FSG Workshop 2014 - Hannover

Continental AG

 All information, documents and advices published on FSG web site

(www.formulastudent.de) in the section Rules & Important documents
are OFFICIAL documents for the FS Germany events
All advices given in this presentation are comparable to rules announcements
and supersede the FSAE rules

U.Steinfurth / Scrutineering FS Germany

Read the rules ! Understand the rules! Follow the rules!

If you do not understand a rule please send an inquiry to the FS Germany organization according to
the in FS Germany rule 3.2 given procedure!!

U.Steinfurth / Scrutineering FS Germany

Questions to FSG

Please do not use another email address than that specified in the FSC / FSE Rules
(otherwise your inquiry is classified as SPAM and you will NOT get an answer)

Uni Name_Rules_[Nr.]
!! Hint:
For technical questions a picture or
sketch can be helpful for a better
understanding !!

Currently FSG is working on a web based FAQ system. FSG will make an announcement when the web system is
operational, until then please follow FSG rule 3.2
The maximum size for attachments is limited to 5MB / zip-files ore exe-files are not accepted
U.Steinfurth / Scrutineering FS Germany

Content
Part 1 Documents and mechanical Scrutineering
Driver Equipment
Structural Equivalency Spreadsheet
Self made fasteners

U.Steinfurth / Scrutineering FS Germany

fotolibra.com

U.Steinfurth / Scrutineering FS Germany

Driver Equipment

Collected driver equipment at Formula Student Germany 2014

U.Steinfurth / Scrutineering FS Germany

Driver Equipment
Why is the driver equipment so important?
All Formula Student cars are PROTOTYPES!
At any time anything can happen (Fire, broken chassis components, accident)!
The driver equipment is classified as fire resistant and can protect the drivers skin!

Any harness system can protect the driver from severe injuries in case of a accident!

Please always remember: It is your and your team members LIFE and HEALTH
U.Steinfurth / Scrutineering FS Germany

Examples of REJECTED Driver Equipment

Helmets with a wrong specification or with a damaged surface
Driver suits, gloves, underwear, socks and shoes with:
A wrong specification
In dirty / oily condition

Extensive wear (holes etc.)

Picture 1: Example of presented driver

equipment at FS Germany 2014
U.Steinfurth / Scrutineering FS Germany

Examples of REJECTED Driver Equipment

Inspection
Inspect the harness belt thoroughly for damage before each use.
Make sure that the inspection of the belt is included with regular checkups of the race car and its equipment.
Picture 2: Seen at FS Germany 2014

Regularly check correct torque of bolts.

Check for expiration date of the racing harness as it applies to the
regulation of FSAE rules.

Schroth safety products

Picture 3: Examples of damaged belts Schroth

U.Steinfurth / Scrutineering FS Germany

Driver / Team Equipment (lost and found)

Helmet and underwear inside

the bag

Picture 4: Teams forgot to get back their collected stuff ( FSG will throw it away in 2015)
U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

SES will be checked by structural specialist from our sponsor
Please first read the TAB Read_Me in the SES file
In general please read the comments given on each TAB

In general please fill out all the yellow marked cells on each TAB
For additional information to the reviewer please insert additional Tab's

Upload the revised version only if ALL the comments / questions of the
reviewer are answered

U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

Use the right Template (last release)
When uploading a new version, please
write in the TAB Version History what
has been changed compared to the
previous version

U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

TAB Cover Sheet
Please fill out the cells for
contact information

Please fill out this yellow marked cells

For the steel tube parts please use the international
material number (e.g. 25CrMo4 or 1.7218).
The Anti Intrusion Plate must be named too
For different parts of the monocoque the numbers of
layers, the orientation and the core must be inserted.
Providing a data sheet with all mechanical properties
is preferred. For this you can use e.g. the TAB
"Additional Info"
U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

TAB Chassis Pics
For monocoque cars it is strictly required that the teams provide pictures, which show the different lay -up types

For this you can insert additional Tab's inside

the Structural Equivalency Spread Sheet
Picture 5: Recommended view of different lay up types for monocoque cars
U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

TAB Material Data
All material parameters must be inserted
For metals at least values corresponding to the given material properties
For different laminates all material properties must be determined experimentally

Please rename the cells

Picture 6: Recommended material properties

U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

For all other Tab's it is strictly recommended that the team shows pictures of the specific frame or
monocoque part in the yellow marked cells

?
Picture 7: Please fill out the yellow marked cells with pictures
U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

Please provide much information as possible to the reviewer

Please describe which section of the monocoque is tested

(e.g. SIS, Front Bulkhead Support or front hoop bracing)
Picture 8: Description of used test specimen
U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

Three Point Bending Test with load applicator is NOT allowed

Picture 9: Test with wrong load applicator (Please read FSAE rule 2015 T3.31.4)
U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet

Three Point Bending Test -> Test specimen with closed flanges are NOT accepted
for FS Germany

Picture 10: Test Specimen with closed flanges are NOT accepted for FS Germany
U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet Requirements 2015 by

Attachment of front hoop to monocoque should not be lower than 50mm
from the top (T 3.13.4 front hoop bracing rule)!

Or the front hoop bracing laminate structure must be attached to the front
hoop (fully laminated or attached with mounting plates, backing plates and
inserts)
Front bulkhead support with laminate structure
should not be lower than 50mm from the top of
front bulkhead and back to the front hoop.

Picture 11: Example of front hoop bracing structure for monocoque

U.Steinfurth / Scrutineering FS Germany

Structural Equivalency Spreadsheet Requirements 2015

The side impact structure (SIS) for 2015 requires three physical tests:
Entire SIS between front and main roll hoop up to a height of 350 mm above the
ground must have a EI of 3 tubes (incl. vehicle floor)
SIS between the upper surface of the floor and 350 mm above the ground must have at
least an EI of 2 tubes (without vehicle floor) and the vehicle floor itself must have an EI
of 1 tube
SIS up to a height of 350 mm above the ground must at least absorb energy of two
tubes (without vehicle floor)

Picture 12: Definition of monocoques side

impact structure
U.Steinfurth / Scrutineering FS Germany

FSAE

Self made fasteners

Self made fastener are NOT prohibited, BUT:
Formula Student is an Engineering Design Competition
The first question is: How can we proof it?
At the Technical Inspection a team has to be able to show that the design and
material of the fasteners is according to the FSAE requirements (T11).
How? (3 things)
Design documentation / material certification (calculations) and
Mechanical tests (test documentation + test samples) and
Delivery note / invoice of the manufacturer
U.Steinfurth / Scrutineering FS Germany

IC 1.7.3 -> Recirculation

Pop-off valve that vent directly to atmosphere are permitted for turbocharger or supercharger and
note that they will be carefully inspected in Tech for compliance to the intent of the rule.

U.Steinfurth / Scrutineering FS Germany

Design Error of the year

Picture 13: Rear toe control arm attachment

U.Steinfurth / Scrutineering FS Germany

See you at the Hockenheimring

July 28th - August 2nd 2015