Clean Formula
managers eager to sign the next find their share of the action? but it was rather the expertise
champion. Not only that, but Where is the starting formula and the culture of attention to
lower formulae are also where that allows the fans to have a detail embedded within OBU
for Success racing enthusiasts can emulate
their idols. Either way, both the
taste of what electric racing is all
about? The answer to these
that impressed Dallara the most.
The signs are everywhere, from
Formula E is making a aspiring professional driver and questions is currently being having one of the top UK
the hobbyist have the developed at Oxford Brookes Formula SAE teams, strong
stand at the highest level
opportunity to race alternative University (OBU) in collaboration industrial partnerships and the
of motorsport – but what versions of the desired and with one of the world’s largest recognition of the talent of OBU
is happening in the lower admired racing cars of higher racing car manufacturers: graduates from leading
formulae? formulae. Dallara Automobili. motorsport and automotive
manufacturers.
With the rise in popularity of
Despite the less advanced Plugging the gap
chassis and the smaller engines Back in 2014 the OBU Dallara quickly recognised
Formula E, electric vehicle racing
making for slower, and more Department of Mechanical the clues that pointed to the
is beginning to conquer the
importantly, safer cars they are Engineering and Mathematical ability to conduct a successful
world of motorsport - bringing
still capable of putting everyone Sciences received a visit from ambitious project and so
the support of not only
on the edge of their seats with Andrea Toso – Head of R&D and decided to make a move.
seasoned motorsport fans, but
close racing action and highly US Racing Business Leader at Having recognised a gap in
also new, fresh to the scene
disputed contests. Single make Dallara. This visit would kick- the market Dallara, the
technology enthusiasts.
championships excel in providing start a project that will fulfil manufacturer of every Formula E
However, while fans are
race action largely as a result of electric racing dreams car on the grid, approached the
currently dazzled by the
every driver on track having everywhere. Department of Mechanical
fantastic display of racing action
access to the same equipment. Engineering and Mathematical
and technology excellence, the
Not only does this format lend Sciences with the idea of
time will inevitably come when
they too will want a taste of the
itself to exciting racing that both FIGURE 1 developing an affordable electric
fans and drivers love, but it does racing vehicle.
action.
so at a sensible cost – foregoing
Motorsport has always been the need for expensive OBU’s impressive facilities - The challenge was promptly
characterised by its entry-level technological development which include equipment such accepted and so started one of
formulae. These classes have essential to success in open as a Scanning Electron the most ambitious projects for
always been there, feeding the formulae. Microscope, 4 engine OBU: The Formula Club-E
bigger classes by providing a dynamometer test cells, a wind Development Project. Every
The question is, where can
stage for new talent to develop tunnel, and a 4 Post dynamic detail of the vehicle from chassis
the electric vehicle enthusiast
and show itself to team test rig - enticed Andrea to visit, dynamics, powertrain options
down to the formula and The Business School helped feature the very latest
business model were to be to support the difficult task of technology and yet be One of the areas where
developed by Oxford Brookes’ characterising the market and fundamentally simple. Focusing knowledge is evolving the most
MSc students guided at every determining the business model on the enjoyment of the driver is undoubtedly the powertrain.
step of the way by experts from most likely to succeed. A at manageable speeds for the The motor and batteries are
Dallara. To ensure the success of thorough analysis of less experienced. Regardless of large, expensive, heavy and
the project at all levels the conventional series and vehicles having a clear idea of their goal crucial components that require
motorsport vehicle design was performed to position Oxford Brookes could not risk the upmost care when being
expertise of the Department of Formula Club-E in the market as getting this formula wrong. As specified. One of the benefits of
Mechanical Engineering and attractively as possible. such, not only were most ideas Formula Club-E will be to help
Mathematical Sciences was considered - they were fully organisations like Tesla raise
supported by the business developed and tested. This public awareness and
strategy and development FIGURE 2 approach eliminates any doubts acceptance of electric vehicle
knowledge from the Business that the final design will be technology – though it has to be
School. This breadth of anything other than the optimal recognised that significant
knowledge coupled with the The performance of electric design. challenges for mass take-up of
chance to work on a real, large cars is largely unknown when
It is important to realise just the technology exist in the
scale project provides an compared to their internal
how complex a study like this is. supply chain, such as the supply
excellent learning opportunity combustion counterparts, and
Every parameter tested is of rare minerals.
