brookes dallara autosport book 2016

FORMULA CLUB-E

[electric vehicle development project]

Andrew if you see this means that you can see what I’m editing!!??

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New update 2!

FORMULA CLUB-E

“I love Formula One, dearly. If I live for 100 years I will still love Formula One. But the world is

going in the direction of electric, we don't know how long it will take but we have to make a

change. It's not that we want to, it's almost mandatory.

If we continue like this for 100 years there will be no planet so basically there is no option.”

Alejandro Agag, Formula E founder and CEO

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“A goal of all formal education should be to graduate students to lead lives of consequence.”

John Henry Brookes, Spiritual founder of Oxford Brookes University

Brookes alumni in employment at major Formula 1 teams

in collaboration with

THE VISION

? Gap in the market

Formula SAE Electric Formula E

At the very pinnacle of the Motorsport world, Formula E is currently leading the way for the electric racing market. At the low

budget end, Formula SAE electric has demonstrated that electric vehicles can dominate over their combustion-engined

counterparts.

Currently, there are very few affordable electric racing cars, so there is a clear gap in the market.

?

Formula SAE Electric Formula E

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Year 1 - Concept: Feasibility study & concept design

Year 2 - Analyse: Identify market opportunities & design specification, design & virtually prototype vehicle

Year 3 - Develop: Establish partnerships, detailed simulation modelling, final design, prototyping & model validation

Year 4 - Refine: Build, test & finalise complete prototype vehicle

The Players

Andrea Toso, Head of R&D and US Racing

Business Leader at Dallara Automobili shares

design ideas with OBU students

Can we use this somewhere to show

OBU’s F1 employment?

Competing in all F3 championships around the world,

Dallara is the sole supplier of cars to the IndyCar, Indy

Lights, GP2, GP3, World Series by Renault and Japanese

Super Formula championships. Dallara’s impressive

Motorsport pedigree, coupled with their experience in

supplying the chassis for Formula E ideally places them to

deliver an electric racing vehicle.

Nestled in the heart of Motorsport Valley, with 92% of our

graduates going on to employment - many in F1, Formula

E and major suppliers to the Motorsport industry - Oxford

Brookes’ Department of Mechanical Engineering and

Mathematical Sciences has an enviable reputation as a

premier institution for Motorsport education, training the

Automotive, Motorsport and Mechanical Engineers of the

future.

Supporting MEMS in this project, the Business School

provides strength in corporate, competitive & growth

strategy, global business, international trade and foreign

direct investment with subjects that focus on leadership,

culture, motivation, practices, strategic human resource

management and the management of the globalisation

process.

Bringing together one of the World’s largest race car

manufacturers, and two departments from one of the UK’s

top new Universities, the Formula Club-E development

project is the work of an unparalleled team.

Dallara Automobili

Department of Mechanical Engineering and Mathematical Sciences

Business School

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Dallara Automobili

Competing in all F3 championships

around the world, Dallara is the sole

supplier of cars to the IndyCar, Indy

Lights, GP2, GP3, World Series by

Renault and Japanese Super Formula

championships.

Coupled with their experience of

supplying the chassis for Formula E,

Dallara’s impressive motorsport

pedigree ideally places them to deliver

an electric racing vehicle.

Mechanical Engineering & Mathematical sciences

Nestled in the heart of Motorsport

Valley, 92% of our graduates go on to

employment - many in F1, Formula E

and major suppliers to the motorsport

industry.

Oxford Brookes has an enviable

reputation as the number one institution

for Motorsport education, training the

Automotive, Motorsport and Mechanical

Engineers of the future.

BUSINESS SCHOOL

The Business School provides strength in corporate, competitive & growth

strategy, global business, international trade and foreign direct investment with

subjects that focus on leadership, culture, motivation, practices, strategic

human resource management and the management of the globalisation

process. This allows us to consider both the mechanical and business aspects.

Unparalleled Team

Bringing together one of the World’s

largest race car manufacturers, and the

leading motorsport education provider,

the Formula Club-E project is the work

of an unparalleled team.


