Browse Topic: Motorsports

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Simulation-Based System-Level Design Optimization for Formula SAE Vehicles2025-01-0380To be published on 10/07/2025
System-level design decisions in Formula SAE (FSAE) vehicles drive all downstream subsystem designs, yet these decisions are often based on historical precedent or anecdotal evidence rather than rigorous analysis. This work presents a simulation-driven methodology to support data-informed decisions early in the design process, specifically examining how overall vehicle parameters—such as engine power, vehicle mass, aerodynamic drag and lift, wheelbase, and track width—influence performance in a representative FSAE endurance scenario. Two types of lap-time simulation tools were used in this study: OpenLAP, a point-mass simulator, and ChassisSim, a transient 3D vehicle dynamics simulator that incorporates suspension geometry, yaw response, weight transfer, and steering effects. Initial simulations with OpenLAP were used to rapidly identify trends and guide early design decisions, while ChassisSim was used for detailed sensitivity analyses and to validate system-level trade-offs in a more
Hernandez, Andy Jose, Bachman, John Christopher
Enhancing Robustness of Electro-Hydraulic Brake-by-Wire Actuators via Linear Active Disturbance Rejection Control2025-01-0341To be published on 09/15/2025
In recent years, motorsport has increasingly focused on environmental concerns, leading to the rise of hybrid and fully electric competitions. In this scenario, electric motors and batteries take a crucial role in reducing the environmental impact by recovering energy during braking. However, due to inherent limitations, motors and battery cannot fully capture all braking power, necessitating the use of standard friction brakes. To achieve an efficient balance between electric motors and friction brakes, the brake pressure can no longer be directly controlled by the driver. Instead, it must be computed by the Vehicle Control Unit (VCU) and sent to a smart actuator, i.e. the Brake-By-Wire (BBW), which ensures that the required pressure is applied. The standard approach to achieve precise pressure control is to design a nested Proportional-Integral-Derivative (PID) control architecture, which requires an accurate nominal model of the system dynamics to meet the desired tracking
Gimondi, Alex, Dubbini, Alberto, Riva, Giorgio, Cantoni, Carlo
Thermal Characterisation of a High-Power Lithium-Ion Pouch Cell and Surface Temperature Prediction for Motorsport Applications2025-24-014209/07/2025
Accurate cell thermal characterisation is vital for battery modelling and thermal management, especially in motorsport, where minor temperature estimation errors can have severe consequences. Conventional methods for determining key thermal parameters, such as the specific heat capacity, often require costly calorimeters or destructive testing. Recent studies propose an alternative approach using a 1D lumped thermal network to solve the thermal balance of a heat-generating cell. However, these studies often overlook critical aspects of the heat generation equation, particularly the entropic term, which is essential for capturing nonlinear thermal behaviour, especially under dynamic cycling conditions. This study presents a cost-effective approach for rapid cell thermal characterisation and accurate surface temperature prediction. A pouch LCO cell was first tested to determine the entropic coefficient, followed by experiments under two convective conditions to evaluate its specific heat
Sciortino, Davide Domenico, Schommer, Adriano, Costa, Andre
Q&A25AUTP08_1308/01/2025
Lyten is best-known as the developer of next-gen lithium-sulfur (Li-S) battery technology. SAE Media spoke with Keith Norman, Lyten's chief sustainability officer, on how 3D Graphene is getting Lyten to branch out into motorsports.
Blanco, Sebastian
How Battery Simulation Is Taking High-Performance EV Development to New HeightsTBMG-5352808/01/2025
In today’s electric age, the definition of ‘high-performance’ is being rewritten, courtesy of electric sports cars, supercars, and hypercars pushing limits that were once thought impossible to reach. Even Formula 1, quite surprisingly to many, has embraced electrification by integrating hybrid electric systems at the pinnacle of motorsport. Every jaw-dropping 0 to 60 mph time or record-breaking lap is backed by a battery system engineered with precision. Increasingly that precision is driven by simulation technology.
Automation and Optimization of the Design and Development Process for a Formula Student Racing Car Suspension2025-01-027007/02/2025
The design, development, and optimization of modern suspension systems is a complex process that encompasses several different engineering domains and disciplines such as vehicle dynamics simulation, tire data analysis, 1D lap-time simulation, 3D CAD design and structural analysis including full 3D collision detection. Typically, overall vehicle design and suspension development are carried out in multiple iterative design loops by several human specialists from diverse engineering departments. Fully automating this iterative design process can minimize manual effort, eliminate routine tasks and human errors, and significantly reduce design time. This desired level of automation can be achieved through digital modeling, automated model generation, and simulation using graph-based design languages and an associated language compiler for translation and execution. Graph-based design languages ensure the digital consistency of data, the digital continuity of processes, and the digital
Borowski, Julian, Rudolph, Stephan
Early Detection of the Loss of Control of Motorsport Vehicles10-09-03-002906/30/2025
The article investigates how to detect as quickly as possible whether the driver will lose control of a vehicle, after a disturbance has occurred. Typical disturbances refer to wind gusts, obstacle avoidance, a sudden steer, traversing a pothole, a kick by another vehicle, and so on. The driver may be either human or non-human. Focus will be devoted to human drivers, but the extension to automated or autonomous cars is straightforward. Since the dynamic behavior of vehicle and driver is described by a saddle-type limit cycle, a proper theory is developed to use the limit cycle as a reference trajectory to forecast the loss of control. The Floquet theory has been used to compute a scalar index to forecast stable or unstable motion. The scalar index, named degree of stability (DoS), is computed very early, in the best case, in a few milliseconds after the disturbance has ended. Investigations have been performed at a dynamic driving simulator. A 14 DoF vehicle model, virtually driven by
