2016 rules changes - scrutineering · 2016 rules changes - summary fsae-all per 2016 fsae rules 2...

October 31, 2015

2016 Rules Changes

Michael Royce Albion Associates, LLC

2016 Rules Changes - Summary FSAE-All Per 2016 FSAE Rules

2 2016 Rules Changes

The rules changed include, but are not limited to, the following:

Rule # System

•  T3.38 Anti Intrusion Plate for Monocoque Chassis •  AF5.2 Required Submissions •  AF7 Additional Non Applicable Rules •  IC1.7.3 Recirculation Valves •  IC1.9.1.b Fuel Rail Materials •  IC1.11 - IC1.16 Electronic Throttle Control •  IC2.6 Fuel Filler Neck and Sight Tube Clarifications •  IC4.4.4 Lithium Battery •  IC4.6 Voltage Limits •  EV4.2 Tractive System Active Light •  S4.11.4 Engine Cost For 2016 Formula SAE Competitions in United States, the Cost Report Submission process may be changed. Please refer to the website for additional announcements and information.

2016 Rules Changes - Summary FSAE All


Rule Number System Change

•  A8.1 & A8.5 Cost Report PART S - ARTICLE 4: “Cost Report” - Report must comply with the Cost Event Rules.

*For 2016 Formula SAE Competitions in United States, Cost Report Submission process may be changed. Please refer to the website for additional announcements and information.

2016 Rules Change FSAE All T3.38 Monocoque IA Anti-Intrusion Plate


Rule Number Change

•  T3.38.1 Composite AI plates must not fail in a frontal impact. Strength of the AI plate must be verified by physical testing or a combination of physical testing and analysis. All physical test results and any analysis completed must be included in the SES.

•  T3.38.2 Strength of composite AI plates may be verified by physical testing under rules T3.21.2 and T3.21.3.

•  T3.38.3 Strength of composite AI plates may be verified by laminate material testing and calculations of 3 point bending and perimeter shear analysis. Composite laminate materials must be tested under T3.30.3 and T3.30.5. Analysis of the AI plate under 3-point bending must show the AI plate does not fail under a static load of 120 kN distributed over 150mm of length, and perimeter shear analysis must show each attachment can hold 20 kN in any direction.

2016 Rules Changes – FSAE All T14.2 Helmets


Rule Number Change

•  T14.2 M2000, K2000 & SA200 helmets deleted,

SAH2010 added

M2015, K2015, SA2015 SAH2015 added

FIA 8859-2015 added

Note: This change has not yet been published

2016 Rules Changes – FSAE All AF Rules

6

AF5.2 A Nastran analysis deck and supporting documentation must be submitted electronically with the “Notice of Intent” and SRCF. Nastran does not have to be used for the analysis, but is the required format for the organizer's to review the analysis input decks. ARTICLE 7: NON-APPLICABLE RULES: CHASSIS/FRAME The following rules are not applicable when building a frame to this alternative rule set. •  AF7.12 T3.33.1 In addition to proving that the strength of the monocoque is adequate, the

monocoque… •  AF7.13 T3.33.2 The EI of the vertical side of the front bulkhead support structure must be

equivalent… •  AF7.14 T3.34.1 In the region longitudinally forward of the Main Roll Hoop and aft of the

Front Roll… •  AF7.15 T3.34.2 The vertical side impact zone between the upper surface of the floor and

350 mm… •  AF7.16 T3.34.3 The vertical side impact zone between the upper surface of the floor and

350 mm… •  AF7.17 T3.37 Monocoque Front and Main Hoop Bracing

2016 Rules Changes – FSAE IC


IC1.7.3 If pop-off valves, recirculation valves, or heat exchangers (intercoolers) are used, they

may only be positioned in the intake system as shown in IC1.6.1 Figure 2.

2016 Rules Changes – FSAE IC IC1.9.1.b Fuel Rails


Fuel Rail – The fuel rail must be securely attached to the engine cylinder block, cylinder

head, or intake manifold with mechanical fasteners. This precludes the use of hose clamps,

plastic ties, or safety wire. The threaded fasteners used to secure the fuel rail are considered

critical fasteners and must comply with ARTICLE 11.

The use of fuel rails made from plastic, carbon fiber or rapid prototyping flammable materials is

prohibited. However, the use of unmodified OEM Fuel Rails manufactured from these materials

is acceptable.

