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Title: Ten years under the Michigan sun and freezing rain a Faculty Advisor's Perspective on Formula SAE Pl


1
Ten years under the Michigan sun (and freezing
rain) a Faculty Advisor's Perspective on
Formula SAEPlus 3 years under English clouds,
1 year under Australian dust, wind and flies
  • Kenneth A. Cunefare, Associate Professor
  • Faculty Advisor, GTMotorsports
  • Member FSAE Rules Committee
  • George W. Woodruff School of Mechanical
    Engineering

2
What is to come
  • FSAE and GTMS
  • The Ideal Competition
  • An FSAE Team
  • A Rookie Team (first year team)
  • Rules
  • The Real Competition
  • When it all comes together

3
FSAE
  • Design, build, defend and race a Formula vehicle
  • Design Apply your book learning
  • Build Hands-on fabrication
  • Defend Communicate your ideas, decisions, costs
  • Race Prove your design on the track
  • Best score out of 1000 points wins
  • 325 points in Design, build, defend
  • 675 points in Race
  • 400 points in endurance/fuel economy
  • Must finish enduro to be top 20!

4
FSAE GTMS Evolution
  • SAE Mini-Indy in 1979
  • 11 schools
  • 5 Hp/3.7 kW limit
  • Formula SAE 1981
  • 4 schools
  • 1982
  • 4 page rule package
  • Universidad LaSalle entry

5
FSAE GTMS Evolution
  • 1985
  • 600 cc limit
  • First forced-induction vehicles
  • 1986
  • 15 cars
  • GTMS founded
  • 1987
  • GTMS first competition
  • Car 66, 1th/36
  • 1988 Car 66 DNF

6
FSAE GTMS Evolution
  • 1990
  • 38 cars
  • GTMS 2nd
  • 1992
  • 54 cars
  • Dr. C. GTMS advisor
  • GTMS DNF enduro
  • 1993 Car 42 3rd/56

7
FSAE GTMS Evolution
  • 1994/95
  • 66 cars
  • GTMS places 6th in 94
  • 11th in 95

8
FSAE GTMS Evolution
  • 1996-1998
  • FSAE grows to 85 cars
  • GTMS DNF enduro 3 yrs
  • Why?
  • Team not ready
  • Undeveloped technology
  • Cool instead of proven

9
FSAE GTMS Evolution
  • 1999
  • FSAE grows to 86 cars
  • GTMS finishes enduro (33 laps)
  • 19th
  • 2000
  • 24th/89 Fuel economy!
  • 5th/17 FSUK

10
FSAE GTMS Evolution
  • 2001
  • DNF enduro oil leak
  • 24th/108
  • 1st place FSUK

11
FSAE GTMS Evolution
  • 2002
  • 3rd/123
  • 1st/44 FSUK

12
FSAE GTMS Evolution
  • 2003
  • 4th/129 (140)
  • 1st FSAE-A
  • U. Adelaide 7th (3rd Oz)
  • 2004
  • Rules 93 pages
  • 140 teams registered

13
The Ideal Competition
14
The Ideal Competition Wednesday
  • Set up paddock
  • Complete early Tech
  • Inspection/leaks/brake noise
  • Polish the car, nut check
  • Put car away
  • Eat/Sleep

15
The Ideal Competition Thursday
  • Polish the car, nut check
  • Static events
  • Design preliminaries
  • Cost event
  • Presentation event
  • Polish the car, nut check, relax
  • Design Semi-finals
  • Put car away
  • Eat/Sleep

16
The Ideal Competition Friday
  • Polish the car, nut check
  • Acceleration event
  • Skid pad event
  • Polish the car, nut check, relax
  • Lunch
  • Auto-Cross
  • Polish the car, nut check, relax
  • Put car away
  • Eat/Sleep

17
The Ideal Competition Saturday
  • Polish the car, nut check
  • Endurance event
  • Polish the car, nut check
  • Lunch
  • Put car away
  • Walk around
  • Visit other teams
  • Dinner at Big Bucks
  • Sleep

18
The Ideal Competition Sunday
  • Polish car, nut check
  • Design Finals
  • Pack car for trip home
  • Banquet
  • Start planning and designing for next year

