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www.cranfield.ac.uk

Advanced Motorsport Engineering MSc

Advanced Motorsport Mechatronics MSc

Group Design Project (GDP) 2020

By Anthere - Own work, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=52315

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GDP background

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GDP background

Objective setting, planning and project management

• Evaluate a client’s project brief

• Develop a set of project objectives appropriate to the client’s brief

• Plan and execute a work programme with reference to key project management processes (e.g. time management; risk management; contingency planning and resource allocation).

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GDP aims

Team working

• Understand the different roles within a team working environment

• Utilise individual skills and expertise to contribute to team output and

collaborate effectively with others in a consultancy team context for

the duration of the GDP

• Contribute to all team meetings during the GDP, rotating the chair

• Actively participate in all presentations

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GDP aims

Processes and activities

• Select and justify a methodology appropriate to the task

• Collect and analyse data, review and critically analyse literature, generate

conclusions

Reporting, communications, reflective practice

• Convene weekly meetings, publishing minutes that record project progress

and each team member’s contribution for the week

• Communicate findings in a professional manner in written, oral and visual

forms

• Reflect upon and evaluate personal and group performance in a team-based

task with reference to peer review and evaluation, including competencies

and contributions.

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In other words…

Welcome to your “first motorsport job”…

Sorry,

It is impossible... (to do everything perfectly)

No-one will tell you what to do

Each day counts

It will be all done for Monday 13th May 2020

And you’ve got competition…

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GDP 2020 teams

Group 1De Melo GomesNugentLe Roux De BretagneRichardsMangion

Group 2DriverLudescherGalaSapollnikSanches

Group 3PeetersFergusonStoneMillerCortes

Group 4PottsMerrettLaukaikulGarcíaSharma

Group 1LammondZhenValencia ContechaRuiz GraciaAlzinaSullivan

Group 2ShahWenSanghrajkaEstorach MatamorosGuzzabocca

Group 3ApteOhmuraGuggillaDelrivoLi

Group 4FormosaYuGeliKovacsSaikumar

Task A

Task B

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GDP academic requirements

• Team work output– 80% of total mark

• Concisely written technical report 80% (10,000 words* max)

• Team final academic presentation 20% (45 minutes duration plus Q & A)

• Poster (not formally assessed)

• Individual evaluation by assessors - 20% of overall mark

• Reflective review report 50%

• Individual contribution 50%

Must achieve 50% minimum to pass each element.

*Excluding references, tables, charts, illustrations, appendices etc. All team members must contribute.

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GDP formal requirements

Group/Team meetings (weekly – minutes sent by 16:00 hrs each Friday)(sent to SasAutoCourses@ subject line e.g. “GDP Minutes - Group 1, Team X, 22/3/2020”

• Minutes of these meetings taken, - discussion, actions and decisions

• Short list of individual contributions for all team members in the last week

• Minutes included as report appendices.

Review presentations (two) to academic panel

(Feedback, but not directly assessed)

• Formal team presentation, 20 minutes to academic panel

• Status, decisions, work in progress, performance projection

• Include planning – e.g. Gantt chart – realistic and up to date

• Feedback from review panel

• After presentation, summarise your notes of the panel’s feedback and email in (~2 pages)

• (To check we communicated all the questions and you heard all the feedback)

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GDP industry day – 13th May 2020

• Industry day not academically assessed

• Feedback and practice prior to event …

• Prizes:

• Racecar Engineering - best poster

• Motorsport UK - best presentation

• Best group report (academic)

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MSc GDP 2020

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Green Gulf

https://westfield-sportscars.co.uk/showroom-brochures/westfield-sport-250/

https://maps.google.com

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Conceptual design of a modified Westfield Sport 250 for a new series in the Arabian Gulf region

• Hydrogen ICE conversion

• Manual gearbox, rear wheel drive

• Electric MGU(s) connected to front wheels for regeneration and boost

• Battery or super capacitor storage

• Metallic space frame and stressed skin primary structure

• Flat composite structural panels are allowed and may be bonded to the spaceframe.

• Design will pass a specified crash test relevant to driver and fuel system

• Must demonstrate an appropriate and validated thermal package.

• Active chassis control is permitted

Target is a low-cost entry level series with maximum performance & genuine green credentials

Project Brief

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• Project rules take precedence over established rules

• This briefing document and the full written version.

• Any subsequent rules updates as issued to all teams

• Rules questions may be raised

• MSA Blue book 2020

• Rules may change at any time

• “Spirit of the series”.

• A vote may be taken but is not binding on the regulator

• No deliberate changes, but if something is clarified at a late stage you may not like it

Rules

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• Ford 2.0l Ecoboost engine

• Existing longitudinal engine, rear drive layout

• Hydrogen conversion – base engine unchanged, Intake and exhaust systems are free, as is turbo or supercharging. Ignition systems are free.

• A single fuel tank must be sized to suit the engine and race duration.

• Front wheels coupled to MGU (one or two)

• Electrical energy storage by battery or supercapacitor. Start race with no usable energy

• Regeneration and deployment strategy are free.

