Down Under Thunder - QUT Motorsport Formula SAE team
Monday, 15 February 2010 18:16
Author: Ash Miller, QUT Motorsport
 
QUT FSAE-Australasia
Queensland is renowned for many things - pristine coastlines (littered with beaches to die for), a climate that screams of tropical perfection and an atmosphere that makes the average sloth look like a high-speed action-seeking hero. As if that weren’t enough, the state can boast of another undeniable drawcard to be proud of.

But it’s far from sand, surf and sunnies.

It’s a Formula SAE team.

Nestled within the heart of the city of Brisbane, settling in between its famous river and bountiful parklands, is the Queensland University of Technology. Whilst the cluster of ornate buildings and blend of history versus technology stand loudly and proudly against the backdrop of arguably one of the most beautiful cities in the world, it’s the small workshop underneath the discrete setting of the Civil Engineering block where QUT’s giant-killing Formula SAE team work their magic.

As far as experienced Formula SAE teams go, QUT’s version are only puppies - having been founded in 2003 after much heated discussion and enthusiastic planning, the team’s first car was constructed in time for the 2004 Formula SAE-Australasia competition. Since then, the team has built just 4 more machines, each a logical and progressive evolution of the last.

That is, except for the latest QUT challenger. Whilst logic certainly hasn’t deserted the clever clogs within the Engineering faculty, the university’s 2009 machine could only be classed as a revolution. With every system on the car undergoing a complete ground-up overhaul, the latest incarnation has a grand total of zero percent carryover parts to display - a testament to the mighty efforts of the car’s design team.
 
the 2009 QUT Motorsportteam
For 2009 the design philosophy was the same as in previous years - reliability is paramount, and although QUT’s young team are still climbing the ladder of engineering prowess, they’re laying the foundations for a reliable car before perfecting the package, and therefore the speed that they all know they have. In addition to that, QUT’s design vision is beyond just the one-hit Formula SAE competition, and the team’s goal to create a simple, lightweight and effective competition vehicle extends its use to the wider motorsport-based public, who could effectively use the QUT machine for hillclimbs and other sprint events. 
 
One of the aspects that proved a hit with the sharp-eyed engineers among the other SAE teams was the revolutionary 3-spring design incorporated in the latest QUT “Ozanne” car (named after a team member who so tragically lost his life as the car went into its final construction stages). This spring set up was in place to solve the problem of dive and squat when the car accelerated or braked - whilst the two outside springs in the cluster independently took care of the forces from each wheel, the centre spring compressed when the forces from both wheels took hold simultaneously, stopping undesirable chassis repositioning. Needless to say, the brainchild of the idea was rather pleased with his efforts. A feat just as impressive as the trick suspension is what’s holding it to the rear of the car; a fully machined aluminium rear end groups the spool, sprocket, braking apparatus and rear suspension components together in one piece of engineering marvel. All this was designed using Solidworks underpinnings, with Ansys, Adams and AVL analysis tools giving the figures. 

drivers view to QUT cockpit
The design overhaul evidently caused some dramas - the car was only just together in time for the 2008 edition of the Formula SAE-A championships after several setbacks, and despite a never-say-die attitude jettisoning the untested car through most rounds of scrutineering, the car’s rear brakes developed a problem, and as such, failed to lock for the brake test. The electronic paddle-shift gave eternal trouble, and was only truly perfected just in time for the 2009 competition. Despite facing incredible odds, the team’s 20-strong competition never put down their tools. 

The said 20-odd competition team members are the prime movers and shakers in a 50-or-so team of highly dedicated QUT students, from all walks of university life - aside from the engineers who form the staple diet of any Formula SAE team, QUT’s sprightly bunch are a combination of business, electrical, finance, journalism, PR and photography students. On top of this, QUT’s second-to-none faculty and university staff have provided unwavering and unmatched support, with academic advisors and staff members alike passionate about making the most of QUT’s exceptional team.

With the engineers taking care of building the car (with the occasional foray into the guild bar for a few ‘meetings’), the business students proudly develop the team’s publicity and media interests. Like any professional race team, QUT are gratuitously proficient at making sure the team’s image and professional relationships are kept at their highest possible level. Sponsor/team events are not uncommon, and the team’s top business brass spread the word at many of the major events in Queensland, including the Gold Coast Indycar round, and the Queensland 500 V8 Supercar round. If not for the efforts of the business gurus, partnerships with such quality supporters such as Mazda, Laser Central and Parsons Brinckerhoff would never have been formed.

