A jövô jármûve 2011 extra Formula Student Hungary Overall results FSH 2011 Partnership in the competition Engin for Formula Student It was fun!
Thanks! Partners: MAF Magyar Autóműszaki Felsőoktatásért Alapítvány Sponsors: MAF Magyar Autóműszaki Felsőoktatásért Alapítvány Partners:
editorial Impresszum Tartalom Innomobilitas Járműipari innováció V. évfolyam, 2012 FSH különszám Alapítva: 2006 Megjelenés: negyedévente HU ISSN 1788-2699 ALAPÍTÓK: Budapesti Műszaki és Gazdaságtudományi Egyetem Elektronikus Jármű és Járműirányítási Tudásközpont (EJJT) 1111 Budapest, Stoczek u. 6., J épület 516. Tel.: 1/463-1753. Fax: 1/463-3255. E-mail: info@ejjt.bme.hu Széchenyi István Egyetem Járműipari Regionális Egyetemi Tudásközpont (JRET) 9026 Győr, Egyetem tér 1. Tel.: 96/613-680. Fax: 96/613-681. E-mail: jret@sze.hu X-Meditor Lapkiadó, Oktatásés Rendezvényszervező Kft. 9023 Győr, Csaba u. 21. Levelezési cím: 9002 Győr, Pf. 156 Tel.: 96/618-062. Fax: 96/618-063. E-mail: ajj@xmeditor.hu KIADÓ: X-Meditor Lapkiadó, Oktatásés Rendezvényszervező Kft. Felelős kiadó: Pintér-Péntek Imre SZERKESZTŐSÉG: Autómédia, Fenntartás, Fejlesztés X-Meditor vállalatcsoport autóipari divíziója Felelős szerkesztő: dr. Nagyszokolyai Iván Lapmenedzser: Dudás Alexander Lapkoordinátor: dr. Komócsin Zoltán, Nagy Viktor Szerkesztő: Sándorné Tamási Rita Tel.: 96/618-074. E-mail: auto@xmeditor.hu 04 Köszöntő Partnerség a versenyben Bevezető gondolatok 06 10 18 22 25 27 30 33 38 44 50 Az FSH számokban Izgalom, versenyláz, élmények (fotógaléria) 1. Metropolia Motorsport (FIN) 2. KA-Raceing e.v. (D) 3. Hawks RAcing e.v. (D) Idén csatlakozunk az élmezőnyhöz BME Formula Racing Team Újoncként is helytálltak KEFO Motorsport Ezért tetszett az FSH partnervélemények Legyen saját motorunk! Motorfejlesztés a Formula Student versenysorozatban Engine for FS Engine development in the Formula Student race series FSH: Egyenes út a sikeres jövőbe Szigeti Márk portréja A SZERKESZTŐBIZOTTSÁG TAGJAI: dr. Bercsey Tibor, dr. Bokor József, dr. Czigány Tibor, dr. Czinege Imre, dr. Kardos Károly, dr. Keviczky László, Lepsényi István, dr. Michelberger Pál, dr. Nádai László, dr. Palkovics László, dr. Réti Tamás. dr. Stukovszky Zsolt, Szilasi Péter Tamás, dr. Tisza Miklós NYOMDAI ELŐÁLLÍTÁS: Palatia Nyomda és Kiadó Kft. 9026 Győr, Viza utca 4. PÉLDÁNYSZÁM: 1500 52 56 59 61 Járműiparunk jövője a tét Interjú Palkovics Lászlóval A legjobbak legjobbjaira van szükségünk (Interjú a győri egyetem Audi-tanszék vezetőjével) Együtt az iparral Felsőoktatási vezetők véleménye A innomobilitas Program szakmára szabott kommunikáció 2012 FSH I innomobilitas 3
Pillantás a jövőbe Köszöntő Partnerség a versenyben Partnerség a versenyben? Mi ez? Fából vaskarika? Ellentmondás? Lehetetlen? Minket izgatnak a lehetetlen kihívások, szeretjük az ellentmondásokat, mert ezek visznek előre. Mi, itt, Magyarországon még csak tanuljuk a versenypiaci szabályokat, az írottakkal csak-csak megbirkózunk, de az íratlan szabályok megismerése, az általuk vezérelt magatartás elsajátítása nem megy máról holnapra. Azt a kérdést tettük fel magunknak, hogy lehet-e a piacon nem ritkán ádáz harcot vívó konkurenseket egy közös cél érdekében összefogni? Az ország egyik legjelentősebb húzóágazata a járműipar, s abban mindenki egyetért, hogy fejlesztése közös érdek. Külön-külön mindegyik szereplőjének ez az egyéni érdeke is. De tudnak-e egymással összefogni, tudják-e erőiket egyesíteni, képesek-e egymással alkotó párbeszédre, ha a közös érdek úgy kívánja? Az X-Meditor csapata megtanulta, hogy kommunikációs problémát kizárólag kommunikációval lehet megoldani. Mégpedig minőségi, semleges kommunikációs platformok létrehozásával. AutóMédia Üzletágunk évtizedek óta kutatja a szakma igényeit, alakítja ki kommunikációs termékeit, alkalmazza és kínálja ezeket partnereinek. Legújabb termékünk A Jövő Járműve Program, mely hármas célt tűzött ki maga elé. Semleges, minőségi kommunikációs