2016 Rules Changes – FSAE IC IC1.11 ETC


•  IC1.11.2 The electronic throttle must automatically close (return to idle) when power is

removed from it.

•  IC1.11.3 The electronic throttle must use at least two (2) sources of energy capable of

returning the throttle to the idle position. One of the sources may be the device that

normally actuates the throttle, e.g. a DC motor, but the other device(s) must be a throttle

return spring that can return the throttle to the idle position in the event of a loss of

actuator power.

NOTE: springs in the TPS are not acceptable throttle return springs

2016 Rules Changes – FSAE IC IC1.12 ETC-TPS


•  IC1.12.1 The TPS must measure the position of the throttle or the throttle actuator. Throttle position is defined as percent of travel from fully closed to wide open where 0% is fully closed and 100% is fully open.

•  IC1.12.2 At least two separate sensors have to be used as TPSs. The TPSs may share the same supply and reference lines only if effects of supply and/or reference line voltage offsets can be detected.

•  IC1.12.3 If an implausibility occurs between the values of the two TPSs and persists for more

than 100msec, the power to the electronic throttle must be immediately shut down.

•  IC1.12.4 Implausibility is defined as a deviation of more than 10% throttle position between the sensors or other failure as defined in IC1.12. Use of larger values may be considered on a case by case basis and require justification in the FMEA.

•  IC1.12.6 Each TPS must have a separate detachable connector that enables a check of these

functions by unplugging it during Technical Inspection, else, an inline switchable break-out box must be made available during Technical Inspection that allows disconnection of the each TPS signal.

2016 Rules Changes – FSAE IC IC1.13 ETC-APPS


•  IC1.13.1 The APPS must be actuated by a foot pedal. Pedal travel is defined as percent of travel from a fully released position to a fully applied position where 0% is fully released and 100% is fully applied.

•  IC1.13.2 The foot pedal must return to its original position when not actuated. The foot pedal must have a positive stop preventing the mounted sensors from being damaged or overstressed. Two (2) springs must be used to return the throttle pedal to the off position and each spring must be capable of returning the pedal to the off position with the other disconnected.

•  NOTE: The springs in the APPSs are not acceptable pedal return springs.

•  IC1.13.3 At least two separate sensors have to be used as APPSs. Separate is defined as not sharing supply or signal lines.

NOTE: it would be normal for the two sensors to have different transfer functions.

•  IC1.13.4 If implausibility occurs between the values of the two APPSs and persists for more than 100msec, power to the electronic throttle must be immediately shut down.

2016 Rules Changes – FSAE IC IC1.13 ETC-APPS-Cont’d


•  IC1.13.5 Implausibility is defined as a deviation of more than 10% pedal travel between the sensors or other failure as defined in IC1.13. Use of larger values may be considered on a case by case basis and require justification in the FMEA.

•  IC1.13.6 If three sensors are used, then in the case of an APPS failure, any two APPSs that agree within 10% pedal travel may be used to define the throttle position target and the 3rd APPS can be ignored.

•  IC1.13.7 Each APPS must have a separate detachable connector that enables a check of these functions by unplugging it during Technical Inspection, else, an inline switchable break-out box must be made available during Technical Inspection that allows disconnection of the each APPS signal.

•  IC1.13.8 The APPS signals must be sent directly to the throttle controller using an analogue signal or via a digital data transmission bus such as CAN or FlexRay. Any failure of the APPSs or APPS wiring must be detectable by the controller and must be treated like an implausibility.

2016 Rules Changes – FSAE IC IC1.14-IC1.6. ETC-Cont’d


•  IC1.14.2 The BSE must have a separate detachable connector that enables detection of error states

and the response of the ECU to be checked by unplugging it during Technical Inspection, otherwise

an inline switchable break-out box must be made available during technical inspection that allows

disconnection of each BSE signal.

•  IC1.14.3 The BSE signals must be sent directly to the throttle controller using an analogue signal or

via a digital data transmission bus such as CAN or FlexRay. Any failure of the BSE or BSE wiring that

persists more than 100msec must be detectable by the controller and must be treated like an

implausibility such that power to the electronic throttle is immediately shut down.

•  IC1.15.2 The power to the electronic throttle and the fuel pump must be immediately shut down, if

throttle position differs by more than 10% from the expected target TPS position for more than 1

second. An error in TPS position and the resultant system shutdown must be demonstrated at

Technical Inspection.

