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Vehicle dynamics on a Formula SAE vehicle are inter-dependent with almost all mechanical systems on the car and require a thorough understanding of design tradeoffs in order to maximize the vehicle's acceleration capabilities while maintaining consistent driver feedback. This thesis summarizes the developments and accumulated knowledge on MIT's Formula SAE team with regards to suspension and vehicle dynamics of the 2018 - 2020 seasons in order to inform the design and vehicle development for future years. Vehicle kinematics, vehicle dynamics, and tire selection are covered, in addition to the impact of aerodynamics, steering, and control arms on suspension development. Areas for further research are described. Throughout the thesis, the importance of quantifying and documenting design decisions is highlighted.
The Texas A & M University Formula SAE program currently has no rigorous method for analyzing or predicting the overall dynamic behavior of the student-designed racecars. The objective of this study is to fulfill this need by creating a full vehicle ADAMS/Car model incorporating an empirical tire-road force model and validating the longitudinal performance of the model by using vehicle responses recorded at the track. Creating the model requires measuring mass and inertia properties for each part, measuring the locations of all the kinematic joints, testing the Risse Racing Jupiter-5 shocks to characterize damping and stiffness, measuring engine torque, and modeling the tire behavior. Measuring the vehicle performance requires installation of the Pi Research DataBuddy data acquisition system and appropriate sensors. The 2002 Texas A & M University Formula SAE racecar, the subject vehicle, was selected because it already included some accommodations for sensors and is almost identical in layout to the available ADAMS/Car model Formula SAE templates. The tire-road interface is described by the Pacejka '94 handling force model within ADAMS/Car that is based on a set of Goodyear coefficients. The majority of the error in the model originated from the Goodyear tire model and the 2004 engine torque map. The testing used Hoosier tires and the 2002 engine intake and exhaust configuration. The deliverable is a full vehicle model of the 2002 racecar with a 2004 engine torque map and a tire model correlated to longitudinal performance recorded at the track using the installed data acquisition system. The results of the correlation process, confirmed by driver impressions and performance of the 2004 racecar, show that the 2004 engine torque map predicts higher performance than the measured response with the 2002 engine. The Hoosier tire on the Texas A & M University Riverside Campus track surface produces 75 " 3% of peak longitudinal tire performance predicted by the Goodyear tire model combined with a road surface friction coefficient of 1.0. The ADAMS/Car model can now support the design process as an analysis tool for full vehicle dynamics and with continued refinement, will be able to accurately predict behavior throughout a complete autocross course.
This set includes Race Car Vehicle Dynamics, and Race Car Vehicle Dynamics - Problems, Answers and Experiments. Written for the engineer as well as the race car enthusiast, Race Car Vehicle Dynamics includes much information that is not available in any other vehicle dynamics text. Truly comprehensive in its coverage of the fundamental concepts of vehicle dynamics and their application in a racing environment, this book has become the definitive reference on this topic. Although the primary focus is on the race car, the engineering fundamentals detailed are also applicable to passenger car design and engineering. Authors Bill and Doug Milliken have developed many of the original vehicle dynamics theories and principles covered in this book, including the Moment Method, "g-g" Diagram, pair analysis, lap time simulation, and tyre data normalization. The book also includes contributions from other experts in the field. Chapters cover: *The Problem Imposed by Racing *Tire Behavior *Aerodynamic Fundamentals *Vehicle Axis Systems and more. Written for the engineer as well as the race car enthusiast and students, the companion workbook to the original classic book, Race Car Vehicle Dynamics, includes: *Detailed worked solutions to all of the problems *Problems for every chapter in Race Car Vehicle Dynamics, including many new problems *The Race Car Vehicle Dynamics Program Suite (for Windows) with accompanying exercises *Experiments to try with your own vehicle *Educational appendix with additional references and course outlines *Over 90 figures and graphs This workbook is widely used as a college textbook and has been an SAE International best seller since it's introduction in 1995.