tereken kínálja: a műszaki értelmiség utánpótlásának minőségi kiválasztását a járműipari versenytársaknak és a műszaki felsőoktatás egymással szintén konkuráló intézményeinek, hogy megvalósulhasson a Partnerség a versenyben; a pályaválasztás előtt álló gyerekeknek, ifjaknak a bemutatkozási lehetőséget, egyúttal a reális életpályamodelleket, karrierépítési utakat az élenjáró járműipari szakmák, cégek bemutatásával, hogy a fiatalok Találkozzanak a jövőjükkel; sikeres szakmabeliek és pályakezdő fiatalok egymásra találásának lehetőségét, Generációk randevúját, hogy egymást biztatva, egymás példájából erőt merítve erősítsék a magyar műszaki értelmiség értékeit. Prémiumkategóriájú nyomtatott folyóirataink kiemelkedően A Jövő Járműve, az azt kiegészítő, támogató, közösségszervező erejű internetes médiumaink, valamint eseményeink élükön a Formula Student Hungary, pályaorientációs, karrierépítő és szakmai kihívást jelentő munkát kínáló Edu+Work rendezvényeink, melyeken találkozóhelyet kínálunk oktatásnak és iparnak ezek mind-mind a fenti célokat szolgálják. Mi az egész régióbeli járműipar és az őt szolgáló egyetemek, főiskolák igényeire, kínálatára figyelünk Önöknek elég, ha A Jövő Járműve Programunkat megismerik, és részesévé válnak. Járműgyártókat, beszállítókat, kutatóintézetek dolgozóit, egyetemek, főiskolák vezetőit, hallgatóit hívjuk az X-Meditor által megalkotott semleges kommunikációs platformra. Ismerjük fel és szolgáljuk együtt közös érdekeinket. Legyünk partnerek a versenyben is! És persze majd a pályán győzzön a jobb, a tájékozottabb, a felkészültebb, a lehetőségeket legjobban kihasználó versenyző. Csütörtöki Tamás divízióvezető AutóMédia Üzletág Pintér-Péntek Imre ügyvezető igazgató X-Meditor Kft. 4 innomobilitas I 2012 FSH
Pillantás ajövőbe Partnership in the competition Partnership in the competition? What is this? Absurdity? Contradiction? Impossibility? We are excited by the impossible challenges, we love contradictions, because they bring us forward. Here in Hungary we are just learning the rules of competitive market, and we can tackle with the written ones although with difficulty - but mastering the unwritten rules and acquiring the behaviour controlled by them cannot be done overnight. The question we asked from ourselves was whether it is possible to unite the competitors - who quite frequently fight a fierce battle in the market - for a common goal. Vehicle industry is one of the most important pulling sectors of the country, and everyone agrees that its development is a common interest. It is also the individual interest of all of its player separately. But can they join with each other, are they able to unite their strengths, are they capable of a creative dialogue with each other if the common goal so requires? The X-Meditor team has learned that any communication problem can be solved exclusively by way of communication, namely by the creation of high-quality, neutral communication platforms. Our AutóMédia branch has been exploring the needs of the trade and developing its communication products for decades, and has been applying and offering them to its customers. Our latest product is the Vehicle of the Future Program, setting triple goals for itself. On neutral, high-quality communication spaces it offers: high-quality selection of the next generation of technical intelligentsia for the competitors in the vehicle industry, and for the technical higher education, who are also competing with each other, in order to be able to materialise the Partnership in the competition; opportunity for children and youngsters before selecting their career for the introduction, and by introducing leading trades and companies realistic models for the life path, ways of building career, so that the youngsters could Meet their future; the opportunity for successful professionals and entrants of meeting each other, the Rendezvous of generations, so that they