B'Energy Racing | Newsletter | January 2021

news January,

Photo: @caiolourencos

B’ENERGY RACING TEAM FACENS

CAPTAIN’S LETTER Ramon Ruis The end of the year is always expected for everyone. Making party, being with the family and taking a rest from the year of work make all the difference. Even being an atypical year, for lots of people it will be the time to renew the energies for the year that is coming, but us from B'Energy, we are still working hard.

Even though the pandemic scenario is not getting better, fortunetely we are in the manufacturing phase of our car, constructing the new chassis, the new accumulator container and machining suspension and steering components.

Remember, all the works are following the OMS' health orientations. Besides that, we dedicate part of the team to the reports of the competition and to document all our works to complement our design presentation material.

B’Energy Racing is grateful for the year of learning and growth, for the confidence in us and would like to inform that for 2021, all the learning we had will be used in our favor. We wish Happy Holidays for everyone, with family, friends, or social isolation. 2021 is waiting for us!

MATLAB APPLIED TO FSAE ELECTRIC JoĂŁo Marcos GuimarĂŁes

MATLAB is a software that allows numerical calculations to be performed, offering the user full support for simulations through its numerous tools and libraries, so it has become an indispensable instrument for the team, because it is possible to make mathematical models that include several areas. So, the tool most used by us within MATLAB is the SIMULINK, which from editable blocks and insertion of parameters it is possible to develop mathematical models and complex simulations in a direct and visual way.

Thus, there are infinite opportunities with MATLAB, from to develop codes for computer vision even to implement simulations of automotive systems, for example, suspension system, hybrid vehicle performance and heat flow from a cooling system.

In relation to the team, a mathematical modeling is done to simulate the car performance in differents drive cycles (FSAE dynamic tests: Acceleration, Skid Pad, Autocross and Enduro), and when entering the vehicle parameters and performing a series of calculations, several results are obtained, such as consumption curves, motor torque, vehicle speed, and more.

Battery's power curve in a driving cycle

PARTNERSHIP EVANPLAST

Sandro Guariglia

During a Formula SAE Electric competition, what is most expected from the mechanical part is a great stress, both by the power of the traction system and by the forces that are applied to the vehicles in moments of curves, braking and accelerations. Every care during the design of this part is of great importance so that everything goes according to the dimensioning and simulation.

Since the beginning of the pandemic, we saw that it would be a great challenge to manufacture our vehicle both because of social isolation and to our sponsors, given that many could not continue with the support. Even with all these obstacles, the Evanplast, signed the support and established all the machinery for the manufacturing of these parts, providing the use of conventional and CNC lathes, milling machines, machining center and knowledge so that we can carry out the manufacture, together with this partnership a new supporter Eng. Wiler Felipe Feliciano who also assists us in all processes.

We are very grateful to the sponsorship from Evanplast and Eng. Wiler for supporting us in the manufacture of our parts, in order to complete the project.

WIRE HARNESS HENRIQUE DINIS

The electric cables have a substantial role on the vehicle’s operation, considering that they are responsible for all the energy and information transfer via them. This arrangement of cables is denominated wiring harness.

project, REV GROUP have supported with proper training to use the company resources, such as cables, connectors, forks, bench and machinery that were necessary to achieve the desired result of B20’s harness.

Aiming at a safe and efficient development, B’Energy Racing Facens used as reference to the wire harness project of the B20 prototype, both national and international standards, that assist to a high quality, safety, and reliability on the electrical system of the vehicle.

Lastly, tests and validations are executed to approve the project, being divided into micro steps, first the wire harness being assembled over a bench and all the electronics modules for control and safety of the vehicle are connected, such as the tractive system. That way, the GLV electronics can be validated before even assembling in the final prototype, predicting the possible failures that could occur.

The project is segmented in three phases, development, manufacture, and validation. Initially the wiring diagram is elaborated in 2D software, followed by the 3D model, using AUTOCAD and PTC® Creo Parametric 6.0 respectively, seeking out precision and excellence in the sizing.

With PTC® software, the cabling tool is utilized, where the cables can be easily created.

The next step is the manufacture, where the wire harness fabrication is performed in bench. For the current

The wiring harness may even be hidden in the car, becoming a “illustrious unknown” for the lay people. But is known the importance and that it is necessary attention on the sizing, following all the safety standards and making in the end, that the car is able to reach its better performance with no electrical problem.

CHASSIS IGOR RICIONE

In a popular way, the vehicle chassis is denominated as a “large support that handles everything in its place�. Being the structure responsible to connect all the systems of a car. There are many ways to manufacture a chassis, but this project is going to be used a tubular chassis.

process that provides a more resistant result and with verry low material addition.

In all chassis manufacture phases we had the University support, that allowed the team to attend the workshop dependencies following all the safety and COVID-19 prevention protocols.

The chassis project to the Formula SAE competition is being developed and refined since 2012. Therefore, the B20 prototype had as the main objectives to reduce mass, improve the serviceability (facility to assemble and maintenance) and manufacture correspondent as in the project dimensions as in the physical prototype.

During the next weeks, the team craves to perform the tests aiming to validate the computational simulations.

Besides that, will also be made the blasting and the electrostatic coating and the laterals will be enveloped with adhesives provided by Alltak.

During December, it was possible to perform the whole chassis manufacture.

The first phase was to assemble the jig, responsible to place the tubes in the right position, making the physical prototype like the ideal project. In this step we had the support from our sponsor Kajihara that assisted with the laser cut of the jig’s plates. In parallel to the laser cut, we did the metal bending with support from Usitubos, specialized in tubes cuts and plates bending.

KAJIHARA

After these steps, it was possible to start the tube ends, allowing the completion of the tubular chassis. To weld the tubes, we used the TIG welding

BALLARD H2 CHALLENGE

Thulio Ferreira

The B19H2 project is, as we already predicted and expected, a very big and knowledge-rich challenge for the entire team. Since its beginning, with all the workshops and lectures given and organized by the SAE Brasil, a lot of specific knowledge about the area of vehicles powered by hydrogen fuel cells has been acquired by the entire team, giving us an overview of the whole area and its increasingly grow in the world.

Since the beginning of the second stage of the challenge, the project developed by the team in the PTCÂŽ Creo Parametric software has been improved, with the positioning of all components and the development of mechanical detailing drawings for manufacturing, with only the electrical representation in CAD to develop.

was carried out and some items have even arrived at the university to carry out tests and validations, such as the fuel cell and the electric motor that will be used.

We also must talk about the great help that we will have for the development of the project. The SAE Brasil, alongside with major automotive and industrial automation companies, entered into a partnership to develop a sponsorship program for the participating teams, where each company was assigned to a team to assist in the project with the technical knowledge necessary for the development of the prototype. In our case, we will have the immense opportunity to work alongside WEG, a company specialized in the manufacture and sale of electric motors, transformers and generators which can add immensely to the project.

In the development of the physical prototype, all the requisition of materials

B19H2

B’ENERGY ON SOCIAL NETWORKS B’Energy Racing Team’s Facebook page currently has over 3,400 likes and followers, that keep up with the team’s updates, like the competition photos and videos, news and memes.

The team’s Instagram page has almost 1,800 followers and posts contents about competition, challenges, news, memes, and even interactive content in the stories.

The professional B’Energy’s social media has over 1,700 followers, that contemplate contents like competition and news, with a more formal bias.

Flickr is the platform where you can find pictures of our projects and competitions, being possible to glimpse a few of the last years of the team.

https://benergyfacens.contactin.bio/ benergy@facens.br