This textbook is appropriate for senior undergraduate and first year graduate students in mechanical and automotive engineering. The contents in this book are presented at a theoretical-practical level. It explains vehicle dynamics concepts in detail, concentrating on their practical use. Related theorems and formal proofs are provided, as are real-life applications. Students, researchers and practicing engineers alike will appreciate the user-friendly presentation of a wealth of topics, most notably steering, handling, ride, and related components. This book also: Illustrates all key concepts with examples Includes exercises for each chapter Covers front, rear, and four wheel steering systems, as well as the advantages and disadvantages of different steering schemes Includes an emphasis on design throughout the text, which provides a practical, hands-on approach
A workbook for introductory courses on vehicle dynamics.
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The Formula SAE Electric competition is a collegiate autocross event in which teams design, build, and race an open-wheeled electric race car. The main motivation is the efficiency advantage of electric motors over internal combustion motors. This thesis presents the design and evaluation of two generations of Portland State University electric race cars. The constraints are the competition rules, finances, human resources, and time required to complete a race car in one year. The design includes the implementation of existing components: battery cells, controllers, electric motors, drivetrains, and tire data for an optimized race car. Also, several circuits were designed and built to meet the rules, including the shutdown, precharge, discharge, brake system plausibility, tractive system active light, and an electric vehicle control unit. The car's performance was modeled with calculations and OptimumLap simulation software, then track tested for actual data. Performance data such as torque, power, and temperatures were logged, and the Formula SAE events were tested. The data were compared to the simulations and records from past competitions, and the car was 21% to 30% behind the best times. The motor generated 410 Nm of peak torque, as expected, but the maximum power was 51 kW, 15% less than the calculated 60 kW. Compared to the best times of past competitions, the car completed Skid-pad in 6.85 seconds (21% slower), and Acceleration in 5.65 seconds (25% slower). The first generation car was tested for range, and raced 31.4 km on a cold, wet track, so tire forces were decreased 6% to 69% from a dry track. During the 22 km. Endurance test with the second generation car, there were problems with imbalanced cell voltages, limiting the test to 4.9 km. Later, there was a catastrophic drivetrain failure, and Endurance testing on a dry track was not completed. In dynamic event simulations, a lighter, axial flux permanent magnet synchronous motor with a decreased counter EMF yielded improved times. Reconfiguring the battery pack from 200 V[subscript DC] 300 V[subscript DC] would provide 50% more peak power. Further testing is required to determine the actual average power use and making design decisions with an improved battery pack.
The aim of this thesis is to provide useful framework for the design of the upcoming electric race car of Lund Formula Student Team. The thesis intends to find the different powertrain concepts on the state of the art. From the configurations, the thesis should provide outcomes of the performance, efficiency, complexity design and cost. Furthermore, the best concept should be find and a simple preliminary design is made.To compare the different concepts developed, a Matlab code was used, which simulates the vehicle dynamics of the race cars. A Simulink model wasbe used to analyse the different electric systems and come up with the most efficient solution. The results of the thesis show that the powertrain configuration that should perform better in a real competition is the design with four motors actuating one in each wheel. The reason behind it, is the abilty of the system to provide different torque at each wheel, known as torque vectoring. By distributing different torque at each wheel the race car is able to create a yaw movement to the body, allowing it to make turns at a higher velocity. The design shows the different parts composing the powertrain, and how each of the parts was chosen. To conclude the thesis, the four motor's configuration is compared to the LFS20 design in order to explain how this powertrain improves the car results in the overall competition.
Formula SAE is a collegiate design competition in which student teams design, build, and race an electric formula racecar every year. In 2019, the MIT team built its first four wheel drive vehicle. The new architecture requires more robust and performant control systems. One major challenge is that the vehicle is not functional for the majority of the year. A longitudinal vehicle simulation was written and tested for the purpose of testing control algorithms without a physical testbed, as well as to learn more about vehicle behavior in general. The simulation was written in Simulink and the structure kept versatile so that it could be easily expanded in complexity in future years. Test data was used to successfully correlate the model to the actual system. Several launch control algorithms were also tested using this simulation, for both a rear wheel drive and four wheel drive architecture. Although basic, the control schemes produced promising results for both speed and stability, notably the normal force proportional controller.