• Electrical store must be air cooled (no liquid circuit).

• A structural solution based on the existing design modified where required.

• MIG-welded steel tube. Alternative alloys may be inserted where justified on a part by part basis.

• Bonded composite panels are permitted, as is composite bodywork

• Design must be simulated and shown to survive a specified crash test. Driver and fuel system safety.

• A thermal system to maintain ICE, energy store, MGU(s) and electronics within operating limits.

• Air cooling of energy store only. Air cooled motors are desirable.

• Validated thermal model

• Ad Diriyah circuit in Saudi Arabia

• 45 minute race duration, plus formation and in-laps.

• Additional circuits may be released later

Initial technical scope

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• Sufficient for evaluation of your concept design by a potential investor

• Robust projection of key performance & design numbers

• Don’t over-claim (or under-claim!)

• Don’t be vague – say where you have uncertainty and what it means overall

• Point out where rules may be particularly restrictive and where a “better” option may be

• Complete the loop and interactions

• Detail where novel, not where standard practice

• “Don’t describe a transistor or a fire handle in detail

• Do describe your novel strategy for equalising tyre force and saving 2s per lap

• Describe new software & principles. Not a Simulink screenshot

• Costing where available

• New ideas welcome

• The future of motorsport

Scope – final team proposal

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• Desire to establish a market for “Chassis” and “Powertrain” suppliers

• Common in previous series up to F1

• Start of the project, Task A = Powertrain, Task B = Chassis

• Conceptual work, come up with a proposal of what you would offer.

• Friday 27th March: “Team Formation Day”

• 10am, submit technical proposal (NOT assessed)

• 11am – each “chassis” group receives all powertrain offerings (& vice versa)

• 4pm – each group submits a rank order of their “supplier” offerings

• Ranks will be combined to match groups (minimum sum)

• 5pm – final team pairings announced.

• 27th – 11th May – work as a complete team for the benefit of that team.

Team organisation

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• In the initial stage, the powertrain groups (Task A) have responsibility for:• The ICE and conversion to hydrogen

• Front wheel motor(s)

• Motor controller(s)

• Battery cell selection

• Electrical system safety

• Control and energy management implementation

• The chassis groups (Task B) have responsibility for:• Battery box design

• Fuel storage design and location

• Aerodynamics - Cooling air inlet and outlet ducting (for all uses)

• Structural safety

• Vehicle dynamics (including energy management strategy)

• After team formation, the team overall is responsible for a unified solution.

Areas of responsibility

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• Research

• Concept development

• “Rough modelling” – get numbers in context

• Down selection

• Detailed modelling – packaging, performance

• Validation – how much confidence in estimate

• Update overall system concept - interactions

• Predict performance

• Review – good or bad, do more, do less

Typical workflow

Maximise validationLiterature where you canPractical where possible

Simple testsAsk early…

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• Westfield Sport 250• Measure, weigh, model

• Vehicle dynamics tests• Validation of your models

• Repeat with additional masses / adjustments.

• Structural validation

• Material properties usually from literature

• Joint properties / joining method validation?

• Thermal system validation (heat transfer)

• Cell or capacitor level testing (up to 100A)

• ?Cell availability?

• Aerodynamics – focus on cooling flows

Validation facilities

Anything new?Rig/fixture?

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• No set tests – each team requests what is most relevant.

• Prioritise what is critical to your design performance

• We don’t repeat what you can get from the literature

• If you have an idea for a simple method to test something – ASK! – but early

• If you can collaborate with another group, don’t duplicate testing the same sample in the same way. But if your idea is unique you can keep it “confidential”.

• Expect to justify why you’re asking, expect to have to modify your plans in view of practical availability.

• We set a date window when it can happen (facility booking, people etc.)

• Unless affected by external factors we won’t postpone because you’ve not decided

• You come and do the tests

• Go and work out what it means in your context.

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Make the most of each contribution you make, don’t wish for what you haven’t got.

Assessment is based on what you do with what you have.

Validation: guidance

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Green Gulf - scheduleW/C Monday Tuesday Wednesday Thursday Friday Practical / info

02/03/2020 Project LaunchRules

Questions

09/03/2020

16/03/2020Brian O'Rourke

Lecture

Cell /

Supercapacitor

details

23/03/2020GDP Review 1 (8

groups)

Group

Reports

Team Form

30/03/2020 Rik Kasius Individual reviews Individual reviews Thermal rig build

06/04/2020 MIA - SilverstonePublic

Holiday

Vehicle dynamics

Test 1

13/04/2020 Public Holiday Motorsport UK visit Thesis reviewsThesis

Reviews

20/04/2020GDP Review 2 (4

teams)

Thermal validation

tests

27/04/2020Press

release

Vehicle dynamics

Test 2

04/05/2020Poster

SubmissionReport Submission

Public

Holiday

11/05/2020 Presentations Rehersals Industry DayIndividual

reflection

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Green Gulf - questions…?