The Objectives

Leading Racing Car

Manufacturer

Renowned Motorsport University

100 Postgraduate MSc Students

Four Year

Programme

60,000 Development

Hours


Determine the market opportunities & customer requirements

Identify market leading technologies & suitable powertrains

Develop a complete 3D CAD model of the vehicle

Simulate the vehicle performance in DYMOLA

Analyse various powertrain configurations

Undertake Driver-in-Loop testing in Dallara’s simulator

Establish partnerships & customers

Produce a complete business plan, BOM and costing

Prototype and test the complete vehicle

Prepare students for employment

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The team: Design

“The experience with the Dallara project has given me the chance to deal with a real

project for the first time. It has made me learn how to manage all different information

and parts coming from all the different team members.”

Aser Murias Closas, Chassis Team Leader

Chassis & Crash

Aser Murias Closas

Quentin Gueriot

Ronan Antonelli

Michael Booker

Battery Development

Pelayo Acevedo Llanes

Daniel Simula

Aero & Cooling

Wayne Diggines

Vivek Jigalur

Mikey Twigge

Marc Ricart Rius

Electric Safety

David Garcia Coz

Team Leader

David Lopez Almirall

Business Plan

Rodrigo Velasco Ramos

Shaunt Avanessian

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Suspension

David Briant

Michael Rooney

Xavier Bas Ferrer

Motor

Tom Driscoll

Siddhant Shah

Adil Adil

Project Chairman: Andrea Toso - Head of R&D and US Racing Business Leader, Dallara Automobili

Academic Principal: Andrew Bradley - Senior Lecturer in Motorsport Engineering


The team: Simulation

Powertrain & Battery

Nikolas Siikkis

Pedro Gonzalez Lorenzo

Shreerama Manjunatha

Javier Herrero de Vicente

Jesus Guiterrez de Quevedo

Team Leader

Cristian Garcia Moya

Pau Joaniquet Calderon

Suspension & Braking

Ana Sanchez Ponce

Alexandre Santos

Raul Ubeda Sala

Driver & Laptime

Alvaro Fraile Martinez

Beñat Pildain Olalde

Sree Varshini

Miguel Freitas

Bruno Braga

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Suspension & Tyres

Rohan Shankar

Federico Sanchez Motellon

Gordana Collier – Programme Lead for Postgraduate Taught Mechanical Engineering, Oxford Brookes University

Gareth Neighbour – Head of Department, Oxford Brookes University


Academic Chair: Professor Gareth Neighbour - Head of Department of Mechanical Engineering & Mathematical Science

Academic Lead: Gordana Collier - Programme Lead for Postgraduate Taught Mechanical Engineering

Simulation Support

Alessandro Picarelli, Claytex

Ideally suited to the UK’s racing circuits

Rear wheel drive

Easy to maintain

Exciting to drive

Affordable

The team at the Formula E London ePrix

The Concept

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-1000 -500 0 500 1000 1500 2000 2500 3000 3500

Car

he

igh

t [m

m]

Car Length [mm]

Mass Distribution Component CoG

Global CoGMass distribution


Define

Product or Service

Strengths and Weaknesses

Opportunities and Threats

Research

Target Market

Competition

Pricing

Customer Requirements

Develop

Design Specification

Operational Plan

Sales Strategy

Sales Projections

Financial Docs

The Market

Strongly Agree 15%

Agree 39%

Disagree but could

be convinced

31%

Strongly Disagree

15%

Electric racing is the future of Motorsport:

The main concern is the price

for the customer

Analysis of the progress of Formula E

Detailed surveys of hundreds of potential customers & fans

Focus groups discussing people’s concerns about electric racing

Identification of desired vehicle design specification

Race schools to offer electric test drives

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The Car

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The Car: Energy Efficiency Lithium Polymer batteries have around 1/30th of the energy density of petrol, so a large proportion of the vehicle mass is due

to the volume of batteries required. Conserving energy is therefore of prime importance in the development of the vehicle.

Gearing ensures the motor operates at ~3x the efficiency of a combustion engine

CFD simulations performed and aerodynamics optimised to reduce drag

Energy recovery using regenerative braking improves the range

Simulations identify energy usage and battery requirements

0,00%

1,00%

2,00%

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6,00%

7,00%

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9,00%

0 20 40 60 80 100 120 140 160 180

Dep

th o

f D

isch

arge

Time [s]

Depth of discharge comparison

Depth of discharge Depth of discharge w/o regenerative braking

XX% of energy lost to drag??

