2009_06
DESCRIPTION
Special thanks and congratulations to our graduating Formula SAE team members. Left FSAE class of 2009. Randy Roque, Douglas Tse, Gary Ta, David Sam, Calvin Chin, Arturo Quintero, and Ken Lau. Right FSAE class of 2010 and beyond. Joey Penniman, Ruben Delgadillo, Chris Lau, Fortune Fresquez, and David Voth. x tTRANSCRIPT
UP 2 SPEED
AnSAEInternationalnewsletterforSponsors,Faculty,andStudents@SJSU June2009
x t
ConGRADUATIONS Whatdoyouwanttobewhenyougrowup?Wheredoyouseeyourselfin5years?10years?Whenwillyoubedone?
AfewofourmembersalongwiththeSanJoseStateUniversityClassof2009cannowanswerthesequestions.Forsome,thisjourneytooklongerthanexpected.Forothers,itonlyseemedlikeyesterdaytheywerejustfreshman.Goalswereaccomplished,dreamsbecamereality,andfriendshipswerecreatedthatwillcontinueforyearstocome.
Congratulationstothegraduatingclassof2009.Mayyourfutureendeavorsleadyoutoprosperous,successful,andwonderfullives.
SpecialthanksandcongratulationstoourgraduatingFormulaSAEteammembers.
The 2010 SAE International SJSU
Officers
Congratulationstothenewlyelected2010SAEInternationalSJSUStudentOfficers.
President–RandyFloresca
VicePresident–DavidVoth
ExecutiveDirector–AlanCheng
Treasurer–TonyLee
PublicRelations/Marketing–MarissaDayton
Members/Receptions–JeffYan
EventsDirector–AnishRamrakhyani
Graphics/Artist–FortuneFresquez
WithprojectslikeFormulaHybrid,FormulaSAE,BajaSAE,andBEUNITEDwehaveabusyscheduleaheadofus.OurSAEInternationalstudentchapterislookingforwardtothe2010academicyearandcan’twaittomakemorepositivedifferencesinandaroundcampus.Formoreinformationpleasevisit:http://www.engr.sjsu.edu/sae
LeftFSAEclassof2009.RandyRoque,DouglasTse,GaryTa,DavidSam,CalvinChin,ArturoQuintero,andKenLau.
RightFSAEclassof2010andbeyond.JoeyPenniman,RubenDelgadillo,ChrisLau,FortuneFresquez,andDavidVoth.
2
Testingstudentsbyhavingafinalsweekisalwaysfun.Butwhatcanbebetterthancelebratingtheendofasemesterbyaseriesoftests?Howabouttestingourveryownstudentdesignedandbuiltformulastyleracecar.Duringfinalsweek,wedidn’tjustchallengeourselvesbystudyingforourclasses,wemadesurethatourcarwouldbereadyforsomeseriousdriving.Itwasn’teasy.
Aftermorethan32hoursoftroubleshootingelectricalgremlinswefoundoutthatourcarwasn’trunningproperlyduetoapinchedfuelpumpline.OncewereplacedthelineourFSAEteamwasabletogetvaluabletimetestingourracecar.InitialtestingwasdoneoncampusatplacesliketheengineeringcourtyardanddrivewaybehindroomE123.
Aftersomediscussion,driving,andnoisepollutingitwasclearthatourcarwastoofastandtooloudforthesesmallareas.Soournextstopwasatthetopofaparkinggaragethatwasrightacrossthestreet.Wewereabletodoafewshortaccelerationandskidpadruns.Thisgaveourpotentialdriversachancetogetafeelforthecarandalsomadethemrealizethatthiswasthefastestcartheyhaveeverdriven.
Whiletestingthecarourteamnoticedafewthings:fastenersvibratingloose,chargingsystemnotcharging,coolingsystemnotcooling,andapedalassemblythatwasmakingmorenoisethantheexhaust.Alltheseproblemsweresolvedbysimplesolutions:replacethefastenersanduselocknuts,replacetheregulatorrectifierwithonefroma2007CBR600RR,andusenutsandboltstopreventthepedalassemblyfromrattling.Oncethesesolutionswereimplemented,wewereofftotheClubAutoSporttestinggrounds.
Formula SAE Testing
ClubAutoSportallowedourteamtousetheirfacilitiestosetupandtestourcar.Wewereabletosetupshortautocrossstyletrackswithaseriesofslaloms,straights,hairpins,andchicanes.Thiswastheperfectopportunitytogetourdriverstrainedandgaveusthechancetoseehowwellourcarcouldhandle.
Wetestedourcarformorethantwelvehoursoveratwo‐dayperiodatClubAutoSport.Wemadesuspensionadjustments,measuredtirepressures,madedriverchanges,andmostimportantly,weworkedasteamtounderstandhowourcarhandlesandperforms.
Thesenextfewweekswewillbefinetuningourcar,gettingourdriversprepared,andpracticingforthedesign,costanalysis,andbusinessproposalpresentations.Checkoutthevideosofourteamtestingthecaronyoutube:http://www.youtube.com/sjsuformulasae
3
!"#$%&'($)*+,-
./0/*
OurFormulaHybridteamkicksitintoahighergearandbeginsthedesignphase.