Della Rossa, Fabio, Fontana, Matteo, Giacintucci, Samuele, Gobbi, Massimiliano, Mastinu, Giampiero, Previati, Giorgio
Design of a Reactive-Style Muffler for a Formula SAE Race Car2025-01-002405/05/2025
The noise generated by high-performance vehicles like Formula SAE (FSAE) race cars, presents a significant challenge in adhering to strict competition noise regulations. In this study two muffler designs were created: muffler design 1 and 2. Each design utilized two chambers to generate destructive interference, targeting two dominant exhaust frequencies of the Honda CBR600RR engine to maximize transmission loss and reduce sound pressure levels (SPL) below the FSAE-mandated range of 103 dBC at idle and 110 dBC at all other operating conditions. For each design, the exhaust noise and muffler performance were simulated using GT-Suite, allowing for an evaluation of noise attenuation across engine speeds. Experimental testing was conducted to validate the GT-Suite model and assess the effectiveness of muffler design 1. This testing involved measuring the SPL with a calibrated microphone, both with and without the designed muffler. Muffler design 1 was based on the dominant exhaust
Labao, Kai, Middleton, Nicholas, Nuszkowski, John
On the Application of Trapped Vortices in Motorsport Application for Improved Aerodynamic Performance Using Passive and Active Flow Controls2025-01-502904/15/2025
New regulations introduced by the Fédération Internationale de l’Automobile (FIA) for the 2026 Formula 1 season mark the first instance of active flow control methods being endorsed in Formula 1 competition. While active methods have demonstrated significant success in airfoil development, their broader application to grounded vehicle aerodynamics remains unexplored. This research investigates the effectiveness of trapped vortex cavity (TVC) technology in both active and passive flow controls, applied to a NACA0012 airfoil and an inverted three-element airfoil from a Formula 1 model. The investigation is conducted using numerical methods to evaluate the aerodynamic performance and potential of TVC in this paper. In the single-airfoil case, a circular cavity is placed along the trailing edge (TE) on the suction surface; for the three-element airfoils, the cavity is positioned on each airfoil to determine the optimum location. The results show that the presence of a cavity, particularly
Ng, Ming Kin, Teschner, Tom-Robin
T.R.I.C.K. 2.0: Enhanced Vehicle Dynamics Analysis and Estimation Harnessing Advanced Vehicle Sensors10-09-03-002504/09/2025
Automotive signal processing is dealt with in several contributions that propose various techniques to make the most out of the available data, typically for enhancing safety, comfort, or performance. Specifically, the accurate estimation of tire–road interaction forces is of high interest in the automotive world. A few years ago the T.R.I.C.K. tool was developed, featuring a vehicle model processing experimental data, collected through various vehicle sensors, to compute several relevant virtual telemetry channels, including interaction forces and slip indices. Following years of further development in collaboration with motorsport companies, this article presents T.R.I.C.K. 2.0, a thoroughly renewed version of the tool. Besides a number of important improvements of the original tool, including, e.g., the effect of the limited slip differential, T.R.I.C.K. 2.0 features the ability to exploit advanced sensors typically used in motorsport, including laser sensors, potentiometers, and
Napolitano Dell’Annunziata, Guido, Farroni, Flavio, Timpone, Francesco, Lenzo, Basilio
Optimal Investigation About Cab of BSC Racing Car Based on Ergonomics2025-01-866904/01/2025
In the Baja race, off-road vehicles need to run under a variety of real and complex off-road conditions such as pebble road, shell pit, stone bad road, hump, water puddle, etc. In the process of this high-intensity and high-concentration race, the unoptimized design of the cab in ergonomics will easily cause the driver's visual and handling fatigue, so that the driver's attention is not concentrated. Cause the occurrence of security accidents. Moreover, lower back pain, sciatic nerve discomfort, lumbar spine diseases and other occupational diseases are basically caused by uncomfortable driving posture and unreasonable control matching, and these have a lot to do with unreasonable ergonomic design. In order to solve these problems, firstly establish the human body model of the driver, and then build the BSC racing car model by using 3D modeling software Catia. Then use the ergonomics simulation software Jack to analyze the visibility, accessibility and comfort. Based on the simulation
Liu, Yuzhou, Liu, Silang
Numerical Investigation on Motorsport Overtake Manoeuvre in Crosswind Conditions2025-01-877304/01/2025
Existing technical literature has primarily focused on the upstream wake effects of single-seater race cars during overtaking, often neglecting the critical factor: crosswinds. This study presents a quantitative computational fluid dynamics (CFD) analysis of how crosswinds impact the aerodynamic loads of interacting race car models during an overtake manoeuvre. For numerical validation purposes, a wind tunnel experimental campaign was carried out on a 35%-scale hill climb race car model to evaluate aerodynamic forces and wake pressure mappings at different ride heights. RANS-based simulations were performed to assess the impact of crosswinds (β = 2°, 6°, 10°) on an isolated race car. Subsequently, a quasi-static approach was used to quantify the effect of crosswind (β = 10°) on an overtaking car under different path strategies. The findings indicated that the overtaking car's performance remained largely stable when a driver opts for overtake paths against the crosswind direction (i.e
Makhija, Jai, Soares, Renan F.