encouraging each other, drawing power from each other s example - could strengthen the values of the Hungarian technical intelligentsia. Our printed periodicals of premium category prominently The Vehicle of the Future -, our supplementary and promoting Internet media with community organisation strength with Formula Student Hungary in the forefront -, our tender-oriented, and career-building Edu+Work events, offering works with professional challenge, in which we offer a meeting place for the education and the industry all serve for the above goals. We are watching the needs and the offer of the entire vehicle industry in the region, together with those of the universities and colleges serving for them all you have to do is to learn our Vehicle of the Future Program, and to be a part of it. We have been inviting vehicle manufacturers, suppliers, research institute employees, leaders and students of universities and colleges to the neutral communication platform created by X-Meditor. Let s recognise our common goals and serve them together. Let s be partners also in the competition! And of course on the ground let the better, more informed, better prepared competitor, the one utilising the opportunities in maximum way, win. Csütörtöki Tamás divízióvezető AutóMédia Üzletág Pintér-Péntek Imre ügyvezető igazgató X-Meditor Kft. 2012 FSH I innomobilitas 5
A Magyar Verseny Az FSH számokban A tavalyi, 11 csapat részvételével magas színvonalon megrendezett formulaautó-verseny után idén 1 perc 58 másodperc alatt telt be a Formula Student Hungary 2011-es versenyének 30-as nevezési listája az interneten! A várakozólistán lévők száma pedig már meghaladta a további 20-at. Végül 28 csapat érkezett meg a győr gönyűi kikötő betonjára, hogy részt vegyen a szigorú megmérettetésen. A verseny licenctulajdonosa, a Mérnökök a Járműves Műszaki Felsőoktatásért Egyesület célkitűzése, hogy a műszaki felsőoktatás színvonalának emelését segítse. Céljai között szerepel továbbá, hogy a műszaki felsőoktatás és az ipar együttműködését hatékony fórumok segítségével előteremtse, vagy a létező kapcsolatokat gördülékenyebbé tegye. Fontosnak tartja ebben a relációban az olyan közös munkát, mely elsősorban a gyakorlati tapasztalatok megszerzését teszi lehetővé a diákok számára. Kiemelt szerepet tulajdonít továbbá annak, hogy az iskola és a ipari vállalkozás együttműködésében a hallgatók csoportos munkában vehessenek részt, lehetőleg valós, felelősségteljes projekteken keresztül. (Elnök: dr. Palkovics László) A győri versenyt lebonyolító X-Meditor csoport és Autó- Média divíziója legfőbb ambíciója újat, frisset, innovatívat, lendületeset alkotni. Ez a gondolat vezérel bennünket minden egyes munkánk elkészítése során. Hivatásunk, hogy Magyarország és Románia területén, vagy a világon bárhol prémiumminőségű és megjelenésű termékekkel és szolgáltatásokkal szolgáljuk ki partnereink legkülönbözőbb igényeit az információk, a design vagy a rendezvények világában. A Formula Student verseny megrendezésével, annak színvonalával bizonyítjuk, hogy csakis a magas minőségű munkát tartjuk elfogadhatónak mondja Pintér-Péntek Imre, a cég vezetője. FSH in figures After the formula car racing organised last year at a high level with 11 participating teams, this year the application list of 30 teams for the 2011 race of Formula Student Hungary was filled up within 1 minute 58 seconds through Internet! The number of the teams on the waiting list was over 20. Finally 28 teams showed up at the concrete of the Győr-Gönyű Port, in order to participate in the stringent assessment. The goal of the license owner of the race, Engineers for the Vehicle Technical Higher Education Association, is to help increasing the level of technical higher education. Its aims contain furthermore to promote the co-operation between the technical higher education and the industry by way of efficient forums, and to turn the existing contacts