The business team take their job every bit as seriously as the guys that build the car, and as the editor of the team’s “OnTrack” news release, none can be in a more savvy position than yours truly. Throw in the fact that the business, engineering and design teams all work together in almost seamless harmony, and you have one fancy little racing team.

Even the drivers are considered seriously - the team’s latest initiative has been a driver development program, where go-karting trials are held and the best and most promising QUT student candidates are selected for proper honing and refined training, to make the most of our home-grown talent. 

The direction for QUT’s revelers is onwards and upwards - with the 2010 car already getting its skeleton tacked together (the chassis and suspension are completed, and assembly has begun), preparation for the upcoming Formula SAE season has never been better. After 2009’s impressive personal best results at the Formula SAE-A competition - where the team collected a creditable fourth place in the autocross event, a phenomenal second place in the prestigious endurance event, and placing fourth overall for the competition - 2010‘s goal is to move even further in to the dizzying heights of the Formula SAE stratosphere. Being so privileged as to be on the inside of this impressive operation, I’m fascinated and excited to see the calm before the storm. All this, and I even get to be so lucky as to be lead driver for the team for a third year running.

2010, the best yet? You better believe it.
 
 
 
Technical Spec Sheet
Car Number
046
University
Queensland University of Technology
   
Dimensions
Front
Rear
Overall Length[mm]
2338
Overall Width [mm]
1476
Overall Height [mm]
1404
Wheelbase [mm]
1600 
Track [mm]
1130 
1090 
Weight with 68kg driver [kg]
132
168
 
Suspension Parameters
Front
Rear
Suspension Type
Unequal lenght double wishbone. Push rod & bell crank actuated spring/damper unit.Unequal lenght double wishbone. Push rod & bell crank actuated spring/damper unit.
Tire Size and Compound Type
20x6,5-13 R25A Hoosier
20x8-13 R25A Hoosier
Wheels
Spun Aluminium Outers and Machined Aluminium Centres 13"x150mm-21mm offsetSpun Aluminium Outers and Machined Aluminium Centres 13"x150mm-21mm offset
Center of Gravity Design Height 290  
Suspension design travel 32mm jounce / 29 mm rebound 48mm jounced / 36 mm rebound 
Wheel rate (chassis to wheel center) 18.4N/mm  47,3N/mm
Roll rate (chassis to wheel center) 1,44°1,47° (Relative to ground)
Sprung mass naturally frequency 2,76Hz 3,56Hz 
Jounce Damping 0,5 0,62 
Rebound Damping 
Motion ratio / type 1,064:1 1,175:1 
Camber coefficient in bump (deg/m) 0,4°/degree roll 13mm LF 9,9mm LR bump 0,5°/degree roll 10,3mm RF 7,8mm RR bump 
Camber coeffizient in roll (deg/deg) 0,4°/degree roll 13mm LF 9,9mm LR bump 0,5°/degree roll 10,3mm RF 7,8mm RR bump 
Static Toe 1mm toe out @ 215mm adj. by tie rods 1mm toe in @215mm adj. by toe links 
Static Camber and adjustment method 1,25° - by rod ends on wishbone 1,25° - by rodends on wishbone 
Front Caster and adjustment method 6° + by rod ends on wishbone  
Front Kingpin Axis 0° + adjustable with Camber  
Kingpin offset and trail 30mm offset, 32,3mm trail  
Static Ackermann and adjustment method  70% Ackermann  
Anti Dive/Anti Squat 8,7% Anti Dive, NA  NA, 4,78% Anti Squat
Roll center position static 37,4mm above ground, CL of the car  42,1mm above ground, CL of the car
 Roll center position at 1g lateral acceleration37,3mm above ground, moves 1,88mm torward outer wheel 42,1mm above ground, moves 0,13mm toward inner wheel 
Steering location, Gear ration, Steer Arm Length Front steer, in line with lower A-Arm  
 
