The formula SAE project in its essence is a time management project and has always been an aspect that previous teams struggle with. The schedule is broken down into three phases: Design, Manufacturing, Testing. The Design phase will consist of research, concept, modeling, and simulation. Manufacturing will include everything to building and assembly of the vehicle. Testing will be on a full system approach to the verify our calculations and fixing any problems that arise. The Design phase is from August to October which after Manufacturing will begin. We aim to start testing a vehicle by the start of February and continue up till middle of May. This year we have made an aggressive schedule to help produce a vehicle that we will be able to test before going to competition.

Chassis & Aerodynamics

A stable aerodynamic concept must be designed with multiple driving situations in mind: straight ahead, cornering, and hard braking. The aim is to maximize downforce without inducing too much drag. A new undertray concept incorporated into the body will generate the majority of the downforce. This is achieved through the use of a large diffuser. The cross section over the entire length of the diffuser continuously compresses the air forcing the ambient air to move at a higher speed. Thereby, the pressure drops below the car, the car is sucked downward helping with traction. The aerodynamic package also includes three-part front and rear wings. The front wing was revised to aid in pathing incoming air under, and along the car body, while moving it away from the tires. This will optimize the flow of air in the subfloor, and to the sidepods to aid in cooling. The rear wing will incorporate a two-position Brake Assist System (BAS) – at the desired approach speed the top airfoil will re-position, creating a large drag force to slow the car down more quickly .

Suspension

The main objective of the suspension subsystem is to connect the chassis of the vehicle to the ground through the use of components such as springs, dampers, rods, bell cranks, bearings, tires, and wheels. The system is designed to ensure safety and performance in high speed cornering, braking, and effective power transmission from the engine to the wheels. Further, the suspension will be adjustable so that it may be tuned to driver preference and specific event goals. The key objectives for RWR this year are to decrease aerodynamic drag by relocating the shock absorber assemblies inboard and implementing a front and back anti-roll system. Improvements to the steering system and braking system will also be areas of focus. Designers will utilize the Dynatune Ride and Handling software package to optimize suspension performance. Rapid prototyping techniques such as 3D printing will be used to create mock up parts and assemblies for fit check and subsystem integration.

Powertrain

The purpose of powertrain is to optimize the power delivery originating from the engine to the wheels. This year, powertrain has been challenged to produce a significantly more powerful engine, while ensuring that all of the components hold up for all dynamic events. RWR is incorporating a turbocharger package on our single cylinder engine. Turbocharging is our best option to increase power while also taking intake restriction into consideration. Turbocharging gives us an option to change our air density to further pack our intake charge. Engine reliability is crucial, so low boost levels will be utilized with adequate tuning time. The drivetrain was designed with priority to ease of maintenance and speed. Many iterations of designs were made and considered to achieve simple maintenance. Speed will be approached in two ways: reducing shift times with the use of a pnuematic paddle shifter and an auto clutch, and obtaining a higher gear ratio. This ratio will provide us with extra torque for use on turns and straights.