more fluent. They find the kind of common work in this relation important, which makes it possible for the students to acquire practical experiences first of all. They assign an outstanding role furthermore to the possibility for the students to take part in group-work within the cooperation of the school and the industrial undertaking, through responsible projects. (Chairman: Dr. László Palkovics) Main ambition of X-Meditor Group and its AutoMedia division the organisers of the Győr race event is to create something new, fresh, innovative and dynamic. We are lead with this thought while preparing any of our works. Our mission is to meet the most various needs of our customers with products of premium quality and appearance in the world of information, design or events in the territory of Hungary and Romania, or anywhere on the earth. By organising the Formula Student race, by its high level we prove that we find only the high-quality work acceptable says Imre Pintér-Péntek, the manager of the company. Overall placing 1 2 3 4 Overall scores 917,377 903,407 883,281 839,532 Acceleration 75 62,982 56,438 65,496 Autocross 100 84,947 97,347 76,831 Cost and manufacturing 80 70,766 59,742 75,198 Design report 132,667 130,542 130,917 126,125 Dynamic overall 629,71 627,099 620,883 579,731 Endurance 283 321,3 325 300,8 Fuel Efficiency 96,74 97,22 89,88 86,11 Presentation 75 75 71,739 68,478 Skid Pad 75 60,671 52,221 50,497 Static Overall 287,667 276,308 262,397 269,802 Car nr. 42 22 69 18 University Metropolia Motorsport KA-Racing e.v. HAWKS Racing e.v. FS Team Tallinn 6 innomobilitas I 2012 FSH
A Magyar Verseny Overall placing 5 6 7 8 Overall scores 838,658 835,881 682,353 670,824 Acceleration 70,942 47,473 59,809 73,419 Autocross 79,627 89,164 65,277 49,81 Cost and manufacturing 66,25 82,937 53,173 43,843 Design report 119,458 125,042 108,542 120,583 Dynamic overall 594,254 570,838 499,442 447,702 Endurance 279 312,8 217,3 184,5 Fuel Efficiency 100 85,9 93,64 83,91 Presentation 58,696 57,065 21,196 58,696 Skid Pad 64,663 35,53 63,454 56,075 Static Overall 244,404 265,044 182,91 223,122 Car nr. 74 14 6 91 University High-Octane Motorsports BME Formula Racing Team UPBracing Team Lions Racing Team Overall placing 9 10 11 12 Overall scores 602,481 596,768 533,92 499,668 Acceleration 64,969 47,512 3,5 65,017 Autocross 52,766 37,47 27,82 82,77 Cost and manufacturing 57,929 70,153 89,484 52,739 Design report 103,125 134,208 105,125 128,25 Dynamic overall 402,297 335,342 282,246 261,614 Endurance 173,4 127,8 152,3 0 Fuel Efficiency 79,44 96,04 79,93 55,71 Presentation 39,13 57,065 57,065 57,065 Skid Pad 31,689 26,557 18,684 58,12 Static Overall 200,184 261,427 251,674 238,055 Car nr. 4 41 77 76 University Bodensee Racing Team Konstanz TUW Racing Technikum Mittweida Motorsport Racetech Racing Team TU Bergakademie Freiberg e.v. 2012 FSH I innomobilitas 7
A Magyar Verseny Overall placing 13 14 15 16 Overall scores 453,586 450,587 443,494 413,872 Acceleration 52,191 64,969 60,991 3,5 Autocross 73,213 79,449 78,502 12,224 Cost and manufacturing 82,617 51,204 84,833 62,204 Design report 122,625 129,25 119,625 83,875 Dynamic overall 176,605 196,763 186,862 220,511 Endurance 0 0 0 74,52 Fuel Efficiency 0 0 0 95,89 Presentation 71,739 73,37 52,174 47,283 Skid Pad 51,202 52,345 47,369 34,379 Static Overall 276,981 253,824 256,632 193,362 Car nr. 1 61 64 89 University Running Snail Racing Team munichmotorsport Unibo Motorsport AM team Overall placing 17 18 19 20 Overall scores 406,373 398,538 369,417 368,948 Acceleration 53,949 51,736 65,4 53,066 Autocross 20,093 71,34 43,404 26,378 Cost and manufacturing 90,261 55,293 72,616 0 Design report 116,708 114,75 116,833 52 Dynamic overall 132,556 186,103 112,304 302,275 Endurance 0 0 0 134,6 Fuel Efficiency 0 22,12 0 70,52 Presentation 66,848 42,391 67,663 14,674 Skid Pad 58,513 40,911 3,5 17,73 Static Overall 273,817 212,434 257,113 66,674 Car nr. 12 63 62 29 University Team HARE Aixtreme Racing Dynamics e.v. KEFO Motorsport 8 innomobilitas I 2012 FSH
