Ecurie Aix – Virtual Info Night Formula Student Team RWTH Aachen Content What to expect

• General presentation about Formula Student and Ecurie Aix

• Slides 1-16 • Group specific presentations

• Frame: Slides 17-21

• Vehicle Dynamics: Slides 22-30

• Aerodynamics: Slides 31-37

• Gearbox & Suspension: Slides 38-43

• Organisation & Marketing; Sponsoring: Slides 44-54

• Electrical Powertrain: Slides 55-68

• Driverless Software: Slides 69-75 The competition What is Formula Student? Top 5 Universities FSG Electric 2019 • Largest student design competition in the world 1. TU München 2. KIT Karlsruhe Annual independent construction of a formula • 3. TU Freiberg racing car 4. RWTH Aachen • Over 500 teams from universities and colleges 5. TU Eindhoven around the world • Divided in Combustion (CV), Electric (EV) & Driverless (DV) classes • European regulations by Formula Student Germany (FSG) Event locations Where do events take place?

• FS East – Zalaegerszeg Automotive Proving Ground • FS – Ring • FS ATA – Riccardo Paletti Circuit • FS Germany – • FS – TT Circuit • FS Spain – Circuit de Barcelona Catalunya • And many more… Event locations Roadtrip summer 2021 Event schedule What awaits us?

• Qualification: Quiz in January • Event duration: 4 - 7 days • Technical inspection: Scrutineering • Disciplines: Dynamics & Statics ACCELERATION Classes 75 BUSINESS PLAN TRACKDRIVE Driverless and Electric PRESENTATION 200 75 SKIDPAD 75 ENGINEERING DESIGN Explain design, layout, and construction decisions to experienced engineers. EFFICIENCY DRIVERLESS EVENT 75 COST AND Disclosure of costs and manufacturing processes. AUTOCROSS ENGINEERING MANUFACTURING 100 DESIGN EVENT 300 BUSINESS PLAN ACCELERATION COST AND 10-minute presentation of a fictional business plan in front of a jury. 75 MANUFACTURING PRESENTATION BUSINESS PLAN 100 PRESENTATION ENDURANCE 22 km circuit with driver change [EV only]. 75 SKIDPAD ENDURANCE TRACKDRIVE Completing 10 laps of a 200-500 m course [DV only]. 75 325 EFFICIENCY Comparison of energy consumption during Endurance/Trackdrive EFFICIENCY ELECTRIC AUTOCROSS Completing a single lap in qualifying mode. 100

SKIDPAD Determination of the maximum achievable lateral acceleration during constant cornering. AUTOCROSS ENGINEERING 100 COST AND DESIGN EVENT MANUFACTURING 150 ACCELERATION Covering a distance of 75 meters from a standing position. 100 Review Formula Student Events 2019

5th Overall 3rd Overall • 6th Endurance • 2nd Trackdrive • 2nd Business Plan • 3rd Business Plan • … • … EV DV

13th Overall 4th Overall • DNF Endurance • 3rd Endurance • 7th Business Plan • 2nd Business Plan • … • … EV EV Rita eace07.d

• Modified vehicle from a previous season • Steering via an integrated servomotor and torque vectoring • Pneumatic actuated brake system incl. recuperation • Route recognition via three cameras and a LiDAR sensor Nuri eace09

• CFRP monocoque in sandwich construction • 6 kWh & 600 V HV battery • Aerodynamic package with underbody, front & rear wing and high nose • All-wheel drive with aluminum CFRP rims • Total weight of 158 kg History 2022 How everything began Merge of Electric & Driverless – eax01 2013 eac10 – last combustion car

2002

eac01 – first

combustion vehicle 2017 Formula Driverless - eace04.d

2010 Formula Electric - eace01

1999 Formula Student Motivation Why Ecurie Aix?

• Experience racing closely • Implement your own ideas • Work practically • Competitions all over Europe • A change from your everyday study life • Become part of a passionate team The Team Who we are

• Approx. 75 active members & 460 alumni • Interdisciplinary work of various courses of study - mechanical engineering, electrical engineering, computer science, industrial engineering, business administration, CES • So far 10 combustion, 9 electric and 3 autonomous racing cars The Team Who we are Requirements What do I need to bring?