AmonthoforganizationhasdonealotfortheHybridteam,whichisnowdrivingfullspeedintothedesignstage.Membershavebeenorganizedintothreecategories:ChassisTeamwhichisresponsibleforsuspension,frame,steeringandbraking;PowertrainTeamwhichisresponsiblefordrivetrain,engine,transmission,andthrottle;andElectronicsTeamwhichisresponsibleforallelectricalcircuitry,servo‐controls,andfusing.
Nowthatweareorganized,wehavebeguntotackletheallimportantdesignstage.OurChassisTeamhasbeenrunninginitialiterationsofsuspensiondesign,whiletheElectronicsandPowertrainTeamshavebeendiscussingwhichmotorstouse.Meetingsarehappeningregularly,sopleasedon’twaittojointheteam.
Theteam’swebsiteisnowupandrunningat:www.engr.sjsu.edu/sae/formulahybrid.Checkitoutforthelatestnews,events,andinfosurroundingtheFormula‐Hybrid@SJSU.
TheTeamistakingatriptoCaliforniaPolytechnicUniversityonMonday,June8th.CalPolytook1stPlaceOverallamongrookieentriesatthisyear’sFormula‐Hybridcompetition.Duringthevisitwewillgetafeelfortheelectricalcircuitryinvolvedaswellasthesuspensioninvolvedinanelectricpoweredracecar.Moreinfotocomesoon!
JoshuaHoganF‐[email protected]@gmail.com(408)807‐4272
SponsorshipPackagesOurSanJoseStateUniversityFormula‐Hybridraceteamwelcomesandappreciatessponsorshipinmanyways.Directfundingwillhelppurchasematerials,parts,tools,andequipmenttomakethisprojectasuccess.Contributionsofpartsorserviceswillalsoaidincreatingacompetitivevehicle.Allmonetarydonationsaretaxdeductibleandgreatlyappreciated.LithiumIonSpartanPackage($7,500)LithiumIonpackagebenefitsplus:• Accesstoteammemberresumes• Additionallogoonthenoseofvehicle• CompanylogofeaturedonallteamhelmetsLithiumIonPackage($5,000+)NickelMetalHydridepackagebenefitsplus:• Upgradetolargestpossiblelogoinhighly
visiblelocationonvehicle• Companymentioninallpressreleasesand
newsletters• Companylogofeaturedonteambannersatallpublic
eventsNickelMetalHydridePackage($2,500+)NickelCadmiumpackagebenefitsplus:• Upgradetolargecompanylogofeaturedonthe
sidefairing• CompanylogofeaturedonallteamapparelNickelCadmiumPackage ($1,000+)Alkalinepackagebenefitsplus:• Upgradetoamediumsizecompanylogoon
vehicle• Teamphotowithmember’ssignaturesAlkalinePackage ($500+)• Smallcompanylogoonvehicle• Companylogoandlinkonteamwebsite• DVDphotoalbumdocumentingthevehicle’s
designandconstruction
4
Bracketiquette
AswecloseinonfinishingourfirstFormulaSAEcar,werealizethatalongthewaywetendtooverlooksmallaspectsofracecarengineeringthatmanywoulddeemsecondaryorunimportant.Wetakecertaindesignelementsforgranteduntilitactuallybecomestimetodesigntheparts.Aspectslikehowbodypanelsarefastenedontoachassis,orhowtheseatofaracecarisincorporatedintothefirewallorevensomethingasuninterestingashowteamsincorporateabrakelightswitchintothepedalassemblyaredesignproblemsthathavemanysolutionsbutmanypeopledon’tgivethemasecondlook.
Perhapsevenmorepervasiveishowlittleattentionisgiventothebracketrydesignedintoaracecar.Whenitcomestimetoinstallaperfectlygoodcomponentintothechassis,frequentattentionispaidtowherethecomponentwillgo,butnotnecessarilyhowitwillbeattached.Itmayverywellendupbeingboltedorrivetedtoanoverlyheavy,improperlyloaded,ill‐“designed”bracketthathasnoplaceonaracecar.Inmyopinionjustasmuchattentionshouldbegiventobothwhereandhowacomponentisinstalled!
CarrollSmithsaysinchapter4ofPreparetoWinthatthemainreasonwhybracketsfail(andtheresultingracelost)isduetothefactthatbracketsareoftentimesanafterthought.Anexampleofthisiswhenafabricatorignoresthefactthatanysortoftankforfluid(fuel,oilorwater)willbemuchheavierwhenfullandbeevenheavierwhenthecarseesanysortofgloading.
Thedifferencebetweenaproperlydesignedbracketandthatofthe“homeandgarden”typeisusuallyfairlysmall.Theworsttypeofbracketisonethatloadedinthedirectionmostlikelytocausefailure(usuallybending)andisoverlyheavy,andalmostalwaysoneoftencomplimentstheother.Inordertokeepthebracketfromfailing,itsmassisincreasedsomuchthatitislaughable.Belowaretwobracketdesignsmeanttobeweldedtoatube:
BracketAshowsatangentialtabwithaholeinit,whileBracketBisalsoatab,butwithtriangulargussetingfoldedintoit.