A Magyar Verseny Overall placing 21 22 23 24 Overall scores 362,223 328,544 320,534 261,81 Acceleration 44,355 34,683 55,745 21,877 Autocross 48,414 9,874 4,5 4,5 Cost and manufacturing 69,896 69,065 90,341 71,165 Design report 108,667 114,375 87,917 112,208 Dynamic overall 151,052 89,669 99,885 41,372 Endurance 0 0 0 0 Fuel Efficiency 27,52 0 0 0 Presentation 32,609 55,435 42,391 57,065 Skid Pad 30,759 45,113 39,641 14,994 Static Overall 211,171 238,875 220,649 240,439 Car nr. 48 50 16 71 University GET Racing Saar-Racing Team Prom Racing KTH Racing Overall placing 25 26 27 28 Overall scores 236,368 224,799 222,525 213,531 Acceleration 37,581 43,416 28,543 0 Autocross 0 15,934 4,5 0 Cost and manufacturing 45,837 36,539 56,022 64,937 Design report 95,875 103 99,417 107,833 Dynamic overall 59,601 90,586 36,543 0 Endurance 0 0 0 0 Fuel Efficiency 0 0 0 0 Presentation 35,054 14,674 50,543 40,761 Skid Pad 22,02 31,236 3,5 0 Static Overall 176,767 154,213 205,982 213,531 Car nr. 125 79 57 55 University UnicaR-Unica Racing Team Tampere UAS Motorsport ENIM Racing Team Riteh Racing Team 2012 FSH I innomobilitas 9
A Magyar Verseny Izgalom, versenyláz, élmények, vélemények Excitement, race fever, experiences, feed back 10 innomobilitas I 2012 FSH
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a Magyar Verseny 14 innomobilitas I 2012 FSH
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a Magyar Verseny Metropolia Motorsport (FIN) Last petrol hurrah from Helsinki UAS! Jarmo Niskala Metropolia Motorsport Formula Engineering Team First things first: we are going to compete with electric formulas from now on. While I am writing this article the planning and design of the new car with battery magic is already on its way. This article, however, is not about the future car but the car which was more succesful than any of its predecessors in the team s history. Here you will get a good view of how our car was desgined and built. The last of the gasoline guzzling monsters from Helsinki UAS. Our Group B. Kezdjük a legfontosabbal: mostantól kezdve elektromos formulákkal versenyzünk. Mialatt ezt a cikket írom, már folyamatban van az akkumulátorcsodás új autó tervezése és szerkesztése. Azonban ez a cikk nem a jövőbeli autóról szól, hanem arról az autóról, amely sikeresebb volt valamennyi elődjénél a csapat történetében. Adunk egy jó áttekintést arról, hogyan terveztük és gyártottuk az autónkat. Az utolsó benzinfaló szörnyeteget a Helsinki UAS-tól. B csoportunk. THE BEGINNING The design process of HPF011 began in September 2010 and already at early stage the roll-out of the car was scheduled for Easter 2011 to ensure that the team is having enough time for testing. With careful planning and hard work HPF011 was revealed to the public in April 22th 2011 in Helsinki Exhibition Centre. The welcome for the car was very warm and many of the former team members titled the car to be with the best finish yet to come out of the workshop. FRAME & COMPOSITES HPF011 is built around a tubular steel space frame. Main design was conducted by Markus Ketonen and the objectives in the design were driver ergonomics and safety, compact dimensions and good support for suspension pick-ups. Target weight for the frame was set to 30kg. Driver ergonomics were researched and tested with two different mock-ups with one focusing on physical size of the driver s cell and the other concentrating on seating and control positions. Safety is improved with the use of composite side impact panels made from aluminium honeycomb and 200g twill weave carbon fibre. Outer panels were also included with carbon-aramid hybrid layer for preventing penetration to drivers cabin in collision situations. Similar panels are utilized in the fully stressed floor pan. Additionally section modulus of the