• High level of self-motivation and reliability • Enjoy teamwork and joint problem solving • Time management and ability to work independently • Commitment to the team and your tasks Application • Application form on our Website: How can I take part? www.ecurie-aix.de/bewerbung • Collection of open positions: Frame and composites. Our tasks?

• Responsible for primary structure → including many CFRP parts • Dimensioning and enhancing of existing parts 1. Monocoque 2. Aero structural design 3. Electrical housing 4. Roll hoops 5. Crashelements • Simulative and physical tests

→ Manufacturing all of these parts Manufacturing Our projects

Monocoque Inner structure of aerodynamic devices Battery housing

• 50 % higher stiffness • Rips and frames for • 2.5 kg less weight than last year • 20 % less weight (<17kg) reinforcement • Aramid-aluminium honeycomb sandwich Requirements

• Motivation to participate in • Interest in fiber reinforced plastic • Ability to cooperate in a team • Willingness to participate in manufacturing • Optional: Experience using • Siemens NX • Altair HyperMesh/ ESAComp • Siemens Fibersim

→ Currently we have several open positions. Vehicle Dynamics

Ecurie Aix Virtual Info Night 28.04.2021 Agenda.

• What is vehicle dynamics and what does that mean for us? • What tools are we using? • What are our control systems? • What could be your task? • Questions What is vehicle dynamics?

• For vehicles such as cars, vehicle dynamics is the study of how the vehicle will react to driver inputs on a given solid surface. • Source: Wikipedia

But what does that mean for us? What is vehicle dynamics?

Racing Concept decision

• Vehicle dynamics is an overall devlopment process Validation Load collectives

Manufacturing Design What does vehicle dynamics mean for us?

• Study the vehicle behaviour • Logdata analysis • Adjusting and simulating the mechanical setup • Application and development of the control systems (Slip control, Torque Vectoring etc.) What does this mean for us?

• What if there is no car yet? • Concept decisions • Create load collectives for mechanical groups

Which tire do we choose? Which forces are acting on the suspension? What tools are we using?

Laptime simulation Multibody simulation • The simulation calculates the vehicle behaviour to • A kinematic model which simulates the complete determine the laptime for the vehicle movement of the suspension • Necessary for concept decisions • It‘s used for design, load collectives and calculating the mechanical setup What are our control systems?

Sensor data input: Onboard calculations on Adapting driving torque for • Driver input microprocessor while driving each wheel • Velocity & acceleration • Torque Vectoring Car drives faster and more • Battery cells • Slip control • Motors & inverters • Derating stable • Energy management

Cycle time: 5 ms Step the Simulink model Read Send inputs outputs from CAN via CAN CAN CAN

Begin Send control data for logging on 2nd CAN What could be your task? Aerodynamics & Thermal management

28.04.2021 Content

• Why do we need aerodynamics? • Components of Aerodynamics & Thermal Management • Our workflow Why do we need aerodynamics? Our Components Downforce ratio % eace09 60

50 Rear wing 40

Diffuser 30

20

10 Cooler 0 Front wing Undertray Rear wing

Undertray CL=-6.2 Front wing Our Components Inverter eace09 cooling Battery plate outflow

Water pump

Motor Radiator cooling Battery sleeves inflow Our components eax01 Current project eax01

• Adapting to new racing class

• Studying alternate cooling system packaging concepts

• Pursuing downforce target of CL<-6.8 • Reworked aero package in synergy with new monocoque • Led by completely new undertray design • Adding further aerodynamic devices for improved wake management Our workflow

Software tools

Iterative design & Preparation of Ply New idea Structural configuration Manufacturing simulation phase Books Gearbox & Suspension

