Formula Student Team Delft
Newsletter
March edition
Formula Student Team Delft
Formula Student Team Delft
Dear reader,
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lthough December has passed months ago, it feels like Christmas again here at ‘t hok. This is because new, long-awaited deliveries arrive every day, putting smiles on the engineers’ faces. The parts that once gave them nightmares, kept them up awake for hours and was just living on a screen in a digital world is now, finally, in his hands. However, even more exciting times are to come, since we are on the verge of the assembly phase. In March we are finishing the production phase. In this newsletter edition we focus on the production
process of the electronics. Next to the usual team update, we will have a closer look at our electric duo, interviewing Tim and Erwin, who are now busy assembling the accumulator. Moreover, we will explain how the team manages to manufacture the PCBs on time in collaboration with tbp electronics. Enjoy reading about the production progress in the March edition. Kind regards, Stijn Pennings Team manager Formula Student team Delft
The DUT15 Core Team
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Team update
Interview
tbp electronics
Sponsors
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Formula Student Team Delft
Formula Student Team Delft
Team update
The 3D printed motor casings have arrived.
Arrival of parts The current team is explaining their design to FS Team Delft alumni.
Design judging preparation
Not only is the in-house production at full speed, but also our sponsors have sent us their latest work. Here and on the next pages we want to show you what has arrived at ‘t hok the past month. We will let the parts speak for themselves, because whether they are
Although the events are still quite ahead of us, we already started preparing for the design judging. This is because this static event is responsible for 15% of the total score. The DUT15 team was thoroughly questioned by alumni, who all have experienced the stress and tension that comes with the task of explaining your design to a number of design judges within a small time span. Afterwards, those alumni gave valuable feedback, strengthening the team’s explanatory skills. 4
Team update
casted, machined or even 3D printed, they are all special on their own. Once all parts have been produced, we can start assembling the car. Every day we are closer to realizing the DUT15, which will be shown publicly on June 5th in Delft.
The machined uprights are extraordinarily shiny. Interview
tbp electronics
Sponsors
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Formula Student Team Delft
Formula Student Team Delft
Uprights for the suspension
Casted steering system housing and brackets
Thin section bearings
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Team update
Brackets for the suspension
Interview
tbp electronics
Sponsors
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Formula Student Team Delft
Formula Student Team Delft
Double interview: Tim & Erwin
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s winter is drawing to an end and flower blossom brings a welcome prelude to the spring, the realization of the DUT15 car is proceeding at full speed. While fabrication is currently well under way, we sit with Tim Steunebrink and Erwin Allebes from the Electronics department. With them, we will reflect on this year’s developments in vehicle electronics, and their role within the team. It comes as no surprise that Tim and Erwin joined FS Team Delft. “Last year, we worked on a joint project together with Efraïm [current Electronics Chief ] at our faculty. During project meetings, we would somehow always end up talking more about FS Team Delft, than about the project that we were actually working on,” Erwin tells us jokingly. “For me, the moment I really wanted to join occurred when I saw the DUT13 drive by; a moment I still remember vividly. That was when I realized how cool FS Team really is. This wasn’t just any car, this was something special. It was really impressive to see,” Tim adds. With the start of their third Bachelor year at the faculty of Electrical Engineering, the decision to complete
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Team update
their required minor at FS Team Delft was quickly made. Although they now have completed the obligatory minor, both Tim and Erwin continue to devote full-time participation to the project. For the DUT15, Tim was responsible for the development of the hardware for the Electronic Control Unit (ECU). Even though the ECU might not be so visible to the casual passer-by, it is of paramount importance to the car’s performance. The ECU functions as the central nervous system of the vehicle, processing all relevant signals and determining the required output. Erwin has developed the safety system and hardware for the Accumulator Management System (AMS). Since the DUT15 is an electric car, utilizing high voltage systems and lithium-ion polymer batteries, the AMS is essential to guarantee a safe driver environment. While the AMS and ECU might not have the exotic allure as various exterior carbon fiber components, they play a key role in allowing for superior, reliable and safe performance of the car.
Interview
Collecting the first version of the ECU and AMS at tbp
Admitting the electronics of the DUT15 are largely based on those of the DUT14, Tim and Erwin are keen to point out the differences compared to the predecessor. For the ECU, the DUT15 will feature a new telemetry system that utilizes wireless sensors. This makes it possible to freely place sensors, while reducing the amount of sensor wires, vastly increasing simplicity. Another milestone in reducing complexity has been the use of combined functionality of the ECU and AMS systems. In the past, these devices used different components, for example separate microcontrollers.
By combining functionality and using modular, interchangeable components, the complex electronic system of the DUT15 was simplified radically.
tbp electronics
Sponsors
This year, by using OEM-boards, the vehicle’s electronics can already be tested and simulated before assembly into the physical car. This also allows for early trouble shooting and less time-consuming debugging during assembly and testing. In fact, Tim and Erwin give such a calm impression, that it is as if progress is being made exactly as expected. Tim:
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Formula Student Team Delft
“In fact, apparently for the first time in FS Team Delft history, we [electronics department] have been able to stick to our schedule since the start of the project.” According to Erwin, this ability to effortlessly meet all deadlines is the result of a higher emphasis on time management, and the fact that the electronics are an evolution of last year’s version. While their journey within the Electronics department has been a surprisingly smooth sailing so far, both Erwin and Tim admit that they didn’t anticipate on spending so much time on the project when they applied last summer. Erwin: “But I really don’t mind though. I’ve learnt more about electrical engineering
Formula Student Team Delft
this past year at FS Team Delft, than I have in all the years that I’ve studied it so far at university.” Tim admits: “In university education, you learn more theoretical, fundamental knowledge. But here, you learn how to apply that knowledge.” Erwin: “Before joining the team, I had studied electrical engineering for two years already, but I still didn’t know how to make a circuit board! At first, I wasn’t sure if I was up for the challenge. When I was told which components I would be responsible for, I didn’t know if I had enough knowledge to successfully complete the task. But in the process, you learn really quickly, and in the end, the task turned out less daft than I had anticipated.”
