Newsletter March by Formula Student Team Delft

DUT racing team

Newsletter

March

Content

Introduction News Interview with a sponsor, NLR interview with an engineer

Racing

Formula Stude

13 facts about DUT #01 The DUT03 is the only car in the history of Formula Student that never drove on the competition but won the Engineering Design Award

#02

The DUT06 is the lightest car ever built in Formula Student history. With its 120kg no competitor has ever made a lighter car.

g Team

Introduction

ent Team Delft Before we have a look at the future, I just want to take a step back and think about the past. In September, a team of 75 enthusiast students started with the design of the DUT13. The concept phase was finished around the end of October and from then on everyone focused to work out their design. This design was then presented with pride at the end of December. The design of the DUT13 brings the DUT Racing team to a higher level. This is something where every team member can be proud of.

ÂŠ Paul Brussee

Although, to fight for the world title this summer there is still a lot of work to do. This brings me to the future. The aim is to start assembling the parts onto the monocoque in the middle of April. The 13th of May, the car should be able to drive its first meters. The subsequent test phase is crucial because the amount of test time has a direct correlation with the achieved points at the competition. In this short period of time the setup of the accumulator,

electronics, suspension and aero package have to be optimized. But also our drivers have to be trained and several other problems have to be solved. In the upcoming weeks we will need all our team members to produce parts. Briefly; exciting but amazing that the most beautiful design in DUT Racing history will be realized. - Vincent de Gelder Technical & Finance Manager

News

We are going to Austria! (FSA)

Racing

Formula Stude

For the first time in 5 years DUT is going to 3 events again Last month we had announced to give it all at these three events. that the DUT Racing team will be that we are going to The United This will be the first time since 2008 attending three official events. Kingdom, (FSUK) and Germany ÂŠ FSA media (FSG). Last week on a late evening we got some surprising news from Austria. We were on the waiting list for FSA but due to another team dropping out, a slot has opened up for us. This means we are heading toward a very intense summer. Everybody is extremely motivated

#03

The DUT13 is not the first DUT car with an wing, in 2002, the DUT01 took part in the competition together with the DUT02. It was upgraded with a huge wing at the back.

#04 The DUT04 was designed so extreme, just on the edge of the rules, such that directly after the competition the rules were changed. Terms like side impact structure were introduced after this extreme car.

News

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ent Team Delft

#05

The DUT03 introduced the term â&#x20AC;&#x153;Delft Conceptâ&#x20AC;? also known as building lightweight cars with less power. This is still a concept where lots of other teams go to. None of our competitors had a car lighter than 200kg at that moment. The DUT03 was about 137 kg. The judges thought that their scales where broken.

#06 Next to a number, each DUT car also gets a ladies name. This name is the name of the girlfriend of the team manager, if the team manager does not have a girlfriend then the car will be named after his mother.

Update about the drivetrain

A lot of parts arrived the last few days and weeks, these will be assembled into our powerfull electic motors. The motor shafts, manufactured by AMK, have been delivered. These shafts will soon be rotating at 20.000 rpm and will enable accelerations comparable to those achieved in Formula 1. These shafts will have a high load and for this reason they will be quite heavy weighing in at 300 grams each. Before these shafts actually drive the car, a lot of things still need to be done. For instance Ter Hoek will firstly put a spline on the shafts by using spark erosion. Next AMK will assemble the shaft into the motor. The motors will have a power output of 26 kW each, which is comparable to the power output of a Mini Cooper. With this power output, accelerations of 0 to 100 km/h are expected to be done in 2.6 seconds. This motor also features a self-designed motor casing and cooling system. The motor casing is specially designed by the team to make the AMK motors, normally used in the industrial automation, suitable for a racecar. A few other important design requirements were of course lightweight and the possibility to fit everything inside the wheel. As you can see VDL has done a great job producing the motor casings.

Interview

Racing

With a Sponsor

NLR

What does NLR do for the team, what kind of NLR is the aerospace knowledge support do you give?

Formula Stude

What is NLR?

enterprise in the Netherlands, developing applied knowledge in aerospace and translating this into market oriented products and services. NLR aims to enhance the innovative strength and the competiveness of the Dutch industry.

Where is NLR active? NLR generates the major part of its revenue from commissions from Dutch organisations and the Dutch government. Furthermore NLR takes part in many large scale European projects, such as the CleanSky project, making European aviation more sustainable and efficient. Lastly NLR views the so called BRIC (Brasil, Russia, India, China) countries as an increasingly important market for its products and services

Apart from the financial support NLR provides the team with design and milling support for several parts. Parts from the suspension such as the uprights and spindles are milled at NLR. Due to space restrictions and high loads these parts prove to be challenging milling and turning work pieces. Much time, knowledge and experience is needed to produce these parts in one go. Apart from the milling of parts NLR looks at the usage of composites in the car to see if any of the new developments are applicable on the car. This enables the team to innovate year on year and stay in touch with the cutting edge developments in composites.