19
An FSAE Team
  • The students
  • Thinkers
  • Builders
  • Managers
  • The Faculty Advisor

20
Achieving the Ideal?
  • Planning
  • Preparation
  • Training
  • Execution
  • The car and team must be completely ready before
    leaving for Detroit (or Tailem Bend, or U.K)
  • Building the car is only 50 of the battle
  • The car must be tested and developed
  • The team must be tested and developed

21
Team Structure
  • Team Leader
  • Business Manager
  • Publicity  Finance  Sponsor relations
  • Chief Engineer
  • Powertrain leader  Electronics leader
  • Suspension leader  Composites leader
  • Chassis leader  Ergonomics leader
  • Faculty Advisor(s)

22
Your Faculty Advisor Character
  • Interested in your success
  • Willing to assist you
  • Someone you respect
  • Ability to
  • Know when to speak up
  • Know when to remain silent
  • Leap tall buildings in a single bound
  • Someone interested in you, your car

23
Your Faculty Advisor Roles
  • Mentor
  • Long-term memory
  • Liaison to other faculty, school, sponsors
  • NOT a designer, NO control over car
  • Will become identified with your team

24
What Must a Rookie Team Do?
  • Build your team
  • Develop students, faculty, sponsors
  • Develop publicity
  • Finish the car
  • Keep it simple, keep it light (under 240 kg)
  • Dont over-optimize/over-design
  • Finish endurance
  • Plan for next year
  • Youre no longer a rookie team (unless no
    continuity!)
  • Evolve the design

25
Advanced Technologies
  • Supercharger  Turbocharger 4 to 8 injectors
  • Electric supercharger  Electric water pump
  • 4-wheel steer  V-8 engine  Shift-without-lift
  • Carbon-fiber body, wheels  Traction control
  • Carbon-fiber composite monoqoque chassis
  • Spiral-wound carbon-fiber duo-tube chassis
  • Two-way real-time telemetry  In-car video
  • Paddle/electro-pneumatic shift Oval-piston
    calipers
  • Custom engine control computer Dry-sump oiling
  • Variable inlet runner geometry Phased
    injection
  • And much, much more.

26
Team Leaders Responsibilities
  • Develop the team
  • Recruit and train students (all years!)
  • Recruit and train faculty advisor
  • Manage the team to complete the car
  • Prepare the team for next year
  • Train new leaders
  • Develop new sponsors, keep old ones
  • Evolve/develop the design

27
Team Member Responsibilities
  • Represent your team with honor
  • Complete your obligations
  • Learn new skills
  • Become self-sufficient
  • Take on increased responsibility

28
Test and Develop
  • Dynamic test and develop
  • Test fuel economy
  • Record driver times, and train drivers
  • Break the car
  • Team test and develop
  • Practice static and dynamic events as if at comp
  • Training of team members

29
Some Rules
  • Read the rules
  • Finish the car early
  • Be competition-ready early
  • Dont expect to complete the car at competition

30
Some Rules
  • Finish the car early
  • Body work should not sag, drag
  • Body work attachments rugged, fast
  • Finish the body work early
  • Finish the design boards early

31
Some Rules
  • Finish the presentation early
  • Deliver the presentation in front of faculty,
    sponsors
  • Keep sponsors and alumni informed
  • Finish the car early
  • Unveil your car at your school

32
Some Rules
  • Nobody owes you anything you earn respect and
    support through your actions and success
  • Test and document, test and document
  • Conduct routine design review meetings
  • Use your graduates as a resource
  • Finish the car early

33
Some Rules
  • Always act to bring honor
  • To yourself
  • To your team
  • To your school
  • To FSAE
  • Keep your Faculty Advisor informed
  • Train your welders, machinists
  • Build it yourself
  • Finish the car early

34
The Golden Rule
  • Finish the car early
  • Chassis build video Click Here

35
The Commandments
  • There shall be no leaks, of any size, anywhere
  • Minimum fuel economy must be met
  • Noise limit must be met (new for 04)
  • Design boards must be complete
  • Presentation complete and rehearsed
  • The car must be competition ready
  • The team must be competition ready
  • Expense of going to FSUK, FSAE-A must not hurt
    next years car

