2013 NDSU FSAE car
North Dakota State University will be building a FSAE car for the 2012-2013 season. This build will be headed by a group of four NDSU Mechanical Engineering undergraduate students as part of a senior design study. The group has many plans for the 2013 NDSU FSAE car.
Using a tuned suspension geometry for an FSAE competion, the final frame design has been decided upon after extensive research and development based on finite element analysis. The focus of the 2013 NDSU FSAE car is centered around a powerful, light-weight, predictable, and controlable car.
For the latest updates, follow the group on twitter @NDSUmotorsports.
Technical Specifications:
Car No. |
112 |
Dimensions |
Front |
Rear |
Overall Length, Width, Height |
2770 mm long, 1367 mm wide, 1180 mm high |
|
Wheelbase |
1549 mm |
|
Track Width |
1219 mm |
1168 mm |
Mass with 68kg driver seated |
124.0 kg |
124.0 kg |
Suspension Parameters |
Front |
Rear |
Suspension Type |
Double unequal length A-Arm. Pull rod actuated horizontally oriented spring and damper |
Double unequal length A-Arm. Pull rod actuated horizontally oriented spring and damper |
Tire Size, Compound and Make |
Hoosier 18.0 x 6.0-10 R25B |
Hoosier 18.0 x 6.0-10 R25B |
Wheels (width, construction) |
Keizer 10.0 x 6.0 |
Keizer 10.0 x 6.0 |
Center of Gravity Design Height |
250 mm, confirmed via tilt test |
|
Suspension design travel |
25.4 mm jounce/ 25.4 mm rebound |
25.4 mm jounce/ 25.4 mm rebound |
Wheel rate (chassis to wheel center) |
6.48 N/mm |
7.71 N/mm |
Roll rate (chassis to wheel center) |
1.5 degrees per g |
|
Sprung mass natural frequency |
1.75 Hz |
1.90 Hz |
Jounce Damping |
60% of critical damping, 150N @ 230 mm/s |
60% of critical damping, 175 N @ 250 mm/s |
Rebound Damping |
60% of critical damping, 220 N @ 230 mm/s |
60% of critical damping, 250 N @ 250 mm/s |
Motion ratio / type |
0.57 / progressive rate |
0.62 / progressive rate |
Rate of Camber Change- Ride Camber (deg / m) |
63.0 deg / m |
16.93 deg / m |
Roll Camber (deg / deg) |
0.33 deg / deg |
0.82 deg /deg |
Static Toe |
-0.2 deg toe out |
0.1 deg toe in |
Static camber and adjustment method |
-2.0 deg, adjustable via shims |
-1.5 deg, adjustable via shims |
Front Caster and Kinematic Trail |
5.0 degrees, non-adjustable, 13 mm trail |
|
Front Kingpin Axis Inclination and Offset |
6 degrees non-adjustable, 13 mm offset |
|
Static Akermann and adjustment method |
50.5% non-adjustable |
|
Anti dive / Anti Squat |
0 % |
0 % |
Roll center position static |
12.1 mm below ground |
16.6 mm below ground |
Roll center position at 1g lateral acc |
9.6 mm below ground, 262.8 mm toward unladen side |
15.8 mm below ground, 96.6 mm toward unladen side |
Steer location, Gear ratio, Steer Arm Length |
Rear steer, 120mm per rotation, 50.8 mm steer arm |
|
Brake System / Hub & Axle |
Front |
Rear |
Rotors |
1018 steel, hub mounted, vented, 190.0 mm diameter |
1018 steel, Single inboard, differential mounted, vented, 216 mm diameter |
Master Cylinder |
16 mm front and rear bore, adjustable front/rear bias bar |
|
Calipers |
2- 28.45 mm diameter, dual-opposing piston |
Single, 31.75 mm diameter, dual-piston |
Pedal Force and Line Pressure @ 1g decel |
0.2 kN, 7.0 bar |
0.2 kN, 4.0 bar |
Upright Assembly |
CNC 6061-T6 aluminum, integral caliper mount |
CNC 6061-T6 aluminum |
Hub Bearings |
Thin section, deep-groove ball bearing |
Thin section, deep-groove ball bearing |
Axle type, size, and material |
Rotating axle, 58.4 mm-1018 steel hardened hollow shaft |
Rotating axle/tripod joint housing, 65 mm-high carbon steel |
Ergonomics |
|
Driver Size Adjustments |
Adjustable driver pedals |
Seat (materials, padding/damping) |
Carbon/Kevlar composite, Nomex honeycomb core |