Development and Validation of a Rear Head Surround Foam Performance Specification for Stock Car Racing2025-01-835304/01/2025
Over the last two decades many improvements have been made in stock car racing driver safety. One of these is the head surround, which is rigidly secured to and an integral part of the NASCAR (National Association for Stock Car Auto Racing, LLC) seating environment and serves as an effective restraint for head protection during lateral and rear impacts. However, previous head impact material specifications were optimized for moderate to severe impacts and did not address low severity impacts that occur frequently during typical driving, such as race restart vehicle nose-to-tail contact. This study focused on developing a test methodology for comprehensive evaluation of rear head surround materials for low, moderate and severe impacts. Specifically, this study aimed to formulate a specification that maintains previous material performance during high speed impacts, while decreasing head accelerations at low speed impacts. Quasi-static and dynamic drop tower testing of sample materials
Gray, Alexandra N., Harper, Matthew G., Mukherjee, Sayak, Patalak, John P., Gaewsky, James
Study on Ergonomic Design Optimization and NVH Characteristics of Baja Racing Car2025-01-861204/01/2025
As a kind of off-road racing car, the driving condition of Baja is extremely bad. In order to allow the driver to control the vehicle well in complex working conditions, it is particularly important to provide a comfortable and convenient driving space and handling space for the driver. In this paper, firstly, RAMSIS is used to carry out the ergonomics verification of the racing car from the comfort analysis, reachable area analysis and visual field analysis, and optimize the design of the cockpit layout of the Baja racing car. Then the NVH characteristics of the Baja racing car frame are studied, and the 12-order modal results are obtained by finite element analysis and simulation. Then the natural frequency of the frame is measured by experiments, and the experimental results are verified to match the theoretical values. The research shows that the above steps can design a comfortable driving posture and operating space for the racer and provide experience for the future layout of
Liu, Silang
Development and Performance Optimization of Formula SAE Racing Active Ground Effect System Based on Fan Drive2025-01-800104/01/2025
For Formula SAE cars, a significant increase in downforce can enable the car to score more points in the race and enhance the competitiveness of the vehicle. This paper focuses on the development of an active ground effect system driven by fans for the FSAE racing car. The system is designed to considerably increase the downforce of the racing car through the forced airflow generated by the fan, enable the dynamic adjustment of the aerodynamic balance of the racing car during the driving process, and achieve the vertical force control on the racing wheels, thereby improving the performance of the racing car. The Star-CCM+ software was employed to conduct CFD simulation to investigate the influence of different flow fans on downforce and optimize the layout and position of the fan. Due to the limited power that the car can carry, the paper will also simulate and calculate the range of pneumatic balance adjustment and vertical force control capability provided by the different openings
Yang, Chengyue
Design and Evaluation of an Adjustable Ackermann Rate Steering System for Formula Student Racing Cars2025-01-800004/01/2025
FSAE is a competition designed to maximize car performance, in which the steering system is a key subsystem, and the steering system performance directly affects the cornering performance of the car. The driver relies on the steering system for effective handling, which is also crucial for cornering and achieving faster lap times. Therefore, while improving the performance of the steering system, it is crucial to match the vehicle design to the driver's habits. Traditionally, steering systems typically use an Ackermann rate between 0% and 100% to offset the slip angle caused by tire deformation, thus achieving the purpose of reducing tire wear. Calculations have shown that a 40-60% Ackermann rate provides a similar compensation effect with little difference in tire wear. The traditional steering design method also does not consider the driver's driving habits and feedback, which is not conducive to the improvement of the overall performance of the car. In FSAE's figure-of-eight loops
Wu, Hailin, Li, Mingyuan
Research and Structural Optimization of Lattice Core based on Monocoque of Formula Student Racing Car2025-01-800304/01/2025
Monocoque is a kind of integrated shell structure technology, which has gradually become the primary choice for various racing teams to make car bodies because of its advantages of small specific gravity and high specific strength. The unit of the monocoque is a carbon fiber composite sandwich structure, which is composed of two layers of carbon fiber skin inside and outside and core material between them. The inner and outer layers of the carbon fiber skin are stacked with carbon fiber composite materials of different directions and types.In this project, we plan to optimize the shape of the monocoque shell using the surface design software Alias, select core materials of different materials and structures, more advanced layups, and obtain feasible layup sequences and core material types through Ansys simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments. Different from the previous lightweight work based a lot on experience, this
Cheng, Zhu H., Liu, JJ
Optimization Design of Formula E Racing Car Transmission and Wheel System2025-01-850504/01/2025
The paper provides a detailed analysis of the transmission system design under the single motor drive scheme, with a focus on the 2024 Formula SAE (FSAE). The selection of the motor type is determined based on race rules and battery box output power limits. In terms of transmission ratio design, this study takes into account the car's power, balancing acceleration ability and maximum speed to determine an optimal transmission ratio through theoretical calculations and empirical values. Furthermore, it explores how to optimize overall drive system performance by considering technical parameters, power requirements, economic considerations of each system assembly, and validates these findings through software simulations. Notably, significant improvements in reliability are achieved with the newly designed transmission system and wheel rim system while also proposing lightweighting methods for key components. We have carried out extensive verification in both simulation and real vehicle
Wang, Liuxin, Li, Chengfeng, Zhu, Xiran, Liu, Minmin
Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars2025-01-800604/01/2025