Motor efficiency map Effect of regenerative braking upon energy consumption

CFD simulations to estimate the drag coefficient

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The rechargeable energy storage system (RESS) is

responsible for storing all the energy required by the vehicle

to run during the entire race.

The main objectives of this section are to evaluate the

requirements for the electric motor and identify suitable cells

for battery construction. Also, it includes the design of the

internal layout to provide the necessary voltage to the motor

and the design of the battery casing to negate any thermal

and electrical issues. It is wanted to optimise the

configuration of the battery pack in order to achieve a

balanced car and the best utilisation of space within the

chassis of the vehicle.

The Car: Battery Design

The cells are contained in single holders which

allow flexibility to do our own design, while it is a

lightweight structure which allows the air to circulate

between the cells.

The cells are assembled in many stacks to achieve

the desired voltage and energy. These cells are

monitored by the Battery Management System.

A part from the battery cells, there

is the Battery Management System

(BMS) which is responsible for

monitoring in real time the status of

the cells (temperature, voltage,

etc.) and provides information such

as the State of Charge (SOC) or

the energy consumed.

The size and weight of the battery have a significant impact

upon the overall vehicle design & handling, and the high

voltage, crash safety & thermal management of the battery

present a challenging design problem.

A few of the design requirements are as follows:

Cell specification for power demand requirements

Safety in the event of an accident

Thermal management

Lightweight design

Electrical safety

Battery design and assembly

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Current flow from banks of cells

The Car: Crash Safety

images

PRIMER

• Element types

• Section

• Material models

• Contact types

• Crash speed &

load

LS-DYNA

• Explicit

• Implicit

D3-PLOT

• Results

• Validating

• Verifying

Crash performance is of primary importance in any racing car, but the high voltage batteries used in an electric race car are

potentially lethal, and their behaviour in the event of an accident must be considered. The following safety precautions have

therefore been taken:

Crash simulation in LS-DYNA of front, rear & side impacts to FIA specifications

Development of instantaneous battery shut-off circuits

Analysis of the battery enclosure during an accident

Insulation Monitoring Device to detect high voltage leak

Side impact affecting the battery enclosure Direct impact to the battery enclosure

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Insulation Monitoring Device & High Voltage Safety


The Car: Vehicle Dynamics

Image of Gould car on 4PR might

be better – can’t seem to find it

The significant mass of the batteries leads to a rearward weight distribution for the car. In order to ensure that the vehicle

handling is maintained, detailed simulations have been undertaken to simulate a variety of handling manoeuvres and

optimise the vehicle suspension & tyre selection.

ADAMS models of the complete vehicle developed

Models used to cross-validate Dymola simulations

Detailed tyre models created

Sensitivity studies undertaken to inform the vehicle design

Optimisations used to tune the ride and handling

4-Post Rig Adams model 4-Post Rig at Oxford Brookes University

High speed damping sweep


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Wishbone loading during dynamic conditions

The Car: ‘Keeping Our Cool’

Brake disc cooling Thermal DYMOLA model of battery Motor core CFD analysis

Velocity streamlines through the radiator

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The driver’s throttle demand, coupled with the motor’s efficiency, results in a

varying heat generation in the motor, batteries and controller.

Thermal management is therefore essential to avoid damage to the motor

and batteries, so the following steps have been undertaken:

Thermal FEA and CFD analysis of motor core and coolant flow

CFD analysis of flow through the radiator

Thermal modelling of motor and batteries in DYMOLA vehicle model

Simulations give real-time component temperatures during lap simulation

Sensitivity studies inform design decisions

The Simulator: Driver Model -250000

-200000

-150000

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0

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0 20 40 60 80 100 120 140 160 180

Po

wer

[W

]

Time [s]

Motor power comparison

Total braking power [W] Motor Power w/o regeneration [W] Regenerated power

Distance [m]

Sp

ee

d [m

/s]

Default driver

Own driver

Edit Text

Velocity profile using different driver models

ChassisSim

Default

Brookes

Brookes driver model

Brookes driver model

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DYMOLA

IMAGESS!!!!

Dallara’s Driver-in-Loop simulator


To identify the performance of the vehicle and the energy consumed during a lap of the track, it is necessary to run lap

simulations. Vehicle models are built using DYMOLA modelling software, tested at Oxford Brookes University and then

implemented in Dallara’s Driver-in-Loop simulator in Italy. A driver model has been developed to perform laptime simulations.

