A TECHNICAL INSPECTOR’S GUIDE TO THE 2015 FSAE RULES PART 1 RULES CHANGE SUMMARY

2015 FSAE Rules students.sae.org /cds/formulaseries/rules/ Format Index Introduction Part A - Administrative Regulations Part T - Technical Regulations Part AF - Alternate Frame Rules Part IC - Internal Combustion powertrain regulations Part EV - Electric Vehicle powertrain regulations Part S - Static Event Regulations Appendix C-1 thru’ C-5 Cost Event Appendices Appendix C-6 Presentation Judging Appendix C-7 Design Judging Part D - Dynamic Event Regulations

T2.1: “Open Wheel” keepout areas 2014 ‘Tennis-ball test’ goes away, new larger keepout areas. Nothing, including wings, can be in these areas, which extend vertically, infinitely. ie: wings, end plates, or bodywork can never be vertically above the tire.

T9: Aero Device Locations New restrictions on wing positions, diagrams below. See rules or tech sheet for dimensions. No aero devices in colored areas! (Includes Open Wheel keepouts from previous slide)

T9: Aero Device Locations New restrictions on wing positions, diagrams below. See rules or tech sheet for dimensions. No undertrays behind rear tire No wings over rear tire

T3.6: Alternative Steel Tubing Thinner tubing (than those shown in minimum thickness tables) is allowed in the chassis structure only if welds are validated by testing. This requires test samples to be presented at Tech. Welded tube specimen (must be bent) Pull Pull

T3.11.6: Main hoop OK OK (Tube cannot be cut, this must be a bend.) Lower part of main hoop can’t lean rearward more than 10° OK OK (Tube cannot be cut, this must be a bend.) 10°

T3.20.2: Front Bulkhead Support Bulkhead support must: “attach to the Front Roll Hoop within a zone extending (4”) above and (2”) below the Upper Side Impact member.” Upper SIS tube Zone

T3.20.2: Front Bulkhead Support Bulkhead support must: “attach to the Front Roll Hoop within a zone extending (4”) above and (2”) below the Upper Side Impact member.” Missing Triangulation

T3.20.2: Front Bulkhead Support Bulkhead support must: “attach to the Front Roll Hoop within a zone extending (4”) above and (2”) below the Upper Side Impact member.” OK

T3.31.1, 3: Monocoque test specimens 1) SIS and 2) primary structure test specimens must be presented @ Tech Primary structure 3-point-bending test (must show specimen)

T4.1.1: Cockpit Opening Template Fore-aft translation is permitted now. Cockpit opening template insertion path Firewall Steering column support structure

T5.2.2: Harness mount tabs Welded harness mount tab (OK) If tabs are bolted to frame, must use two ¼” grade 5 fasteners, minimum. Welded harness mount tab (OK) If bolted to frame (instead of welded,) needs two ¼” bolts.

T6.5: Rear Wheel Steering Max 6° Is allowed; limited to 6° travel. Travel limits must be demonstrated at Tech. Max 6°

T6.5.10: Steering Column “Joints between all components attaching the steering wheel to the steering rack must be mechanical and be visible at Tech Inspection. Bonded joints without a mechanical backup are not permitted.” Parts that make up the column must be bolted or welded together; no bonded composites, etc.

T7.4.1: Strip-LED brake lights LED “tape” is becoming very common. It is sold in flexible strips as shown to the right. When LED lights are used without a diffuser, they may not be more than 20mm apart. If a single line of LEDs is used, the minimum length is 150mm. (this was enforced in 2014 actually) It must be a single, “rectangular, triangular or near round shape,” on the centerline of the vehicle. Bad OK

T8.2.3: Fluid catch cans Differential: If differential is vented, must go to 50mL catch bottle; same for any other oil-filled system that is vented to the outside air (ie: transmission gearbox.) Differential: Needs a catch bottle if it has a vent. (But most FSAE diff’s don’t use a vent…)

T9.5.1: Minimum Radii of Edges of Aerodynamic Devices Only forward facing edges need the round edge radius (5mm for horizontal edges, 3mm for vertical edges) Vertical, forward-facing (min radius 3mm) Horizontal, forward-facing (min radius 5mm) Trailing edges: no requirements

T9.7.1: Aerodynamic Device Stability Wings can’t wobble around. If wobbly in Tech, call organizer over for formal evaluation.