•  The electronic throttle and fuel pump shutdown must remain active until the TPS signals indicate the

throttle is at or below the unpowered default position, for at least one (1) second.

2016 Rules Changes – FSAE IC IC2.6 Fuel Filler & Sight Tube


•  IC2.6.2 At least 125 mm (4.9 inches) vertical height of the fuel filler neck must be above the top level of the tank, and must be accompanied by a clear fuel resistant sight tube for

reading the fuel level. (Figure 14)

•  IC2.6.3 The sight tube must have at least 125 mm (4.9 inches) of visible vertical height and

a minimum inside diameter of 6 mm (0.25 inches).

•  IC2.6.6 Fuel Level Line - A permanent, non-moveable fuel level line must be located

between 12.7 mm and 25.4 mm (0.5 inch and 1 inch) below the top of the visible portion of

the sight tube. This line will be used as the fill line for the Tilt Test (Rule T8.5), and before and after the Endurance Test to measure the amount of fuel used during the Endurance

Event.

2016 Rules Changes – FSAE IC IC4.4.4 Lithium Batteries


•  2016 Rule: •  IC4.4.4 Battery packs based on Lithium Chemistry:

a. Must have overcurrent protection that trips at or below the maximum specified discharge current of the cells. b. Must have a rigid, sturdy and fire retardant casing. c. Must be separated from the driver by a firewall as specified in T4.5

The 2015 Rule was:

•  IC4.4.4 Battery packs based on Lithium Chemistry: a. must be commercially manufactured items b. must have over voltage, under voltage, short circuit and over temperature cell protection c. must be separated from the driver by a firewall

2016 Rules Changes – FSAE-E EV4.12 TSAL


EV4.12 Tractive-system-active light (TSAL) •  EV4.12.1 The vehicles must include a single Tractive Systems Active Light (TSAL) that

must illuminate when the tractive system is active. The TSAL must not perform any other functions.

•  EV4.12.2 The tractive system is active when any of the following are true: a. An accumulator isolation relay is closed. b. The voltage outside the accumulator containers exceeds 60V DC or 25V AC RMS.

•  EV4.12.3 The TSAL itself must: a. Be directly controlled by the voltage present within the tractive system using hard wired electronics. Software control is not permitted. b. Be red in color. c. Flash continuously with a frequency between 2Hz and 5Hz when illuminated.

2016 Rules Changes – FSAE-E EV4.12 TSAL-Cont’d


•  EV4.12.4 The TSAL mounting location must: a. Be near the main roll hoop at the highest point of the vehicle. b. Be mounted lower than the highest point of the main roll hoop. c. Be no lower than 150 mm from the highest point of the roll hoop. d. Not allow contact with the driver’s helmet in any circumstances. e. Not be in proximity to other lights.

•  EV4.12.5 The TSAL must be visible: a. From every horizontal direction, except small angles which are blocked by the main roll hoop. b. From a point 1.6m vertically from ground level, within a 3m horizontal radius from the TSAL. c. In direct sunlight.

2016 Rules Changes - Summary FSAE All



•  A8.1 & A8.5 Cost Report PART S - ARTICLE 4: “Cost Report” - Report must comply with the Cost Event Rules.

*For 2016 Formula SAE Competitions in United States, Cost Report Submission process may be changed. Please refer to the website for additional announcements and information.

2016 Rules Changes – FSAE IC Cost Report


•  Engine cost includes transmission (whether integral or not by design), components used to transmit power between engine and transmission and all components necessary to run including spark plugs, coils, wires, oil filter, etc. with the exception of the air induction and fuel system components.

•  Any driveline component downstream of the transmission output gear/shaft is not included.

•  Cost includes engine as received by manufacturer but not custom parts such as drysump pans, PCV changes, etc.

•  Fully internal engine changes are free.

•  If covers or other parts are removed disassembly labor must be included in labor cost.

2016 Rules Changes – Summary Formula Hybrid


For the benefit of the teams, below is a summary of the major rules changes for the 2014 Formula SAE competitions. It is not a complete list and is not binding. If there are any differences between this summary and the official rules, the Rules will prevail. Therefore, it is the responsibility of the competitors to read the published Rules thoroughly.