Basic driver models used to perform handling manoeuvres

Detailed driver developed for Laptime Simulation using forward preview technique

Simulations validated against ChassisSim, ADAMS and MATLAB

Driver model used to perform sensitivity studies and aid design decisions

Driver-in-Loop simulator used for validation and driver feedback

The Simulator: vehicle model

Tyre Model

Various tyre sizes and

compounds are modelled

to enable selection of ideal

tyres for rearward weight

distribution

Suspension Model

Includes kinematic

behaviour, damper models,

masses & inertias from CAD

Body & Powertrain Model

Accounts for inertias &

weight distribution from 3D

CAD, and motor, controller

& drivetrain details

Aerodynamic Model

CFD simulation data at

various pitch and yaw

angles gives dynamic aero

balance

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Driver-in-Loop Interface

Custom driving simulator

interfacing and visuals have

been created to enable real

driver feedback at both OBU

and Dallara

The Simulator: Powertrain

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Motor Model

Detailed model including

efficiency, mechanical,

and thermal properties

from FEA and CFD

Battery Model

Simulates intensity and

thermal effect at cell level

Drivetrain Model

Optimisations used to

select gear ratios for

maximum efficiency

Controller Model

Converts driver throttle

demand into electrical

input to the motor

The Simulator: Battery

Battery model Battery thermal model

Vo

lta

ge

[V

]

Battery voltage discharge and charge cycle

Time [s]

Time [s]

Vo

lta

ge

[V

]

Motor I

Motor IV

Battery voltage discharge for two different motors

Vo

lta

ge

[V

]

Battery I

Battery II

Battery III

Battery IV

Voltage discharge for different battery cells

Time [s]

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The battery makes up a significant proportion of the vehicle mass, so it is necessary to accurately simulate and predict the

range of the vehicle. An in-house battery model has been developed which can predict individual cell discharge and

temperatures.

Simulations of an entire race weekend, including discharge / recharge cycles

Cell-level modelling of entire battery pack

Thermal models of individual cells

Battery results Different combinations of motors and battery cells are

simulated: high performance, low performance, cheaper,

expensive, etc. The results show how long each battery pack

last until the cut-off voltage.

The Simulator: Results

Sp

ee

d [km

/h]

Time [s]

Motor I

Motor II

Motor III

Motor IV

Motor V

Speed profile for different motors

Time [s]

Inte

nsity [A

]

Intensity comparison between default model and Brookes model

Time [s]

Po

we

r [W

]

Heating and cooling power

Time [s]

He

at [W

]

Heat dissipation for different battery cells

motor results

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The main aim of simulating the vehicle is to find the balance between the vehicle’s performance, drivability and cost that

meets the customer requirements - whilst ensuring that the battery will last the race duration.

Assorted motor and battery combinations analysed to determine cost / performance trade-off

Thermal performance of motor, battery and cooling system analysed in real-time

Range prediction in both laptime and Driver-in-Loop simulation

Multiple UK circuits and race formats simulated

In-wheel motor design

CFD analysis with wing model

Torque vectoring Simulink model

In-wheel cooling analysis

The Ideas that didn’t make it

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Torque vectoring effect


If you’re wondering ‘Why didn’t they do it another way?’ the answer is ‘We probably did’.

During the development of the vehicle several concepts were considered in detail and rejected for various reasons. A few of

the vast array of ideas explored, modelled, simulated and analysed include:

Multiple battery pack locations

4-wheel drive powertrain configuration

2 on-board motors

2 in-wheel motors

Front and rear wings

Torque vectoring

The Business case

Competitor's Car Price 0-60 mph (sec) Top Speed (mph) BHP

BRDC Formula 4 39,980£ N/A N/A 230

MSA Formula 36,000£ 5.8 127 157

Radical SR1 37,500£ 3.6 138 185

Radical SR3 RS 40,000£ 3.1 155 210

Radical SR3 SL 58,200£ 3.4 161 300

Radical SR3 RSX 66,958£ 3.1 155 210

Caterham Seven CSR 46,495£ 3.1 155 260

Caterham Seven 420 26,995£ 3.8 136 210

Formula Ford 1600 15,000£ 6.0 130 115

Competition Average 40,792£ 4.0 145 209

Dallara Electric Emrax228 39,990£ 6.9 134 134

Dallara Electric Yasa400 45,000£ 5.8 140 221

Formula E 350,000£ 3.0 140 268

2%

4%

24%

42%

4%

3%

13%

8% Brake System

Drivetrain & Cooling

Frame & Body

Electrical

Miscellaneous, Fit & Finish

Steering System

Suspension & Shocks

Wheels & Tires

The business case for the Formula Club-E is being carefully considered in order to ensure that the output of the project is not

just a ‘pie-in-the-sky’ idea; the Formula Club-E will be a fully designed, developed, prototyped, tested and budgeted vehicle,

with a business plan to match.