tubes was increased with the use of larger outer diameter tubes. The bodywork was sketched and modelled by Helsinki UAS industrial design students: Juha Tuomola, Otso Leppänen and Mikko Hyrkkänen. Objective for the shape was to keep the fit as Main design goals for HPF011 were to make it easier and lighter to drive but also to make it as reliable as possible still keeping weight under 200kg in ready to race condition. Highly accurate 3D-assembly with every part of the car was done to avoid as much as possible the probable problems when manufacturing parts and assembling the car. Complete assembly also made a good starting point for the cost report. First tests were conducted in mid-april 2011 and the total mileage was over 1000km. Use of data acquisition and numerous sensors gave us a good starting point to find the best possible setup for our car. For example, during the testing we used three infrared temperature sensors on each tire to monitor tire dynamic temperatures and strain gauge measurements were conducted to confirm the real forces in suspension linkages in different dynamic driving situations. 18 innomobilitas I 2012 FSH
a Magyar Verseny tight as possible around the car and its components whilst having a sleek and distinctive appearance. Bodywork was made from two layers of aramid fibre with vacuum epoxy injection method. Additional carbon fibre strips and foam core reinforcements were used where necessary. To support the suspension, nodal pick-ups are used and the target rigidity was set to a maximum of 0.5 rotational distortion in any driving condition (maximum a-arm stress = worst case scenario). Finite element analysis was used to research frame geometry options and individual tube dimensions to reduce stresses and to achieve a frame stiffness of 3000Nm/. The base material of the frame is Ruukki Form high tensile strength steel which is designed for use in safety structures such as crash zones in a passenger vehicle. Tube ends are laser cut for perfect fitment and all welding was done with TIG. Finished product including paint and brackets weighed just 29.9 kilograms. Car s impact attenuator is constructed of bonded structural foam, shaped into quadruped block sloping to a common flat front level. The middle section is filled with light extrusion foam with a hollow cavity in the center of rear section. The block is covered with one layer of wet laminated carbon fiber to form a protective shell. Composites manager in 2011 was John-Robert Yrjölä. CHASSIS Suspension is designed by Jani Hattunen and Toni Ristolainen. The design itself was based around two main components: Hoosier 13 tires and Öhlins dampers. Main objectives in suspension design were to make the car easier and lighter to drive and easier to adjust. Suspension and steering geometries are designed with OptimumK kinematics software and self-made Excel spreadsheets. Suspension geometry design began with analysing tire data available through Tire Test Consortium. Based on the data it was decided to use Hoosier R25B tires on 6 wide rims. Compared to 7 wide rims, 6 wide rims offer more lateral force on small slip angles. Although maximum lateral force is slightly reduced, the car is more driveable on small slip angles. Wheels themselves are 3-piece with in-house designed centres, milled from high strength aluminium and shells manufactured by Keizer. The wheels are fastened with centre lock nut with self-made special locking mechanism. 2012 FSH I innomobilitas 19