#07

The DUT01, 02 and 03 are painted by hand with the Delft blue color.

Why do you support the team? Whatâ&#x20AC;&#x2122;s in it for NLR? For years and years there have been strong ties between the TU Delft and NLR and a shared interest. Universities and knowledge enterprises such as NLR develop innovative products together with the industry in the Netherlands. This way the Netherlands stays competitive on the global market. Next to the aerospace sector NLR branches out to other sectors with spin off products such as lightweight composite structures applicable in for example transport and shipping. The design and build of the DUT racing car is also an educational project. How do you develop the techniques, apply them and sell the result, i.e. your newly built car? It is an exercise in designing and management. In a high-tech environment it is about taking the initiative, in working together as a team, in public relations and in finding sponsors. This project trains these vital skills to NLR. These skills are also important for achieving the goals in the social and business life of the students.

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Senne, what did your DUT experience bring you and your career?

ent Team Delft

What makes supporting DUT so interesting for NLR? What does NLR aim to achieve with the sponsorship? NLR presents itself as a hightech research organisation where interesting career opportunities lie for TU Delft graduates. We like to make a lasting connection with the students. For example a former team member of DUT (Senne Sterk) became an NLR colleague. By sponsoring the DUT Racing team we present NLR to a wide audience. In part it is a different, younger audience. People interested in motorsports and car technology. Reaching a different audience will in the end increase the social and political support for NLR in our society.

#08

Former team members of DUT now work for Formula One teams, Porsche, Mercedes, Tesla, Audi, Shell, NLR and lots of other companies.

In first instance I joined the DUT Racing team purely out of love for technology and motorsports That it had a positive effect on my further career is obviously a very welcome bonus. The first positive effect is that you come in contact with many different organisations welcoming you to take a look behind the scenes. This gives you a pretty accurate picture, which organisations would make a potential future employer. And as a former team member you also offer value to these organisations since you need less time to orientate within the company because you already gained experience in working in teams, honing your design skills, managing the project and practically applying the techniques during the project and in working together with these organisations. The fact that I was an active team member was a big plus for NLR

in hiring me. Along the way you are bound to meet other (former) team members with whom you worked in the past on a complex and high-tech design creating a very strong bond. In many aspects the DUT experience gives you an entry point at these organisations and forms the basis of your future professional network.

#09

DUT was the first team to use carbon fiber drive shafts, even before Formula One Teams did. DUT was the first to use rims of carbon fiber in combination with aluminum as well. There are rumors that Formula One Teams copied it from DUT.

Interview with DUT engineer

Racing

Formula Stude How did you end up at DUT Racing?

At the TU Delft open days you can see some of the DUT racing cars at different faculties, with team members explaining about the project. The moment I first saw a DUT-car, I decided to study at the TU Delft, so that I could contribute to such a car. At the TU Delft it is possible to do your minor and earn credits (ETCS) at a student project like DUT. I took this opportunity to join the DUT Racing Team.

What is your task within the DUT racing team?

Name: Marinus Geuze Nickname: Mars/Wolverine Study: Applied Physics DUT experience: 6 months Task at DUT: Designing and manufacturing the accumulator

The first half year it was my responsibility to design the accumulator. Now the design is finished, it is my task to make sure the production of the accumulator is going well. A pretty big responsibility since one batterypack contains 144 separate cells. And as we produce 2 complete accumulators, we have to connect 576 cells with each other.

How does this fit into your field of study: Applied Physics?

Applied Physics is a wide study and therefore a good foundation for mechanics, electromagnetism, electronics and physical transport phenomena. This knowledge could be directly utilized to both

g Team

ent Team Delft design the electronic part of the accumulator and the heat transfer for the cooling of the accumulator.

#10

DUT is competing in Formula Student, this is the biggest student design contest worldwide. 450 teams all over the world are taking part in this competition.

Is it a valuable addition to your study?

With the whole process from design to the production of a racing car you will learn so much, that the study itself cannot match that in practical terms. In preparation for the engineering after the study, this project is of indescribable value.

#11

In 2008, DUT organized an own Formula Student event. This was the first competition below sea level.

â&#x20AC;&#x153;The moment I first saw a DUT-car, I decided to study at the TU Delftâ&#x20AC;? Where do you see yourself in 20 years, and how will your experience with DUT Racing help you with that? Although the design of a racing car is a great project, you will probably not find me in the automotive industry in 20 years time. For me it is important to develop myself in as many areas as possible. The experiences you will gain as part of a team such as DUT Racing, can apply in many branches.

#12

Only one DUT car has ever driven outside Europe. In 2008, the DUT07 EVO competed in the FSAE competition on the Michigan International Speedway in United Stated.

#13

DUT01 was not built on the terrain of TU Delft but in a garage next to TNO automotive which has moved some years ago to Helmond.