Rule Number Section Change

A1.2.3 Battery Capacity Added description of capacity calculations A7.5 Multiple year vehicles Allowed, but caveats on expectations and scoring. A9.3 Late submissions Several changes to late penalties A9.4 Early submissions New section! Bonus points for early SES approvals T2.1.2 Definition of Open Wheel Aligned with 2015 FSAE definition T4.1.1 Cockpit Opening Template Movement of template allowed (as FSAE) T4.1.2 Cockpit Cross Section Templt Added note on vertical movement T5.1.2(e) Driver’s Harness Lap Belt Added recommendation for 2 tilt lock adjusters T6.5.5 Rear Wheel Steer Now allowed T7.4 Brake Light Aligned with 2015 FSAE rules T8.1.2 Cooling Fluids “Opticool” approved as electrical system coolant

2016 Rules Changes – Summary Formula Hybrid (Cont’d)



EV2.2.1 Accelerator Error Checking If in motor controller, no extra circuits required.

EV2.3 Accelerator Signal Isolation Must be galvanically isolated from TS and bonded to GLV ground.

EV3.3 Accumulator Housings New section, “Virtual Accumulator Housings”

EV3.4.4 SMD Lockout Removed padlock at a locking means EV3.4.7 Accumulator Voltage Indicator Now applies to removable containers only

EV3.5.8 Accumulator Openings Cooling openings “reasonable size”, no completely open side pods

EV3.6.3 Isolation Relays Clarified (now includes no TSV to IMD)

EV3.7.8 AMS Shutdown Clarified that some GLV systems can stay active.

EV3.7.10 AMS Test Port Updated Test Connector Wiring drawing, Fig. 28 EV3.7.10.a AMS Test Port Changed Banana Jack spacing (now 0.75” was 1.0”)




EV3.9 Pouch Cells MAJOR CHANGES!

EV4.3.2 Grounding Max resistance changed to 100 ohms (was 5 ohms) EV4.4.6 TSMP Protection Fuses no longer permitted.

EV4.7.4 HVD Lockout Removed padlock as a locking device. EV4.10 TESL Indicator All references to TSAL changed to TSEL

EV4.10.2 TESL Indicator Required color changed from red to amber. EV5.1 Shutdown Circuits Shutdown Button (BRB) sections clarified & reorganized.

EV5.2 Master Switches Section rewritten & reorganized. EV5.5.6 Elect. w/Internal Power Was a note, now a rule.

EV5.6.1 Side Mounted S/Down Buttons Location clarified




EV5.9.4 IMD Shutdown Some GLV systems may remain energized.

EV8.2.2 Charging Chassis/frame must be grounded while charging. EV8.4 Required Equipment Updated list. Was EV8.3.6.

EV9.1.4 ESF Must now include MSDS sheets for accumulator cells.

S1 Pre-Event Peer Review Rewritten.

2016 FH Rules Changes S1 Peer Review


•  S1.1.1 The first inspection of a vehicles electrical systems will take place at the team’s home institution approximately three (3) weeks before the competition.

The review will be performed by volunteer Electrical Engineers from the IEEE or by other qualified professionals. Note: The electrical reviewers are professionals who have volunteered their time to assist your team meet the Formula Hybrid electrical rules requirements. For the review to be effective, the vehicle ESF and schematics must be complete and as accurate as possible. Asking these engineers to review your vehicle with incomplete system documentation could be seen as disrespectful.

•  S1.1.3 Teams will be contacted by the organizers approximately one month before the competition to schedule the technical reviews.

2016 FH Rules Changes S1 Peer Review - (Cont’d)


•  Vehicles should be presented in a condition that will allow an inspection of its electrical systems.

•  At a minimum this would be:

-  Major electrical components mounted in their final locations within the vehicle.

-  GLV control wiring in place and functional

-  TSV wiring in place with conduit and strain relief where required.

-  TSV protective covers mounted in their final positions.

-  Accumulator enclosures finished and mounted to the vehicle structure with conduit, strain relief etc. in place.

Note: Accumulator devices do not need to be installed for the PEER inspection. However the AIRs should be located in their final positions and should be functional, with all TSV wiring outboard of the AIRs in place. AMS sense wiring should be complete up to where they would connect to the accumulator cells.




S2.3 Inspection Condition Waived for HIP and SEO vehicles.

S3 Project Management Reorganized and many clarifications S4.10.2 Static Events Only (SEO) Rule rewritten and clarified.

D5.4.2 Acceleration Event Order of runs restriction removed for hybrids Appendix J Firewall Flame Test Required torch changed from Mapp gas to Propane

2016 rules changes - scrutineering · 2016 rules changes - summary fsae-all per 2016 fsae rules 2...

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