a Magyar Verseny HPF011 s wheelbase is 1550mm. Short wheelbase helped to make the frame design in rear end very compact. Track is 1200mm in front and 1150mm in rear. Weight distribution with a 68kg driver is 45%/55% front/rear. Öhlins 4-way adjustable dampers are positioned up and horizontally on both ends, making them easy to adjust and maintain. Dampers are operated via Excel Composites composite pushrods and rockers milled from high strength aluminium. Bespoke anti-roll bars are used on both axles to reduce body roll and to change the balance of the cars roll stiffness. Design goal for steering system was to allow the driver to hold both hands on the steering wheel even on tightest corners while keeping the steering torque at acceptable level. As a result 305 lock-to-lock steering angle with 6.2:1 ratio is used. Steering components are designed to minimize free play and therefore use of angle gear is adopted. Cast aluminium steering gear housing is bonded between floor panels but still allows full service of the steering system. Responsibility of steering system was on our technical manager Timo Elonen. Strong but very lightweight a-arms are made from carbon fibre tubes with aluminium inserts that are bonded together in a specific jig. Tie-rods and pushrods are also made in similar fashion. Left handed thread in the other end of push- and tie rods allows easy adjustment even when installed. Motion ratio is designed to be linear with effective motion ratio of 1.16 in front and 1.17 in rear. Suspension movement is measured with rotary potentiometers mounted straight to the rockers. BRAKES The main responsibility for brake system during season 2011 was on the shoulders of Antti Järvinen. The design basis for calculating and choosing the brake components was a self-made Excel spreadsheet calculator, which helped the team understand brake system mechanical design and component choosing. The brake system was designed to give a firm and fast pedal response for the driver. To achieve 1.0G lateral deceleration, approximately 500-550N pedal force is needed. Pedal assembly is designed to allow fast adjustment of the pedal distance to three different positions. The preferred length of the driver is 150-185cm. Driver can adjust the brake balance mechanically while driving from the balance knob on the left side of the dash. Pedal ratio is also adjustable to three different ratios. To improve the driver ergonomics a composite constructed heel support was designed to give better pedal control and relieve effort from the driver to hold ones feet in place. Master cylinders are push-type Tilton 77-Series and offer a great value for the money: lightweight, adjustable cut-off distance and compact design. Stäubli clean-break coupling is used in rear 20 innomobilitas I 2012 FSH
a Magyar Verseny hydraulic circuit to make service easier. Rear section of the frame can be removed and installed without bleeding the rear circuit! ISR lightweight and reliable aluminium calipers are used, 4-piston in front, 2-piston in rear. Same brake pad is used in front and rear to make maintenance easier. A floating type 195mm hub mounted brake disc is used both in front and rear. Brake disc is self-developed, laser-cut from mild steel and then ground to 4 mm thickness. Brake discs are also easy to service due to smart design which allows removal and installation of the brake disc without removing the caliper. The brake disc hubs are CNC machined from Al 7075-T6 and designed to reduce weight and brake noise. Discs are fastened with riveted stainless steel pins, which have a wave spring to reduce vibration while allowing components to have enough space for thermal expansion. clearance, to avoid knock and to reduce the hydrocarbon emissions which also means improved BSFC. The exhaust manifold is 4-2-1 type and made from thin wall stainless steel tube. The primary headers have steps to prevent exhaust gas backflow during overlap and to get better mid-range torque. The lightweight titanium muffler is of absorption type. The whole exhaust manifold is assembled with springs for easy maintenance. A wideband lambda and a resistive EGT-sensor have been fitted into the secondary. POWERTRAIN & ELECTRICS Our engine team for season 2011 was Aleksi Ojala, Antti Kokko, Tero Romunen and Atte Schumilov engine team manager being