Detailed bill of materials for the vehicle allows accurate costing

Market research provides projected sale price and volumes

Detailed simulations provide data for cost / performance decisions

Various business models thoroughly considered

Detailed financial projections

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Cash Postion Area Expenses Revenues Cash Position

2017 2020

Cash flow Cost breakdown

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Competitor's Car Price 0-60 mph [s] Top Speed [mph] BHP

BRDC Formula 4 £39.980 N/A N/A 230

MSA Formula £36.000 5,8 127 157

Radical SR1 £37.500 3,6 138 185

Radical SR3 RS £40.000 3,1 155 210

Radical SR3 SL £58.200 3,4 161 300

Radical SR3 RSX £66.958 3,1 155 210

Caterham Seven CSR £46.495 3,1 155 260

Caterham Seven 420 £26.995 3,8 136 210

Formula Ford 1600 £15.000 6,0 130 115

Competition Average £40.792 4,0 145 209

Dallara Electric Emrax228 £41.000 6,90 110 134

Dallara Electric Yasa400 £45.000 5,80 134 221

Formula E N/A 3,0 140 268

Competitor analysis

V1

V2

A complete market research of the

latest technologies applied to electric

vehicles is carried out. Many battery

cells, motors, inverters are listed and

simulated to choose the best

combination overall.

As a result, a full electric formula

racing car is designed that meets the

customers’ needs and covers the gap

that is currently in the market.

“What we are trying to do is make driving clean cars exciting and fun, and to try to encourage manufacturers to come into

this area because, if they don’t, they are going to be left behind.”

Richard Branson

If you are interested in joining the project, please email [email protected] with the subject “Dallara”.

In particular, we are particularly interested in hearing from the following:

Race organisers, schools & race car rental companies

Motor / controller manufacturers & suppliers

Battery manufacturers & suppliers

Potential customers & distributors

Sensors and electrical suppliers

Tyre manufacturers & suppliers

Financial investors

Get involved!

We are actively looking for partners to join us in the

development of this project. In particular we are

looking for;

Driver model developed using forward preview

technique

Simulations validated against ChassisSim,

ADAMS and MATLAB

Driver model used to perform sensitivity studies

and make design decisions

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The following have provided exceptional levels of support to the project, and have been instrumental in the development of the vehicle:

Simulation Support: Alessandro Picarelli - Claytex Services

Market Research: Jaqui O’Rourke, Madelaine Robinshaw & Nicoletta Occhiocupo - Business School

Electric Powertrain: James Broughton & James Larminie - Department of Mechanical Engineering & Mathematics

Chassis Development: Allan Hutchinson & James Balkwill - Department of Mechanical Engineering & Mathematics

There are also many more people who contributed to the project - thanks, we couldn’t have done it without you!

YASA Motors Amlin Aguri Cooper Avon Tyres Mark Preston Brian Sims

Tim Woolmer Neil Fellows Shpend Gerguri Denise Morrey Geoff Goddard

Nick Bowler Daniel Bell Colin Bell Khaled Hyatleh Andrew Baxter

John Twycross Gabor Lukacs Tom Elsworth Eric Cassells Ana Domingos Canhoto

Miguel Ferreira Adrian Ward Terrance Floyd Kevin Hort Ian Spacksman

Dom Daly Mashael Alnosayan Quiyang Ge Viktor Weber Xinyi Xu

The department’s digital printing facilities used in the creation of this book were provided & supported courtesy of:

Artwork & print design by David Lopez Almirall and Andrew Bradley. Binding by Maltby’s the Bookbinders, Oxford











The PARTNERS



looking for;


technique


ADAMS and MATLAB



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looking for;


technique


ADAMS and MATLAB



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