In Formula SAE , the primary function of the frame is to provide structural support for the different components and withstand the applied load. In recent years, most Formula Student teams worldwide to adopt monocoque made of carbon fiber composites, which are lighter and stronger. Enhancing the mechanical performance of carbon fiber laminates has been a key focus of research for these teams. In three-point bending tests, significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, often lead to potential adhesive failure. Consequently, experimental boards often exhibit delamination between the outer skin and the core material, and premature core crushing, which compromises the mechanical performance of the laminate and fails to pass the Structural Equivalency Spreadsheet. Therefore, it is necessary to consider the influence of the bonding factor of toughened epoxy prepreg film on the mechanical properties of the laminated plate. This
Ning, Zicheng
Cost-Effective Sideslip Measurement: Beta for the People!2025-01-879604/01/2025
Vehicle sideslip is a valuable measurement for ground vehicles in both passenger vehicle and racing contexts. At relevant speeds, the total vehicle sideslip, beta, can help drivers and engineers know how close to the limits of yaw stability a vehicle is during the driving maneuver. For production vehicles or racing contexts, this measurement can trigger Electronic Stability Control (ESC). For racing contexts, the method can be used for driver training to compare driver techniques and vehicle cornering performance. In a fleet context with Connected and Autonomous Vehicles (CAVS) any vehicle telemetry reporting large vehicle sideslip can indicate an emergency scenario. Traditionally, sideslip estimation methods involve expensive and complex sensors, often including precise inertial measurement units (IMUs) and dead reckoning, plus complicated sensor fusion techniques. Standard GPS measurements can provide Course Over Ground (COG) with quite high accuracy and, surprisingly, the most
Hannah, Andrew, Compere, Marc
A Design of Electric Drive System for All-Wheel Drive Formula Student Racing Car to Improve Racing Performance2025-01-800504/01/2025
This paper introduces an innovative in-wheel electric drive system designed for all-wheel drive Formula Student Electric racing cars. The system utilized AMK's DD5-14-10-POW-18600-B5 model as the driving motor, with a gearbox transmission ratio of 13.2 determined through Optimum Lap simulation. A two-stage gear reducer was integrated into a unified hub-spoke assembly, which connected directly to the ten-inch carbon fiber rim. In this paper, three conventional FSEC planetary gear reducer shafting designs are introduced, and a new shafting structure is proposed. Then the four structures are compared in multiple dimensions. Subsequently, we designed the shafting of the gear group, determined the size parameters of the shafting structure and the bearing type, and completed the verification. The planetary carriers were integrated with the wheel-edge suspension columns. Meanwhile, a special floating brake disc mounting method was employed, which increased the brake disc's heat capacity by
Guo, Ruijie, Zeng, Junhao, Yang, Yuancai, Hou, Yijie, Zhu, Zhonghui, Xiong, Jiaming
Optimized Design and Analysis of a High-Performance, Track-Focused Quad Bike for the Indian Market2025-28-006102/07/2025
This paper presents a complete approach to the optimized design and analysis of a trach-focused quad bike suitable for the Indian market. The process of design integrates several analytical factors, including driver ergonomics, aesthetics, and strategic component placement, to establish optimum vehicle dimensions. The primary objective is to address the unique demands of the Indian terrain and user preferences through ensure comfort, functionality, and visual appeal. The selection process for tires and suspension geometry is precisely conducted with the advanced OptimumKinematics software. This optimization provides greater performance and stability that the vehicle can accurately manage a variety of road conditions. The space frame chassis of a vehicle’s core structure features, engineered to minimalize tubing and facilitate ease of fabrication, contributing to both structural integrity and weight reduction. A robust 600cc four-cylinder engine is selected that emphasizing an optimal
Thanikonda, Praveen Kumar, Shaik, Amjad, Tappa, Raju, Ratlavath, Ramu, Navar, Adarsh, Challa, Ajith Kumar
Numerical Study of Aerodynamic Flow and the Effects of Spoiler Wings on a Formula Student Race Car2024-01-524701/28/2025
Current work details the preliminary CFD analysis performed on custom-built race car by Team Sakthi Racing team as part of Formula SAE competition using OpenFOAM. The body of the race car is designed in compliance with FSAE regulations, OpenFOAM utilities and solvers are used to generate volumetric mesh and perform CFD analysis. Formula student tracks are typically designed with numerous sharp turns and a few long straights to maintain low speeds for safety. In order to enhance the cars’ performance in sharp turns, the race car should be equipped with aerodynamic devices like nose cone and wings on both the rear and front ends within the confines of the formula student racing rules. Thus, efficient aerodynamic design is highly critical to maximizing tire grip by ensuring consistent contact with the track, reducing the risk of skidding, and maintaining control, especially during high-speed maneuvers. In this work, the performance and behavior of the race car, both with and without the
Rangarajan, Kishore, Pushpananthan, Blesscin, Anumolu, Lakshman, Selvakumar, Kumaresh, Jayakumar, Shyam Sundar
Enhancing Engine Lubrication: Design and Evaluation of Oil Sump Surge Control in Racing Vehicles2024-36-007412/20/2024
During accelerations and decelerations of a race car whose engine has a wet sump, the forces generated by the vehicle’s motion cause the engine oil to vigorously shift towards the walls of the oil pan and crankcase, contributing to the phenomenon known as ‘sloshing.’ This phenomenon often leads to fluctuations in oil pressure, resulting in oil pressure surge, when the oil is pushed away from the pump pickup point. Via the logged data, the Formula UFSM FSAE Team had witnessed a recurrent lack of oil pressure in the race track during the 2023 Brazilian FSAE competition. In the AutoCross Event, the recurrence of this problem was 80% of the right corners on lateral accelerations between 0.80G and 1.30G. The average oil pressure in this condition was 0.80 bar, even reaching 0.10 bar above 5000 RPM. Therefore, it was necessary to develop a new set of baffles for the oil pan, capable of minimizing the effects of sloshing and, consequently, the oil surge. As a method of research, a test bench
Zimmermann, Natalia Diovana, Junior, Luiz Alfredo Coelho, Martins, Mario, Hausen, Roberto
Modeling and Simulation of an Electromagnetic Brake-by-Wire System for Formula SAE Vehicles2024-36-016912/20/2024
