Technical

» MR Damper

Cardiff Racing has designed, manufactured and developed a complete set of custom active magneto-rheological dampers specifically for Formula Student. High standards of vehicle handling are essential in the dynamic events of the competition. To improve vehicle balance during transient maneuvers the active dampers are used to control the load transfer distribution and so the contact patch load distribution of the tyres to minimize unwanted  under/oversteer.CR03 features in-house designed and manufactured active magnetorheological dampers that are used to control handling balance during manoeuvres typical of the autocross and endurance events of Formula Student.

The system has undergone many months of testing and development by Rich Elliott on CR03 and the hydraulic damper dyno, where back to back tests demonstrated the advantages over passive dampers in several respects.The control strategy monitors the balance of the vehicle during a turn and will control the roll damping distribution to effect the distribution of corner patch loads to correct for under-steer and oversteer.

This has translated to a car that is more consistent and easier to drive at the limit which in testing has led to an average lap time reduction of 3% and has reduced the likelihood of cone penalties.The MR dampers are also 45% lighter than the Nitron racing dampers they replace and the damping range is greater, while the static breakout friction of the seals is 50% less. The method by which the MR damper operates means that the level of damping is continuously variable within its range with a response time of less than 6 milliseconds. Therefore, the shape of the damper curves can be controlled electronically and changed instantly.

The data acquisition and damper control is handled via real time reconfigurable hardware from National Instruments with all of the required code written by the team using the dataflow language of LabVIEW. The output is a data file with 50 channels of calculated and raw data and the 4 control signals to each damper. The system has enough memory to record several endurance runs.

» Honda CBR 600

Most teams at the Formula Student event will have used a donor bike engine for their entry this year, although it is not unheard of for a team to develop their own engine. The type of donor engine chosen varies according to the design and style of each car; however there is one engine which is very popular among the teams.

The IMechE and SAE rules allow a maximum capacity of 610cc for a formula student car, making the CBR 600 commonplace among FS teams, known for its reliability, and adored for the availability of spare parts and tuning kits.

The CBR 600 generates 60bhp (as standard) up to 75bhp, even with the Formula Student 20mm restrictor. There is a broad scope of development from using forced induction (turbocharger, supercharger) to engine tuning kits that replace the standard cam profile and engine timings.

It is not hard to see that Formula Student is based largely on Formula one, and other motor sports, however unlike its bigger brother; it is far more common to see a transversely placed rather than a longitudinal engine package. This is due to the availability of the quaife differential, which was developed for kit cars and cars modified using a replacement bike engine.

Cardiff racing has been using the CBR 600 from 2002 season, and has enjoyed a lot of success from the 3 cars developed with the engine.

» Aluminium Honeycomb

It is most common for Formula Student teams to use a space-frame chassis design, using varied steel grades. This is because of the cost-effectiveness of steel, and the simplicity of manufacture.

Cardiff Racing is among the few teams who use aluminium honeycomb for a monocoque structure.The aluminium honeycomb is far lighter than steel, and has proven to be stiffer than its steel counterpart, making it an ideal replacement.

Manufacturing often proved to be labour intensive, and a tough learning curve. However Cardiff Racing has persisted with its endeavour and perfected its techniques, and now can develop a chassis design into aluminium honeycomb in a cost effective way.

» Aprilia SXV550

It is most common for Formula Student teams to use a space-frame chassis design, using varied steel grades. This is because of the cost-effectiveness of steel, and the simplicity of manufacture.

Cardiff Racing is among the few teams who use aluminium honeycomb for a monocoque structure.The aluminium honeycomb is far lighter than steel, and has proven to be stiffer than its steel counterpart, making it an ideal replacement.

Manufacturing often proved to be labour intensive, and a tough learning curve. However Cardiff Racing has persisted with its endeavour and perfected its techniques, and now can develop a chassis design into aluminium honeycomb in a cost effective way.