Driver Visibility (angle of side view, mirrors?) |
100 degree side visibility |
Shift Actuator (type, location) |
electrically-actuated 12V drill, steering wheel mounted paddles |
Clutch Actuator (type, location) |
Automatic clutch, adjustable engagement rpm |
Instrumentation |
Custom L.E.D. tachometer and warning light display (temp), gear indicator |
Electrical Power, Control, Systems Management |
|
Power Distribution Management / Control |
Relays and fuses to limit the amount of current throughout the car |
Wiring / Loom / ECM mounting |
Braided, abrasion resistant loom, ECM mounted behind the seat |
Battery / Charging System |
Sealed lead-acid battery with easy acess charging ports |
Grounding |
Star topology to all high current devices, sensors grounded to ECU |
Driver Assist Systems |
Electronic paddle shifting, over-temp light, tachometer and gear indicator |
Logging / Telemetry |
Internal ECU logging, wideband O2 sensor logging |
Special Sensing Technology |
Custom cam angle sensing communicating with the EMS-4 ECU, Knock sensor tapped into block |
Frame |
|
Frame Construction |
Tubular space frame |
Material |
4130 Chromoly steel tubing |
Joining method and material |
TIG welded, ER70S2 filler rod |
Targets (Torsional Stiffness or other) |
1000 N-m / deg |
Torsional stiffness and validation method |
1453 N-m/deg CAE beam model |
Bare frame mass with brackets and paint |
27 kg |
Crush zone material |
Aluminum honeycomb |
Crush zone length |
203.2 mm |
Crush zone energy capacity |
Quasi-static crush: 8243 Joules |
Powertrain |
|
Manufacturer / Model |
KTM 525 EXC |
Bore / Stroke / Cylinders / Displacement |
95mm bore / 72mm stroke 1 cylinder / 510 cc |
Compression ratio |
11.0:1 |
Induction (natural or forced, intercooled) |
Forced induction, Intercooled |
Throttle Body / Mechanism |
35mm, butterfly valve throttle actuation |
Fuel Type |
E85 Ethanol |
Max Power design RPM |
8000 |
Max Torque design RPM |
6000 |
Min RPM for 80% max torque |
3000 |
Fuel Injection System (manf'r, and type) |
Custom EFI, one 450cc pindle and ne 450cc split-type injector controlled by AEM EMS-4 |
Fuel System Sensors (used in fuel mapping) |
MAP for base table, TPS for acceleration enrichment |
Fuel Pressure |
3.0 bar |
Injector location |
90 mm before valve stems and directed towards valve stems |
Intake Plenum volume and runner length(s) |
1270mm runner length |
Exhaust header design |
2-1 configuration, 38 mm primary, unequal length configuration to help smooth exhaust pulses |
Effective Exhaust runner length |
150 mm |
Ignition System |
Coil near plug controlled by AEM EMS-4 |
Ignition Timing |
8 degrees advance at idle, 32 degrees at WOT |
Oiling System (wet/dry sump, mods) |
Pressure circulation, two rotor pumps |
Coolant System and Radiator location |
Single radiator, side mounted, single fan pulling 300cfm |
Fuel Tank Location, Type |
Behind firewall mounted, aluminum tank |
Muffler |
Titanium structure |
Drivetrain |
|
|
Drive Type |
Chain Drive |
|
Differential Type |
Zexel-Torsen, torque-sensing, limited slip, 3.2:1 maximum torque biasing, rotating vented housing |
|
Final Drive Ratio |
2.71 : 1 |
|
Vehicle Speed @ max power (design) rpm |
|
|
1st gear, 2nd gear |
52 kph |
69 kph |
3rd gear, 4th gear |
85 kph |
105 kph |
5th gear, 6th gear |
129 kph |
N/A |
Half shaft size and material |
17.75 mm diam. -left, 18.67 mm diam. - right, 4340 steel |
|
Axle Joint type |
Non-plunging CV joint-inboard, plunging tri-pod-outboard |
|
Other Information |
|
Body Work (material, process) |
Carbon/kevlar weave made from a fiberbglass mold from bondo plug |
Clutch |
Automatic clutch acts as traction control and improves drivability for beginner drivers |