BothweredesignedinSolidWorkstohavethesamelengthandweightandthenanalyzedinCosmosas4130chromoly.BracketAhadaresultingthicknessof0.125inwhilebracketBhadathicknessof0.065,abouthalfofbracketA.A50lbloadwasapplied3inchesoutfromthefixedendofthebrackets.Elementsizewasheldconstantforbothbrackets.Thecorrespondingdataforthebracketscanbefoundintable1.
Table1
BracketA BracketBWeight(lb) 0.0136 0.0136Thickness(in) 0.125 0.065Deflectionatend(in) 0.0758 0.0035FOS(toyielding) 1.3 4.7
Althoughphysicaltestingshouldbedonetovalidatethesenumbers,theincreaseinrigidityandstrengthbyputtingalittleextrathoughtintobracketsishardtoignore.It’shardtoarguewithafactorofsafetyincreaseofover3.5andanincreaseinstiffnessofover200percent.
Thepointofallthisisthatit’snotveryhardtodesignabracketthatwillbelightandstrongaslongasyouputalittlethoughtintoit.Iliketothinkthatthereasonpeopleglazeoverbracketdesignsooftenisduetothefactthatwhentheyseeaproperlydesignedbracket,theysimplywriteitoff.Whenpeopleseesomethingdesignedproperlytheydon’tanalyzeit,theysimplythinkitlooks“right”andmoveon.Hopefullywithalittlethoughtandingenuity,wecanmaketheworldabetterplaceonebracketatatime.
JoeyPennimanChiefEngineer–SJSUFSAE
Tech Talk
BracketA BracketB
5
June13,2009ActiveAutoBody
PaintingofourFSAEcar
June116,2009EngineeringRoomE123PreparingforFSAEWest
June6,2009
EngineeringRoomE114BHotelandShirtpaymentsdue
June89,2009SanLuisObispo
FormulaHybridCollaboration
June10,2009EngineeringRoomE114B
2010FormulaSAEKickOffMeeting
June1621,2009Fontana,CA
FormulaSAEWest
June21,2009SanJoseStateUniversity
2010FormulaSAEDesignBegins
July352009VolunteeringforMotoGP
MazdaLagunaSecaRaceway
Upcoming Events
SeveraloftheFormulaSAEteammembersmanagedtofindthetimetodesignandcompleteaBajavehicleforthe2009BajaWestcompetitionwhilststillplayingvitalrolesinFormulaSAEandkeepingupwithschool.The2009BajaSAEcompetitiontookplaceinPortlandOregonandWashougalWashingtonfromMay6‐10th.Ourvehiclefeatured4‐linkrearsuspension,anextremelylightweightandcomfortablecustomseat,andcharacterthatcanonlybedevelopedhereatSanJoseStateUniversity.Thisyear’svehiclewasalsosignificantlylighterthanthevehiclefromlastyear.
Thehighlightoftheendurancewastheso‐called“logdrops.”Theselargedropswereseparatedbytelephonepolesacrossthemuddytrack.Manyteamsrolledtheirvehicleshereandsomewereremovedfromthecompetitionforcracksintherollhoops.Wetalkedwithmanyteamsabouttheirexperiencesinendurance.Ourfavoriteteamswere:EcoledeTechnologieSuperieure(ETS),OregonState,andMichiganTech.However,mostimpressivewasNebraskaState’steamandtheirfirstyearvehicle.Theymadeitthroughallbutthelasttenminutesofendurancewhenabrokenaxleputthemoutoftherace.Attheendoftherace,everyonelookedthesame:completelycoveredinmud.
Thecompetitionalsogaveourteamachancetoseefirsthandwhichfeatureshelpedandhinderedvehiclesindifferentevents.Forexample,ifateamwantedtobecompetitiveintherockcrawltheywouldneedtohaveagearboxwithreverseandneutral.Cuttingbrakesordifferentialbrakingwouldalsobeadvantageous.However,iflightweight,simplicity,andreliabilityforenduranceweretopprioritiesthenasingle‐speedgearboxwithaCVTmightbethebestchoice.Overall,participatinginthecompetitionwasverymotivational.Thereweremanytalentedandcreativeteamsoutthere.Wehavebeeninspiredmorethanevertobringawinningcartocompetition.Formoreinformationpleasevisit:http://www.engr.sjsu.edu/sae/minibaja/
Baja SAE at SJSU
Newsletter Staff: Editor/Writer: Randy Floresca Writer: Joey Penniman Writer: Johanna Knudsen Writer: Josh Hogan
6
BajaSAECaptain‐DarrenSchwald–[email protected]–JoshHogan‐[email protected]‐RubenDelgadillo‐[email protected]
Thank You to our Sponsors
RandyFlorescaPresident(510)206[email protected]
Gold Sponsors
Silver Sponsors
haven
Bronze Sponsors Bronze Sponsors
R S RACING SPARTAN
www.spartanracing.net
At San Jose State University
gpBIKE PARTS