Electric vehicles represent a shift towards sustainability in the automotive industry, with the Brake-by-Wire (BBW) system as an innovation to enhance safety, and performance. This study proposes an electromagnetic BBW system for Formula SAE vehicles, optimizing an electromagnet with a genetic algorithm as the actuator. Through a selection process from a million individuals, the system was modeled. Integrated with electric motors using CarMaker® software, the optimized electromagnet surpassed the minimum required force of 228.08 N without reaching its nominal current of 12.5 A, achieving a force of 231.1 N for 150 W power, indicating an energy efficiency of 0.706 N/Watt. The system also exhibited a response time of 17.92ms for an 80 bar increase, 1.52 times better than compared systems. Simulation under varying braking intensities demonstrated dynamic behavior, with settling times for slow, moderate, and sharp braking at 193 ms, 62 ms, and 21 ms, respectively. Efficiency during
Salgado, Vinícius Batista Alves, Gomes, Deilton Gonçalves, Andrade Lima, Cláudio
Optimization of a 2-D Multi-Element Rear Wing on a Formula 1 Car2024-36-010312/20/2024
The aerodynamic force produced by external flows over two-dimensional bodies is typically decomposed into two components: lift and drag. In race cars, the lift is known as downforce and it is responsible for increasing tire grip, thereby enhancing traction and cornering ability. Drag acts in the direction opposite to the car’s motion, reducing its acceleration and top speed. The primary challenge for aerodynamicists is to design a vehicle capable of producing high downforce with low drag. This study aims to optimize the shape of a multi-element rear wing profile of a Formula 1 car, achieving an optimal configuration under specific prescribed conditions. The scope of this work was limited to a 2-D model of a rear wing composed of two 4-digit NACA airfoils. Ten control parameters were used in the optimization process: three to describe each isolated profile, two to describe their relative position, and two to describe the angles of attack of each profile. An optimization cycle by finite
Souza Dourado, Guilherme, Hayashi, Marcelo Tanaka
Verification of Continuously Variable Transmission Performance Tuning Based on Bacha Racing Vehicle’s Power Matching and Transmission Performance2024-01-509710/15/2024
Due to the compact structure of the Bacha Racing vehicle, the continuously variable transmission (CVT) serves as a crucial transmission component. It is essential to tune and verify its performance to ensure the power matching and transmission efficiency of the entire vehicle. This paper conducts a kinematic analysis of CVT based on transmission theory, designs real vehicle traction experiments, and CVT bench tests. Additionally, it proposes a method to utilize Hall sensors for real-time monitoring of CVT motion to assist in its tuning. The results demonstrate that the optimal performance tuning of the CVT for the Bacha Racing vehicle has been achieved through various experiments.
Li, He
Automotive Engineering: September 202424AUTP0909/05/2024
BMW, Classiq find better architectures through quantum computing Everything from electric motors to robot arms can be looked at through the lens of a powerful algorithm. Blazer EV is a steel-intensive showcase GM elevates the ferrous state-of-art with new body and battery structures. Steel targets EV structures, battery boxes The industry fires back at aluminum's growing 'gigacasting' threat. Editorial No, really, what's an SDV? Supplier Eye A new reckoning Altair honors innovations in automotive lightweighting and sustainability GM EVs will soon provide V2H backup power during blackouts Supplier technologies could deep-freeze the steering wheel Mazda Motorsports keeps the MX-5 cool with a new differential plate 2025 Lucid Air review: unnecessarily fast, astonishingly efficient Refreshed 2025 Cadillac Escalade features 55-inch dash display Product Briefs Spotlight: Testing Tools and Sensors Q&A VW engineering chief on wireless charging at DC speeds
Gaussian Processes for Vehicle Dynamics Learning in Autonomous Racing10-08-03-001906/12/2024
In high-speed autonomous racing, it is necessary to have an accurate racecar vehicle dynamics model in order to push the vehicle closer to its limits. The choice of the dynamics model has to be made by balancing the computational demands in contrast to model complexity. Learning-based methods, such as Gaussian processes (GP)-based regression, have shown promise toward approximating the vehicle dynamics model. In particular, such methods use a simplified model structure that is easy to tune and then use GP to model the mismatch between the output of the simple model and observed system dynamics. However, current GP approaches often oversimplify the modeling process or apply strong assumptions, leading to unrealistic results that cannot translate to real-world settings. This article presents a comprehensive GP-based design for modeling the dynamics of an autonomous racing car. We do so with high-fidelity simulation data, a 1/10-scale autonomous racing car platform, and a full-scale
Ning , Jingyun, Behl, Madhur
A CONSUMER'S VIEW: Perry Parts 3D-printed bump stops24AUTP06_0106/01/2024
Making a Miata feel at home off-road takes ingenuity and some help from modern 3D-printing tech. I have always loved off-road racing. I love the innovation, grit and determination it takes to get across the finish line after 250, 500 or even 1,000 miles (402, 805 or 1,609 km) of racing. I have also always loved Miatas. I bought my first NA in 1994 and never looked back. I currently own a 2004 Mazdaspeed Miata and a 2001 lifted Miata.
Hall, Emme
SAE TOMORROW TODAY: Driven by Speed, Fueled by Engineering1345605/28/2024
Who's better to design a sports car than the person who races it? Meet Kevin Boehm of Boehm Motorsports, a championship-winning professional racer and accomplished OEM principal engineer. Driven by speed and fueled by innovation, Kevin's ability to uncover automotive potential and translate it into on-track victories has made him a true standout both on and off the racetrack. As a principal engineer and test driver at Honda Research and Development, Inc., Kevin supports research design and product development for a wide array of Honda production vehicles. For insight on his professional journey, we sat down with Kevin to discuss his approach to racing, engineering, and coaching--and how Formula SAE played an instrumental role in his ascent into the world of motorsports. To learn more about how Formula SAE challenges students to conceive, design, fabricate, and compete with formula-style racing cars, visit fsaeonline.com.
Hineman, Marcie
SAE TOMORROW TODAY: Florida: A Vibrant Hub of Mobility1345305/14/2024
Whether it's aerospace, theme parks, maritime or motorsports, there is no doubt Florida is helping to build the future of mobility. Home to the Everglades, the state boasts one of the most unique ecosystems in the world. And, with one of the largest EV markets in the country, there is a growing interest in building out sustainable infrastructure. To learn more about Florida's approach to mobility, we sat down with Rebecca Vollmann, Chair, SAE Florida, to discuss the latest advances in automotive, air, rail, and maritime transportation, as well as the revival of the Space Coast. Listen in as she shares her passion for sustainable manufacturing efforts though automation and electrification ? and the importance of encouraging future generations to pursue engineering careers that support the state's vibrant mobility ecosystem.