T11.1.3: Fasteners Bolted joint in primary structure Bolted joints in frame must have > 1.5 dia from edge of hole to edge of material. (But not suspension pickups; frame only.) AKA “edge distance ratio “e/D” of 2 or greater” Bolted joint in primary structure D D * 1.5 edge This tab is too small

T11.2.1: Positive locking mechanisms Nylon lock nuts (“Nylock” nuts) only acceptable in locations not exposed to heat (not above 80°C, such as very close to exhaust system.) Watch for this especially for the critical fasteners related to intake and fuel rail.

IC1.4.3, 1.9.1: Engine: Critical fasteners New locations considered ‘critical’ and require positive locking mechanisms: Fasteners that attach intake manifold to cylinder head Fasteners that attach the fuel rail Fuel rail fasteners Intake manifold fasteners

IC1.6, 1.7.6: Intake system New: compressor before throttle The position of the throttle for intake systems has been changed so that it must now be after the compressor. Intercoolers must be downstream of throttle. New: compressor before throttle (optional) intercooler location

IC1.7.4, 5: Intake system Max 60mm No plenums (enlarged air chambers) between compressor and throttle; all tubes in this area max 60mm (2.36”) diameter. Max 60mm

IC1.11-16: Electronic Throttle Control Permitted, but adds many requirements, including: Demo @ Tech: Throttle and fuel pump turn off if Brake + Accel pedals applied together. Demo @ Tech: Throttle and fuel pump turn off if throttle position sensor fails Demo @ Tech: Throttle and fuel pump turn off if (hard braking && >10% throttle position)  If there is no throttle cable, we’d like to see it: come get the Tech organizers. Accel Pedal ETC Throttle

IC2.5.1: Fuel System Location “In side view no portion of the fuel system can project below the lower surface of the frame…” Fuel tank exposed below frame

IC2.6.1, 3: Fuel Filler Max 30° Longer than 2014 Fuel filler must be within 30° of vertical Sight tube vertical span must be 4.9” minimum (was 3” in 2014) Max 30° Longer than 2014

IC2.6.7, 9: Fuel Filler (cont’d) Entire (4.9”) vertical span of sight tube must be visible, even when bodywork is installed. Fuel fill cap needs to be secure enough to withstand pressurization of the tank (cap needs threads or latches.) Fuel sight tube not visible w/ bodywork installed

IC3.1.4: Exhaust System Exhaust manifold insulation wrap. “The application of fibrous/absorbent material, e.g. “headerwrap”, to the outside of an exhaust manifold or exhaust system is prohibited.” Exhaust manifold insulation wrap.

IC4.2.2: Primary Master Switch …must be installed so on-position is near horizontal. Master switch lever horizontal when vehicle running (good)

Other Things IC3.3: Maximum Sound Level: Will be measured at idle speed, in addition to part-throttle. IC4.6: Voltage Limit: A voltage limit is specified for IC Engine cars (60 VDC) IC1.5.9: Carburetors: Carbs not allowed for boosted engines. (AKA forced induction, turbocharged, supercharged, etc.) AF: Alternate Frame Rules: Lots of revisions, not covered in this presentation due to infrequent attendance of AF teams at FSAE-Michigan. EV: Electric Vehicles: Lots of revisions, not covered in this presentation. EV tech is a separate activity.

We don’t keep the forms until the team passes tech. Tech Sheet (pg1 shown) Each team receives these forms (4 pgs) at registration, and will bring them to you. We don’t keep the forms until the team passes tech. Until they pass, take notes on the sheet to indicate problems that need fixing.

10am Wednesday: Safety Gear check Like last year, we will inspect the following items first on Wednesday, before the team brings the car for inspection. (See instructions at top of Tech Form pg 1) All Helmets (we apply stickers) Shoes Nomex socks Nomex gloves Driver Suits Wrist restraints 2 Fire Extinguishers (team should label with school name) Rain tires (all teams are required to have some) Balaclavas

Special Inspections Activity 2014 (previously) 2015 Tube wall thickness checks Designated, circulating individual Same Aero device location inspection (Part of regular inspection) Designated, circulating individuals (2) Electronic Throttle not permitted Special inspection (organizers) Monocoque frame inspections John Burford circulating Fuel filler Regular, + supplimental check by circulating fuel station volunteer Cockpit templates East end Designated individuals in the waiting queue. Egress 1st driver during regular inspection. Additional drivers must wait till Thursday! Regular Inspection West end Full Garage

End