for the students, and crucially there is a serious concern
regarding the safety of these coupled with at least one other After considering torque
prepares them for employment.
systems - with careful area of the vehicle making this a vectoring strategies, a single
The Department is very keen on
precautions being taken at this multi-dimensional problem of motor was determined to be the
this - 92% of graduates go on to
stage. optimisation. The cooperation ideal solution in view of
employment; many in F1,
between groups of different efficiency and cost control. Most
Formula E and other major The level of detail of the
development areas is suitable motor options available
suppliers to the automotive analysis undertaken highlights
paramount. in the market have been
industry. the commitment to this project -
simulated. However, since this is
The project is scheduled for making it impossible to ignore
a constantly evolving technology
4 years and is now mid-way this as a serious bid for the
future of affordable electric
FIGURE 3 new solutions are always being
through completion. More than considered when they become
100 postgraduate MSc students racing.
Simulating the future available.
will have collectively contributed Defining the winning None of this would be As far as powertrain
over 60,000 hours for the
Formula possible without extensive use performance is concerned
success of this project by the
The possibilities that arise of simulation tools. Starting currently the biggest limiting
end of the fourth year. The
from starting with a blank sheet from a solid base of expertise in component are the batteries.
numbers alone show the th
can soon turn into a vehicle simulation and modelling With around 1/30 of the
commitment and ambition of
conceptually confusing product the Department of Mechanical energy density of petrol they
this institution. However, it’s the
if care is not taken to define the Engineering and Mathematical make up a large portion of the
quality of their work that really
right goals. Oxford Brookes is all Sciences continues to push for vehicle mass. Furthermore, the
shows why they were chosen for
too aware of this and very early better, faster and more reliable requirements for batteries in
such an important step for the
in the project started to define simulations. DYMOLA was motorsport are also very
manufacturer - and more
the character of this vehicle. adopted as a tool to build the extreme with very high power
importantly for motorsport.
Developed for a less advanced ‘virtual prototype’ draw and charge making for
Electric fences to jump experienced or even amateur models required. Upon aggressive usage cycles. The
The design, manufacturing group of drivers the driving completion and assembly of all batteries need to be charged
and commercialisation of a experience had to be simplified. the individual models testing will quickly between races, and also
vehicle and racing series is a All too often nowadays cars are be undertaken at the state of absorb and store the energy
challenging task at the best of equipped with so much the art Dallara Driver-in-Loop from regenerative braking while
times and it only becomes more technology that the driving simulator, allowing test drivers in use.
difficult when the vehicle in experience is diluted by the to experience the vehicle before Within this area, there are
question is electric. Plenty of devices implemented to make it comes to reality as a physical significant materials science
organisational and engineering the car faster. Even though the product. Feedback on the challenges - but the constant
challenges arise in this area - lowest lap time may be the vehicle performance can be need in motorsport to push the
some from the lack of ultimate goal for some others gathered and improvements boundaries of performance
knowledge and experience with are discouraged by all the tried before production costs makes it the ideal test bed for
the electric powertrain, some experience, preparation and are incurred. the development of materials
from the uncertainty of the budget that a fast car requires. and disruptive new
customers’ reaction to a technologies.
With this in mind the
technology in its relative
Formula Club-E is meant to FIGURE 4
infancy.