36
At Competition
  • Keep your team and Faculty Advisor informed
  • Be specific as what the plan is, and why.
  • You are not only keeping them informed, you are
    training them.
  • Each team member should know exactly what they
    are responsible for

37
At Competition
  • Ensure that everyone knows when theyre supposed
    to be at the paddock, and what theyre supposed
    to do when they get there.
  • Dont let team members leave the site without
    being told when to come back.
  • A sign that youre not managing your teams time
    properly is when you have team members sitting at
    the hotel not knowing what is going on.

38
At Competition
  • After pushing the car back from an event,
    immediately prepare the car for the next event.
  • Never delay car preparation. Have a set routine
    for checking fluids, setup, bolts, shock
    settings, hose clamps, etc.
  • Develop and use checklists for car preparation.
  • The team members who are to prepare the car
    should be trained to their exact tasks, and
    should be practiced before coming to competition.

39
At Competition
  • The team leaders head should not be down inside
    the car tightening bolts
  • The team leader should keep an eye on the big
    picture
  • Plan activities to avoid rushed preparation
  • You must be ready well before an events queue
    actually opens
  • Example, the endurance entrance queue is highly
    structured, and the team will be called into
    position well before the car actually runs.

40
At Competition
  • When the car pushes out to an event
  • A support crew follows the car
  • A support crew operates from the paddock
  • Use radios to coordinate between car and paddock
  • Use runners to ferry items
  • Team members should know exactly which crew they
    are on
  • Driver checklists! (helmets, gloves, arm
    restraints)

41
At Competition
  • Keep the paddock clean and organized
  • You work better in organized space
  • You are representing your school, and you want to
    convey a professional image
  • Pay attention to the fatigue and hunger levels of
    your team
  • Dont over use and burn out your key people
  • Have sunscreen available
  • In cold weather, watch out for hypothermia

42
At Competition
  • If you perform a critical repair at competition
  • Get on the practice track prior to the next event
  • Test that the repair works as intended
  • There can be no fluid leaks of any kind, of any
    magnitude, ever
  • The endurance event has zero tolerance for leaks
  • Expect that, in time, so will all other dynamic
    events

43
At Competition
  • Time behind you is worthless time ahead of you
    is priceless. The clock is not your friend.
  • The car cannot speak for itself
  • You must sell it to the judges, using data and
    analyses.
  • You must interpret the data for the judges,
    drawing them to the same conclusions that you
    made.
  • Never argue with the design judges or organizers
  • Keep the FA up to date at all times the more the
    FA knows what youre doing with the team, the
    less likely the FA is to interfere.

44
At Competition
  • Write down design judge questions
  • Use them to train/test next years team
  • At the end of each competition year each leader
    should write an after action report
  • What was done right
  • What could be done better
  • Maintain an archive of reports so that future
    teams can use them to learn what to do, and what
    not to do.

45
At Competition
  • Never let the team believe
  • That the organizers have treated the team
    unfairly
  • That it was just bad luck
  • The team must accept responsibility
  • For the performance and reliability of their car
  • For the performance and execution of the team
  • The team's fate is under their own control
  • Never act to dishonor your team, your advisor,
    your school

46
The Real Competition
  • The Weather
  • From 0 C to 35 C
  • From hypothermia to sun burn
  • Rain, rain and more rain

47
The Real Competition
  • The Waiting
  • You and 100 other cars in line
  • The clock is ticking
  • The schedule is unforgiving

48
The Real Competition
  • Anticipate problems, be ready
  • Expect to be time-constrained

FSAE 2000 Taking shelter in SilverDome 100 kph
wind, tornado warnings, twice!
49
The Real Competition
  • The pride of accomplishment

50
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51
Finale
  • Build it because you have passion
  • Race it because you love it
  • Expect and deliver your best
  • Learn all you can
  • You will form lifelong bonds with team mates,
    other teams, faculty

52
In memory of Carroll Smith 16/5/2003
53
(No Transcript)
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