Hineman, Marcie
Optimizing High-Lift Airfoils for Formula Student Vehicles2024-01-505905/13/2024
This document presents a study on the design and simulation of a high-lift airfoil intended for usage in multielement setups such as the wings present on open-wheel race cars. With the advancement of open-wheel race car aerodynamics, the design of existing high-lift airfoils has been altered to create a more useful and practical general profile. Adjoint optimization tools in CFD (ANSYS Fluent) were employed to increase the airfoil’s performance beyond existing high-lift profiles (Selig S1223). Improvements of up to 20% with a CL of 2.4 were recorded. To further evaluate performance, the airfoil was made the basis of a full three-dimensional aerodynamics package design for an open-wheel Formula Student car. CFD simulations were carried out on the same and revealed performance characteristics of the airfoil in a more practical application. These CFD simulations were calibrated with experimental values from coast-down testing data with an accuracy of 8%.
Karthikeyan, Prthik Nandhan, Radhakrishnan, Jayakrishnan
Electrification and Control of a 1:5 Scale Vehicle for Automotive Testing Methodologies2024-01-227104/09/2024
The design and testing of innovative components and control logics for future vehicular platform represents a challenging task in the automotive field. The use of scale model vehicles constitutes an interesting alternative for testing assessment by decreasing time and cost efforts with a potential benefit in terms of safety. The target of this research work is the development of a customized scale vehicle platform for verifying and validating innovative control strategies in safe conditions and with cost reduction. Consequently, the electrification of a radio-controlled 1:5 scale vehicle is carried out and a customized remote real-time controller is installed onboard. One of the main features of this commercial product is its modular characteristics that allows the modification of some component properties, such as the viscous coefficient of the shock absorbers, the stiffness of the springs and the suspension geometry. The original vehicle is equipped with a 2-stroke internal
Vella, Angelo Domenico, Biondo, Luca, Tota, Antonio, Vigliani, Alessandro
Regenerative Energy Control Technology of Charging Vehicles in Electric Road System2024-01-217104/09/2024
This Electric Road System was devised that would provide electric power to EVs directly from the infrastructure so that EVs could undergo intermittent charging while driving. This system is a conductive dynamic charging system that operates from the side of the vehicle (roadside), and research has been underway on the application of this approach to passenger cars and race cars. This paper focused on resolving issues with freight vehicles, which account for most of the CO2 emissions in the transportation sector. This Electric Road System that operates by contact from the roadside was applied to heavy-duty trucks, which have been considered a challenge to convert to EVs, and at the same time the infrastructure technology was also expanded and evolved. And verification tests using actual vehicles were conducted for regenerative energy absorption control of a charging vehicle while driving. The results confirmed that this control system appropriately controls the distribution of power
Tajima, Takamitsu, Abe, Hiroyuki
Formula 1 Race Car Aerodynamics: Understanding Floor Flow Structures and Why It Is a Key Component in Modern Racing2024-01-207804/09/2024
This paper delves into the intricate realm of Formula 1 race car aerodynamics, focusing on the pivotal role played by floor flow structures in contemporary racing. The aerodynamic design of the floor of a Formula 1 car is a fundamental component that connects the flow structures from the front wing to the rear end of the car through the diffuser, thus significantly influencing the generation of lift and drag. In this work, CFD was used to predict the structure of the vortices and flow pattern underneath a Formula 1 car using a CAD model that mimicked the modern Red Bull Racing Team’s car in recent years. Through comprehensive analysis and simulation, a detailed understanding of the complex flow patterns and aerodynamic phenomena occurring beneath the floor of the car and its vicinity is presented. This entails a close examination of how air interacts with the floor of the car and how the flow around the car can be manipulated to alter the flow rate and the quality of air going into the
Shaalan, Amr, Assanis, Dimitris, Raman, Aditya, Wijeyakulasuriya, Sameera, Senecal, Kelly
Automatic Optimization Method for FSAE Racing Car Aerodynamic Kit Based on the Integration of CAD and CAE2024-01-207904/09/2024
In the process of designing the aerodynamic kit for Formula SAE racing cars, there is a lot of repetitive work and low efficiency in optimizing parameters such as wing angle of attack and chord length. Moreover, the optimization of these parameters in past designs heavily relied on design experience and it's difficult to achieve the optimal solution through theoretical calculations. By establishing a parametric model in CAD software and integrating it with CFD software, we can automatically modify model parameters, run a large number of simulations, and analyze the simulation results using statistical methods. After multiple iterations, we achieve fully automatic parameter optimization and obtain higher negative lift. At the same time, the simulation process is optimized, and simulations are run based on GPUs, resulting in a significant increase in simulation speed compared to the original. The results show that automated optimization saves a lot of manpower costs, and compared to
Chen, Yanjun
Improve the Durability and Maintenance Feasibility of the Universal Joint Based on the Original Half-Shaft Foundation2024-01-244104/09/2024
Based on the particularity of the racing field of the Baja SAE China, the Baja Racing Team of our university has adopted rzeppa universal joint for vehicle design and field competition in the semi-axle parts of the race car in previous years. In view of the complex conditions of the Baja Competition, such as gravity test, climb test, handling test, endurance test, etc., it is necessary to optimize and develop a more convenient maintenance model. Installation and use of better performance, more suitable for off-road conditions of the shaft. In this paper, based on the development dynamics of automobile axles and the transverse comparison of various axles, a kind of telescopic cross-shaft universal joint axles is designed by using CATIA software to model and simulate kinematics and dynamics by using ANSYS software. At the same time, the stress and strain of the model are continuously optimized according to the change of axle wheel Angle and the torque matching of Baja Racing. The object
