fee use of CNC Machine Income and Expenditure Account: Income and Expenditure Account:

19 Website Problems to be solved Sources: Investigation: Conclusions: 1. What makes a good website 2. How to create a website 3. Hosting and URL Other F1 Websites 2. Web Expert: Adam Gammell A good website is: Nice crisp and clear Easy to read User friendly Full of information 2.Talk to expert Create Website 3.Prices for URL and Hosting 1. Website should have: Team page Sponsors page Contact Us Game Gallery 2.Create website in accordance to action plan. 3.Hosting acquired from Hostica, URL acquired from hosting365 The Home page on our website

20 PROJECT MANAGEMENT Set up team office Got new desktop computer. 2 laptops donated to team for home use. Chairs and desks put in room.. Put up Whiteboards Regular Team meetings: Discuss progress Team Address For communication between team members and outside bodies such as sponsors and media outlets Team Diaries: All team members kept day to page diaries which kept records of activities and plans for each day.

21 Action Plans