mr. Ojala. The base of the powertrain is a 4 cylinder 599cc Yamaha R6 2010 engine. The main goals for the engine development were high performance in whole operating range, fast throttle response, good driveability and throttle control, reliability and low fuel consumption. After intensive period of GT-Power simulations, dynamometer and track testing, the engine final output is 75kW @ 10700 rpm and 72Nm @ 8300 rpm. Everything this with the mandatory 20mm intake restrictor. Measured data from the dynamometer was used to correlate and improve the simulation model. The intake runners, camshaft timing, exhaust primaries and secondaries were all tested on the dynamometer to find the most suitable setup for our demand. Restrictor has been integrated into the guillotine type throttle valve. Intake manifold and plenum with internal air filter is self-designed and developed. The secondary injectors are staged to get extra performance and efficiency on high rpm. The standard oil pump has been removed and replaced with a 3-stage drysump unit. Scavenge and pressure pipes are integrated into 6mm thick, self-designed magnesium oil pan. Fuel tank is selfdesigned and manufactured and features trap doors to prevent air suctioning on high transient lateral accelerations. Cooling system is self-designed around a single radiator with cast aluminium ends. PWM controlled electric pump circulates the water from engine to radiator and back through aluminium tubing. The intake ports have been made significantly smaller to keep the flow velocity high and ramming pulses strong. The camshafts are self-designed with steeper ramps, reduced overlap, duration and lift. This allows the dynamic compression ratio to go up as 9.62:1. The pistons have been modified to keep the squish area The integrated gearbox has also been modified. The 5th and 6th gears have been removed and the gear drum is redesigned with neutral at the bottom of the pattern. Gearshift is electropneumatically actuated via steering wheel paddles. With the aid of a force sensor in the pneumatic actuator and a gear drum position sensor, the ignition cut time during gear change is as low as 40ms. Sprocket driven final drive utilizes a single 428 chain and Drexler limited slip differential with adjustable ramp angles. Responsible of drivetrain was also technical manager Timo Elonen. Vehicle electric system was designed by Sami Koistinen and it is built around MoTeC M880 engine management system, ADL data-acquisition unit, PDM 15 power distribution module and a self-manufactured steering wheel ECU. All ECU:s are connected to vehicle CAN-bus. Rotary encoder and push button data from steering wheel is used to adjust parameters in different ECU:s e.g. engine maps, traction and launch control, dash display views etc. All wire harness routes, bundle lengths and branch points are derived from an accurate 3D-model of the harness. Harness is self-built on table from spec-44 wire, shrink tubing and shape pieces and Deutsch IMC connectors. Start battery is a Lithium-based 8-cell pack weighing only 600gr. SUCCESS Like said, this car was more successful than any other before in our teams history. The pinnacle being overall win in Hungary, we also managed to get 6th place in England, 4th in Germany and 3rd in the Baltic Open s friendly competition. The design shown above managed to get us into the design finals in every competition excluding Baltic Open which does not have any of the static events. In design event, again the pinnacle was the event in Hungary where the final position was 2nd. This is something I am sure many of the people who have seen the car will agree with me: this was a good car to end the legacy of petrol cars in Helsinki. The future of car design in Metropolia Motorsport is still yet to be seen but the racing itself with petrol cars is not going to end. At least not until the next Ice Racing... 2012 FSH I innomobilitas 21