Zhang, Hengyu, He, Li, Xiao, Miaoqi
CAATS - Automotive Wind Tunnel Test Techniques2024-01-254304/09/2024
This paper contributes to the Committee on Commonized Aerodynamics Automotive Testing Standards (CAATS) initiative, established by the late Gary Elfstrom. It is collaboratively compiled by automotive wind tunnel users and operators within the Subsonic Aerodynamic Testing Association (SATA). Its specific focus lies in automotive wind tunnel test techniques, encompassing both those relevant to passenger car and race car development. It is part of the comprehensive CAATS series, which addresses not only test techniques but also wind tunnel calibration, uncertainty analysis, and wind tunnel correction methods. The core objective of this paper is to furnish comprehensive guidelines for wind tunnel testing and associated techniques. It begins by elucidating the initial wind tunnel setup and vehicle arrangement within it. Subsequently, it delves into a diverse array of test techniques, encompassing aerodynamic force measurements, ventilation drag assessments, flow field analyses, and surface
Wittmeier, Felix, Bianco, Antonello, Bratby, James, Howard, Kevin, Roper, Thomas, Senft, Victor
CAATS – Automotive Wind Tunnel Statistical Process Control2024-01-254204/09/2024
This paper presents the application of statistical process control (SPC) methods to Windshear, a 180-mph motorsports and automotive wind tunnel equipped with a wide-belt rolling road system. The SPC approach captures the complete variability of the facility and offers useful process performance metrics that are based on a sound statistical framework. Traditional control charts are explored, emphasizing the uniqueness of variability experienced in wind tunnels which includes significant, unexplained short-term and long-term variation compared to typical manufacturing processes. This unique variation is elegantly captured by the three-way control chart, which is applied to estimate the complete process reproducibility with different levels of repeatability of vehicle drag coefficient. The sensitivity of three-way control charts is explored including the evaluation of an alternate group assignment within the same dataset. A practical example is provided evaluating secondary boundary layer
Bringhurst, Katlynn, Walter, Joel, Best, Scott
Design, Modeling, and Analysis of Heave and Roll Decoupled Suspension Geometry for a Formula Student Prototype2024-01-207704/09/2024
This work aims to present the application of mode coupling to a Formula Student racing vehicle and propose a solution. The major modes of a vehicle are heave, pitch, roll, and warp. All these modes are highly coupled – which means changing suspension rates or geometry will affect all of them – while alleviating some and making others worse characteristics. Decoupling these modes, or at least some of them, would provide more control over suspension setup and more refined race car dynamics for a given layout of the racetrack. This could improve mechanical grip and yield significant performance improvements in closed-circuit racing. If exploited well, this approach could also assist in the operation of the vehicle at an optimal kinematic state of the suspension systems, to gain the best wheel orientations and maximize grip from the tires under the high lateral accelerations and varied excitations seen on a typical road course. Previous strategies used by other researchers to achieve
Panchal, Tanmay, Bastiaan, Jennifer
Analysis and Design of Suspension State Observer for Wheel Load Estimation2024-01-228504/09/2024
Tire forces and moments play an important role in vehicle dynamics and safety. X-by-wire chassis components including active suspension, electronic powered steering, by-wire braking, etc can take the tire forces as inputs to improve vehicle’s dynamic performance. In order to measure the accurate dynamic wheel load, most of the researches focused on the kinematic parameters such as body longitudinal and lateral acceleration, load transfer and etc. In this paper, the authors focus on the suspension system, avoiding the dependence on accurate mass and aerodynamics model of the whole vehicle. The geometry of the suspension is equated by the spatial parallel mechanism model (RSSR model), which improves the calculation speed while ensuring the accuracy. A suspension force observer is created, which contains parameters including spring damper compression length, push rod force, knuckle accelerations, etc., combing the kinematic and dynamic characteristic of the vehicle. Subsequently, the
Zeng, Tianyi, Liu, Zeyu, He, Chenyu, Zeng, Zimo, Chen, Haotian, Zhang, Feiyang, Fu, Kai, Chen, Xinbo
Lightweight Design of Integrated Hub and Spoke for Formula Student Racing Car2024-01-208004/09/2024
In the racing world, speed is everything, and the Formula Student cars are no different. As one of the key means to improve the speed of the car, lightweight plays an important role in the racing world. The weight reduction of unsprung metal parts can not only improve the driving speed, but also effectively optimize the dynamic of the car, so the lightweight design of unsprung parts has attracted much attention. In the traditional Formula Student racing car, the hub and spoke are two independent parts, they are fixed by four hub bolts or a central locking nut, the material of these fasteners is usually steel, so it brings a lot of weight burden. In order to achieve unsprung lightweight, a new type of wheel part design of Formula Student racing car is proposed in this paper. The hub and spoke are designed as integrated aluminum alloy parts, effectively eliminating the mass of hub bolts or central locking nuts. After proper iterative optimization, the part achieves a weight reduction of
Cui, Jiarui, Chen, Yichao
Full speed ahead for second-generation Indy autonomous racers24AUTP04_0404/01/2024
Major hardware and software upgrades underpin the Indy Autonomous Challenge racecar for 2024, proving self-driving vehicle capabilities at triple-digit speeds. After three years and more than 7,000 miles (11,265 km) of racing, the Indy Autonomous Challenge (IAC) enters year four with an updated platform and embedded software upgrades. Among the highlights for the second-generation open-wheel racecars are pending patents and first-time applications. “We've achieved several impressive milestones since our start in 2020,” IAC President Paul Mitchell said. The achievement list includes setting a speed record for passing in autonomous racing (170 mph [273 km/h]), netting the autonomous vehicle land speed record (192.2 mph [309.3 km/h]) and establishing the fastest lap speed for an autonomous vehicle (180 mph [289.68 km/h]). “More than anything, we consider the IAC an applied-research platform for industry and academia to work together on advancing high-speed autonomy,” Mitchell said.