Tim and Erwin are assembling the accumulator.
Needless to say, Tim and Erwin are certain that they want to be part of next year’s team, working on the DUT16 while completing their final Bachelor degree courses. However, while Erwin would like to work within the electronics department again next year to gain more in-depth knowledge, Tim would prefer to pursue work on another component to broaden his scope. “I would like to work on the mechanical properties of a component, a component with an electronics interface, for example
working on the accumulator,” Tim says. After rounding up the interview, Tim and Erwin lean forward, continuing the assembly of one of the many load cells making up a battery unit, working in complete tranquility with utmost precision, dedication and focus. We hope that Erwin and Tim continue to sail smoothly through the development and assembly process of the DUT15 as they have done so far, and that they will be part of next year’s team.
tbp electronics
Sponsors
Mario Verhagen
Erwin admiring his AMS design 10
Team update
Interview
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Formula Student Team Delft
Formula Student Team Delft
tbp electronics The newest car of Formula Student Team Delft will, like last year, be an electric four wheel drive powered vehicle. Almost all the electronic systems of the DUT15 will be designed by a team consisting of ten members. Many of these students had little to no experience in the engineering profession at the start of their Formula Student career. With the help of tbp electronics, this small group of inexperienced engineers was able to design almost all of the electronics in a timespan of a few months. The help and support to the team consists of early involvement as well as Design for eXcellence (DfX), the methodology of tbp electronics. DfX stands for the methodologies that contribute to the high quality of the Printed Circuit Boards (PCBs) that tbp produces in a minimal amount of time. These methodologies consists of the three following pillars: First, Design for Logistics (DfL) focuses on the availability of components and minimizing the number of residual components. This makes sure that all components are delivered on time and no delay
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Team update
is caused during the manufacturing phase. Following the logistics comes the Design for Manufacturing (DfM), which makes sure that tbp electronics is able to manufacture high-quality PCBs and have low slip through (i.e. the percentage of delivered PCBs that may still contain errors). A low slip through is important since our time to develop the PCBAs is extremely short. The team cannot afford any mistakes in the production process. Finally, Design for Testing (DfT) determines the best testing strategies to maximize the quality of the produced PCBs. The critical point is that the DfX can only be successful if both tbp electronics and the engineers of FS Team Delft work closely together. The collaboration started when this year’s engineersbecame acquainted with the methodology of tbp electronics. Before the design process started, a delegation of the team’s electronics department visited tbp in Vlakbodem (Zeeland, Netherlands). Here they got a tour of the factory,a presentation followed by a meeting about the ins and outs of early involvement, data-exchange guidelines and
Interview
Due to close collaboration, the team can start testing early in the year
the use of tbp’s shortlist of stock components. Once the first rough design of the PCBs was finished, a bill of materials was sent to tbp. This design contained the key components of the PCBs. Here, the first part of early involvement comes to play: DfL. This made sure that all the key components arrived ontime at tbp when the manufacturing phase started. The team was therefore able to focus more on the design of the PCBs, creating a more reliable electrical system overall. When the first designs were sent, they went through a DfM
tbp electronics
and DfT analysis. These analyses ensured that any overlooked design issues could be notified and resolved before production started. After some design tweaks and another round of DfM and DfT analyses, tbp electronics could start the production of the first batch of PCBs. This is how, with a strict planning and close collaboration with tbp, the team has been able to engineer reliable electronics within a year! Learn more about tbp electronics at http://www.tbp.nl/
Sponsors
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Formula Student Team Delft
Formula Student Team Delft
Faculties Mechanical, Maritime and Materials Aerospace Engineering Industrial design Technology, Policy and Management Electrical Engineering, Mathematics and Computer Science
EXPERTS IN PRECISION PA RTS
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Team update
Interview
tbp electronics
Sponsors
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Formula Student Team Delft
General info Contact details Department
Phone number
Address
Electronics & Powertrain Suspension & Vehicle Dynamics Chassis & Aerodynamics Team Manager & Chief Engineer Operations Manager & Technical-Finance Manager
+31 152 787 008 +31 152 788 436 +31 152 787 007 +31 152 788 891 +31 152 787 531
Stevinweg 1 2628 CN Delft The Netherlands
Important dates Friday the 5th of June DUT15 Roll out in Delft From the 9th till the 12th of July FSUK at Silverstone, UK From the 28th of July till the 3rd of August FSG at Hockenheim, Germany
Next edition The April edition will cover the assembly phase and might cover the first meters!
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From the 10th till the 13th of August FSA at the Redbull Ring, Austria www.FSTeamDelft.nl info@FSTeamDelft.nl
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