FAUmax ny

For the first time in our 14-year history, we were able to use a lap time simulation to help us define the top priorities of our design. Combined with the feedback of our drivers and previous generations of team members, we decided on the following three crucial ingredients to create a fast racing car: Aerodynamic Efficiency, Lightweight Design and Driver’s Ergonomics.

Without colliding with these ground rules, specialties of our subassemblies, like engine efficiency for the drivetrain, still need to play a big role within their sub-teams.

To achieve our goals, we made radical changes in almost all areas of the vehicle: Aerodynamics, Chassis, Powertrain and Suspension. To create as much space as possible for our side mounted aerodynamic devices, we chose a single-cylinder KTM engine mounted transversely. This resulted in a narrow monocoque shape with a width of 320mm from the front hoop to the rear end at the height of the diffuser.

Erfolge:

  • 3. Place Cost and Manufacturing Event @ FSG2021
  • 3. Place Engineering Design Event @FSG2021
  • 4. Place Engineering Design Event @FSEast2021
  • 4. Place Engineering Design Event @FSN2021
  • 5. Place AutoX @FSA2021

Technical Data

Overall Dimensions L2860mm | W1900mm | H1198mm

Wheelbase 1560mm

Front track 1240mm

Rear track 1150mm

Mass without driver Front 78,3 kg | Rear 78,7 kg | Total 157 kg

 

Body and Frame

  • Frame Construction
    • Single piece CFRP full monocoque in sandwich structure
  • Impact Attenuator
    • Honeycomb with Aluminium Anti Intrusion Plate

Ergonomics

  • Driver Size Adjustments
    • perfect fit seat due to 3d impression of drivers and mockup, adjustable headrestrain, additional foam paddings
  • Seat
    • self-developed cfrp seat, ligthweight foam headrestrain
  • Steering Wheel
    • self-made cfrp sandwich plate sla-printed handles, Diameter 240mm
  • Shift Actuator (type, location)
    • electromechanic shifting, shift paddles on steering wheel
  • Clutch Actuator (type, location)
    • electrohydraulic clutch actuator, electronic clutch lever on steering wheel
  • Instrumentation
    • self-designed vehicle information system (VIS), shows needed information and warnings, shifting lights integrated in VIS

Aerodynamics

  • Configuration
    • full cfrp package consisting of rearwing, frontwing, undertray and diffusor
    • self-developed airfoil
    • infinity style frontwing concept
  • Coefficients
    • Cl = 4,6
    • Cd = 1,5

Suspension

  • Setup
    • Front axle: Double-wishbone with roll-heave-system
    • Rear axle: Double-wishbone with anti-roll bar
    • KW dampers and carbon tubes
    • Static camber adjustment with shims on upper wishbone attachment
  • Wheels and tires
    • Front Tire: Hoosier R25B 16,0 x 6,0 – 10
    • Rear Tire: Hoosier R25B 16,0 x 6,0 – 10
    • Rim: self-designed and manufactured carbon rims
  • Brake System
    • four external floating steel brake discs
    • Front wheels brake calipers: Wilwood GP200
    • Rear wheels brake calipers: AP Racing CP4226
  • Steering
    • compact, self-developed rack-and-pinion steering gear with carbon steering column
    • Kingpin and caster adjustment via plates under upper wishbone attachments

Electronics

  • Power Management / Control
    • decentralised CAN-BUS
    • self-developed control units
    • electronic fusebox
    • relays in ignition injection and fuelpump control unit
  • Wiring
    • self-designed wiring harness
    • wires dimensioned according to respective current needs, stranded wires, wires protected with wire sleeves, wires rated for U≥300 V and T≥120 °C,
    • control units mounted to the chassis with 3M Dual Lock for vibration isolation
  • Battery
    • LV 4S 10 Ah 15C discharge rate lithium polymer battery
    • charging via Accumulator Monitoring System outside of the car
    • no on-board charger/alternator, generator
  • Driver Assist Systems
    • HUD
    • shift-by-wire
    • shift without lift
    • clutch-by-wire
    • automatic shifting and tire slip control for acceleration event
  • Logging / Telemetry
    • Onboard logging on GIN GL1010 Compact Logger
    • live telemetry via Kvaser Blackbird v2
  • Special Sensing Technology
    • Optional laser ground distance sensors
    • inertial navigation system
    • suspension travel sensors

Engine and Drivetrain

  • Engine
    • Modified KTM 450 SX-F single cylinder
    • Displacement: 510 ccm
    • Bore: 95,0 mm
    • Stroke: 72,0 mm
    • Compression Ratio: 14,2:1
  • Engine output
    • Peak Torque: 55 Nm @ 7000 rpm
    • Peak Power: 46 kW @ 9000 rpm
  • Lubrication system
    • KTM dry sump 1,2 l
    • spring controlled bypass, crank driven
    • Motorex KTM Racing 4T SAE 20W/60
    • target oil pressure: 2,4 bar
  • Airbox
    • Naturally aspirated with intake plenum
    • Intake plenum volume: 6,8 l
    • Throttle body: double barrel valve, electrically actuated
  • Exhaust system
    • Additive manufactured exhaust manifold from Inconel 718
    • Side-mounted dual flow-through absorption muffler with long tailpipe
  • Fuel system
    • Aluminium fuel tank without bladder located between engine and driver
    • internal fuel pump
    • Capacity: 4,7l
    • Low pressure (5 bar) intake manifold injection system
  • Cooling system
    • side mounted one core cross-flow radiator
    • 530 cfm fan mounted to cfrp radiator duct
  • Ignition system
    • Bosch P65-T single fire ignition coil and NGK spark plug
    • predefined ignition timing
    • mapping, based on throttle position and engine rpm
    • average: 33°BTDC
    • maximum advance to 45°BTDC
  • Drivetrain
    • 5-speed sequential gearbox
    • Chain drive (520 pitch)
    • Drexler limited slip differential
    • Bias ratios: 60% drive, 42% decel, preloaded 40 Nm
    • Final drive ratio: 3:1
    • Maximum vehicle velocity vmax = 117,7 km/h