Buchholz, Kami
Design and Optimization of the Steering System in Go-Kart2023-01-514702/23/2024
The steering system is one of the most critical and important systems in the vehicle. The steering system of the vehicle must be highly accurate and sensitive to the inputs given by the driver through the steering wheel, such that the vehicle must be able to take high-speed corners and tight corners with high stability without any mechanical failure. In this study, the development and optimization of the steering system in the go-kart are studied elaborately. Go-karts are small racing vehicles with a low center of gravity, low ground clearance, and high speed. The steering system in the go-karts must be highly precise to initiate the tight corners. This study involves the design and optimization of the steering system for the go-karts, which uses the Pitman steering mechanism as the primary steering mechanism and relies on Ackermann steering geometry. In this study of the steering system in a go-kart vehicle, the modeling of the steering system is carried out in SolidWorks and Catia
YUVARAAJ KUMAR, S., Srivarshani, P., Nitin Sanjeeth, S.V., Sudhakar, M.
Enhancing Aerodynamic Performance of a Formula Car through Modification and Evaluation2023-01-516702/23/2024
Aerodynamic resistance stands as a pivotal factor impacting the performance of race cars, creating significant impedance to their movement. Diverse strategies exist to alleviate this resistance, including the integration of aerodynamic elements and refinement of the vehicle's body contours. By emphasizing drag reduction without altering the powertrain, race car designs can effectively curtail drag. This study centers on the exhaustive examination, analysis, and experimentation with a model representing a Formula Student (FS) car, with the primary objective of augmenting its aerodynamic efficiency for motorsport applications. In compliance with the SAEINDIA Supra regulations, a meticulously crafted CAD model of the formula car is developed. After this, the model undergoes simulation utilizing computational fluid dynamics (CFD) tools, facilitating the identification of turbulent zones and areas of enhanced drag. A scaled-down 3D printed model is then employed for comparative analysis
Rangarajan, Kishore, Velayudhan, Gautham
Integrated Numerical and Experimental Workflow for High-Performance Vehicle Aerodynamics2024-01-501602/06/2024
The high-performance and motorsport vehicle sectors are pushing the performance frontiers of aerodynamically efficient vehicles. Well-balanced use of accurate and consistent numerical simulation tools in combination with wind tunnel experiments is crucial for cost-effective aerodynamic research and development processes. Therefore, this study assesses the simulation performance of four Reynolds-averaged Navier–Stokes (RANS) turbulence models in relation to experimental and high-fidelity delayed detached eddy simulation (DDES) data for the aerodynamic assessment of a high-performance variant of the DrivAer model (DrivAer hp-F). The influences of predominant wind tunnel conditions on the vehicle’s aerodynamic force coefficients and flow field are also investigated. Additionally, a novel CFD-based blockage correction method is introduced and applied to evaluate the accuracy of conventional blockage correction methods. Among the RANS models, the k-ω SST model exhibited notable relative
Rijns, Steven, Teschner, Tom-Robin, Blackburn, Kim, Brighton, James
Numerical Analysis and Optimization of Heat Transfer for FSAE Radiator for Various Sidepod Designs2023-28-005511/10/2023
Heat transfer optimization is a crucial aspect of the design process for Formula Student race cars, particularly for the radiator, usually housed in a side pod. For the car to operate at peak performance, a well-designed radiator-sidepod system is essential such that it can dissipate heat generated by the engine faster, for the car to run in optimal performance. Testing the car physically for various radiator-sidepod design iterations is a very difficult task, also considering the costs to manufacture the radiator-sidepod setup. The objective of this study is to develop a comprehensive methodology for analysing heat transfer through radiator setup using Computational Fluid Dynamics and to validate it through experimental investigations, to enhance performance and efficiency of the radiator setup. It further explains how to find out its heat transfer efficiency, and to choose the right radiator-sidepod setup, giving optimal performance. The flow of coolant inside the radiator, as well
Suresh, Sankar, Sundar, Mahima, Bhaskara Rao, Lokavarapu
Numerical Iterative Analysis of Drag Reduction System for a Racing Car Rear Wing2023-01-507911/08/2023
In Formula Student competitions, the active adaptation of the aerodynamic components to the current race track conditions can significantly enhance the overall dynamic performance of the car. Due to the abundant low-speed corners, angles of attack of fixed aerodynamic components are usually exaggerated, preventing the car from achieving higher acceleration capabilities due to induced drag. This issue can be tackled by introducing an active drag reduction system (DRS). In this work, a strategy for performing iterative numerical simulations is proposed, with the goal of obtaining a range of different configurations suitable for certain track conditions. Specifically, the case of lowest drag is exploited. Different macros were developed to couple the utilization of computational fluid dynamics tools for aerodynamic analysis with an extensive iterative process with minimal user interference. An initial mesh refinement study was conducted. Afterward, angles of attack and centers of rotation
Monteiro, Carlos, Brito, Moisés, Vieira, Diana Filipa da Conceição
SAE TOMORROW TODAY: Building a Winning Career in Motorsports1342010/30/2023
Long regarded as one of the most influential women in NASCAR, decorated auto racing engineer Alba Colon came to Hendrick Motorsports as Director of Technical Partnerships after a storied career with General Motors that spanned more than two decades. Under Colon's leadership, Chevrolet was the most dominant manufacturer in the NASCAR Cup Series, amassing 286 race wins, 12 driver championships and 14 manufacturer titles. Since joining Hendrick Motorsports in 2018, the team has won 48 races and 2 driver championships. If history is any guide, many more are in store. From her early years in Puerto Rico to taking part in her first Formula SAE competition, we sat down with Alba to discuss her passion for motorsports and her dedication to advancing women in engineering which won her the prestigious Rodica Baranescu Award for Technical & Leadership Excellence from SAE International in 2022. SAE Awards honor the very best in mobility, recognizing the extraordinary achievements of executives
Hineman, Marcie
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