Brake System / Hub & Axle
Front
Rear
Rotors
Student designed Water cut 5mm thick solid disc, mounted outboard of upright, hub mountedStudent designed Water cut 5mm thick solid disc, mounted inboard on maschined rear end
Master Cylinder Tilton 77 Series pivot-type master cylinders(7/8" and 5/8") and Tilton driver adjustable mechanical bias bar  
Calipers 30,4mm Wilwood GP320 4-pot 30,4mm Wilwood GP320 4-pot 
Hub Bearings NTN 6815 LLU, deep groove roller bearing NTN 6913 LLU, deep groove roller bearing 
Upright Assembly
Machined 7075 aluminium, integral caliper mount and bolt on steering arm  
Machined 7075 aluminium with bolt on toe link arms
Axle type, size and material IFS, gun drilled hollow 4340 steel IRS, 4340 steel 
 
Ergonomics
Driver Size Adjustments
Fixed seat and steering wheel. Pedal box adjust fore and aft 300mm
Seat (materials, padding)
Carbon Fibre/Kevlar base headrest, adapted to driver with individual padding 
Driver Visibility
220° side visibility, no mirrors 
Shift Actuator (type, location)
Electrically controlled Electric Solenoid acting on Shift Lever
Clutch Actuator (type, location)
Foot pedal, cable actuated and or electrically controlled Electric Solenoid acting on Shift Lever
Instrumentation
ILED Tachometer, Gear Indicator, Shift Light and LED Engine Temp and Oil Pressure Displays
 
Frame     
Frame Construction
Chrome molly tube space frame with bonded Carbon-fibre Stress Skins
Material
4130 Chrome Molly tube
Joining method and material
Tig welded
Targets (Torsional Stiffness) 8500Nm/deg 
Torsional stiffness and validation method 8300Nm/deg Finite Element Analysis 
Bare frame weight with brackets and paint [kg]
29
Crush zone material
Aluminium honeycomb and high-density foam
Crush zone length [mm]
200
Crush zone energy capacity 150kN + (estimated) in linear absorbtion 
 
Powertrain
Manufacture / Model
2003 Yamaha YZF R6
Bore [mm]
65,5
Stroke [mm]
44,5
Cylinders
4 cylinder
Displacement [cc]
599
Compression ratio
12.4:1
Induction
Atmospheric
Throttle Body / Mechanism
34mm, throttle plate, cable actuation    
Fuel Type
98 octane petrol
Max. Power design RPM 9.000 
Max. Torque design RPM 8.000 
Min RPM for 80% max torque 7.200 
Fuel System
Student designed/built aluminium tank, Direct Port Injection
Fuel System Sensors
TPS, CAS
Fuel Pressure 3,5bar (static) 
Injector location 18mm above mounting face of head and pointing at back of inlet valves 
Intake Plenum volume and runner length(s) 1,800l plenum and 275mm runner lengths 
Exhaust header design 4-2-1 equal lenght (+/- 20mm), 32mm primaries, 38mm secondary and 50mm into the muffler 
Effective Exhaust runner  length1200mm 
Muffler Single perforated steel and glass fiber baffled camber muffler 
Ignition System
M&W ignition unit
Ignition Timing Digitally programmable by engine management system 
Oiling System
Wet sump accompanied by pressurised oil storage vessel(Accusump)
Coolant System and Radiator location
Side pod mounted radiator with electric fan and electric water pump controlled by engine management
 
Drivetrain
Drive Type
Chain #52, RK 520GXW
Differential Type
7075 Aluminium Spool
Final Drive Ratio 3,154:1 with 13 tooth front and 41 tooth rear sprockets 
Vehicle Speed @max power (design)  
1st gear 72,3km/h 
2nd gear 105,7km/h 
3rd gear 132,3km/h 
4th gear  154,4km/h 
5th gear 173,0km/h 
6th gear 190,1km/h 
Half shaft size and material 20mm OD, 225mm lon, 4340 steel 
Joint type
Tripod type CV with custom Aluminium housing
  
Aerodynamics (if applicable) 
Front Wing (lift/drag coef, material, wheight)N/A 
Rear Wing (lift/drag coef, material, weight) N/A 
Undertray (downforce/speed) N/A 
Wing mounting N/A 
Optional information Rear End: Machined Aluminium, bolts to the engine + chassis securing driveline, chain tensioner, rear brake caliper, suspension 

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