Virtual Info Night 28.04.2021 Gearbox

28.04.2021 Suspension

28.04.2021 Suspension

28.04.2021 Driver Interface

28.04.2021 Driverless Actuation Organisation & Marketing; Sponsoring 28.04.2021 The main tasks of O&M and Sponsoring

Cost Report Business Plan Public Relations Sponsoring The Cost Report Points • Develop and present the bill of material: • an overview of all components • including manufacturing processes and costs for individual systems 100/1000 • Preparing and presenting the cost- understanding presentation: • discussion with judges on economic and financial topics Dynamics Cost Report Business Plan Design Event

The Business Plan Points • Develop and present a business plan to market our race cars in creative ways

• Elaboration of the finances 75/1000 • Shooting a pitch video

Dynamics Cost Report Business Plan Design Event

Public Relations

• Creating enthusiasm for the team through pictures, videos and publications in university and social media

• Design and creation of media • Newsletters, flyers, Christmas cards, calendars, etc.

• Getting you here Sponsoring

• Acquisition and maintenance of corporate partnerships • Networking • Source to be financially able to build our cars • Essential for the long-term success of the team What we do

• Correspondence with partners • Written and via a lot of telephone calls • Preparing and delivering of presentations • Organization of trade fair appearances and visits from partners • Contract negotiation What you should bring

• Good English skills • Motivation • Organizational talent • Work independently • Be communicative Some tasks for everyone

Quizzing Manufacturing Sundries

• Necessary for the event • Contributing to internal • Participation in events such as registration manufacturing of carbon, plastic Girlsday, university • Learning the rule book and and metal parts performances, photo shoots building technical knowledge • Routing the wiring harness, • Teambuildings soldering circuit boards, etc. • Cleaning up the workshop Electrical Powertrain Virtual Info Night

eace09 eace07.d E-Powertrain E-Powertrain E-Powertrain High Voltage Powertrain

Motor Motor Inverter Inverter High Voltage Battery Inverter Inverter Motor Motor Electronics Front Box

• Mountplate design • ECU • Telemetry • Driver radio • Under damper cover Rear Box

• Vehicle Control Unit • CAN data logger • PDU • Step down • TSAL/BSPD Sensors

Pedal Box • Throttle position • Brake force

Steering wheel sensor • Steering angle IMU Kistler Correvit SF2 • Acceleration x/y/z-axis • Velocity x/y-axis • Gyroscope x/y/z-axis • Swim angle Damper sensor • GPS • Wheel travel Development & Design

Devices & Harness design connectors in NX in Mentor VeSys

Connections with optimized routing in NX

Real wire dimensions exported for manufacturing Development & Design

…since we‘re electrical engineers, we do hard/software CO-Design Testing

Testing and analyzing with Vector CANoe, vSignalizer, CANape Testing Open Positions

➢ Embedded Systems ➢ Hybrid Supply System ➢ LV/HV Wiring Harness/Architecture ➢ LV/HV PCB and Battery Packaging ➢ Motivation ➢ Telemetry & Communication Systems (CAN) ➢ 1. Semester ➢ Time ➢ High Voltage Accumulator & Periphery ➢ ET 2 passed ➢ Team project ➢ Electric Motor Development ➢ Electric Motor Testbench ➢ Inverter Hardware Develpopment ➢ Inverter Software Development ➢ Administrative Group Leader ➢ Display Development Driverless Software

28.04.2021 Driverless Software • What is our task?

We write a program to replace this guy Driverless Software • What is our task?

We develop sensor/computer concepts … … build simulations …

… analyze data … … define software and testing workflows … Driverless Software • What is our task?

… design, implement and test software.

Control Estimated States IMU Velocities

Sensor SLAM GPS preprocessing Slip ratios / filtering Yaw rate 4 x wheel odometry Extended Kalman Filter Architecture • Driverless Software Perception

Control State Estimation SLAM

Planning DV Software: Results What we see What our Software sees DV Software • What can you do? • A lot of open positions for 2021/2022 • Perception • State Estimation • Planning • Control • Simulation • Infrastructure • Open positions also coming to our website in the future