The importance of choosing detrimental to the vehicle …and keeping it cool
the appropriate batteries dynamics than a modular design Motors and batteries have a Currently at the midway
becomes even clearer when one that could be spread around the temperature window of point the project has a few
realises that the team even driver, this solution is more operation relatively small with questions to be answered and
simulate where and how the robust, and more likely to meet exponentially decreasing components to be finalised. The
vehicle will be raced. This is due safety regulations. performance when operating simulation models developed
to different energy levels and Crash scenarios have been outside of range. If control over are prepared for this, and
conditions encountered at considered and simulated to the temperature is lost the alternative emerging
different locations. analyse the structural behaviour damage can build up to severe technologies can now be rapidly
of the system, and failures of the system. Not simulated and evaluated, thus
instantaneous shut-off circuits leaving a single detail to chance the team are actively looking for
Keeping it safe… relying on monitoring of power a considerable amount of effort partners to help contribute to
Due to vehicle dynamic usage and demands have been has been made to understand the project. In fact, they have
considerations and the amount developed. The crash the heat transfer interactions in much industrial support for the
of mass involved batteries have simulations were run in LS-DYNA place. Extensive thermal project, including some famous
to be placed in a location that following FIA guidelines for computational fluid dynamics, names such as David Brabham,
will place the centre of gravity safety requirements - once again finite element analysis and Allan McNish and Petter Solberg.
(CoG) in a favourable location. highlighting the attention to DYMOLA simulations were If you would like to add your
When it comes to the influence detail employed throughout this performed, with expert training name to the list the team are
of the CoG on the dynamic project. & support in the use of the inviting people to contact
behaviour of the vehicle, the
In fact, having so many software provided by Claytex mems-enquiry@[Link]
more central and lower the
bright minds on the case has Services. Many hours of with the subject “Dallara”.
position the better. Although
even allowed Oxford Brookes to modelling work later, a The answer to budget
using a battery composed of
prepare the vehicle for future simulation capable of calculating electric racing is coming - and
cells can allow for some
technologies and regulations. real-time component not surprisingly - by the hands of
freedom in configurations there
Should there be a need for it, temperatures was completed. two world leading organisations
is one major aspect that
and permission from regulatory This model will be one of many in Motorsport engineering:
somewhat limits the creativity –
bodies, the Formula Club-E is running simultaneously in the Oxford Brookes University and
safety!
designed to allow for battery driver-in-loop Dallara simulator Dallara Automobili.
changes during the race, in true providing valuable data with a
FIGURE 5 ‘refuelling’ style. The safety
challenges here are so high that
resolution down to each
individual battery cell.
Authors
Miguel Fernandez Ferreira –
even the pinnacle of the sport -
Technical Instructor,
Motorsport has been making Formula E, has opted not to use
huge efforts to ensure the safety it for the time being on grounds FIGURE 7 Department of Mechanical
Engineering & Mathematical
of the drivers, marshals and of safety. As a consequence, two
Sciences, Oxford Brookes
public. Electric batteries are not cars per driver are required with
Currently simulations are University
necessarily any more or less a change of cars mid-race. The
dangerous than a full tank of same scenario would not be being carried for charge/
Andrew Bradley – Senior
fuel, but battery specific sustainable for a low budget discharge cycles for the duration
Lecturer, Department of
considerations have to be taken formula. of the whole event, including
Mechanical Engineering &
into account to ensure the level track driving, energy recovery
To incorporate a removable Mathematical Sciences, Oxford
of safety required. The speed at and battery recharging with the
battery design Oxford Brookes’ Brookes University
which the energy stored can vehicle stationary.
students have not only to cope
inflict severe injuries makes More than a concept Andrea Toso – Head of R&D and
with existing challenges but also
containing that energy in the US Racing Business Leader,
with the ones the solution itself The scale of the project
event of an accident one of the Dallara Automobili
creates. In other words, from coupled with meticulous
biggest priorities. In view of the the moment a battery pack is analysis that is being undertaken Gareth Neighbour, Head of the
priority for safety, the sealed, in order to guarantee in Oxford Brookes and Dallara’s Department of Mechanical
arrangement of the cells has safety, something else becomes Formula Club-E project conveys Engineering & Mathematical
been kept in a more traditional a hot topic – temperature a sense of purpose - of Sciences, Oxford Brookes
configuration, which in turn led control. something that will not settle for University
to a solution that consists of a being a mere concept.
single unit containing all the
cells behind the driver. Even FIGURE 6
though it may be more FIGURE 8
FIGURE 1
Andrea Toso, Head of R&D and US Racing Business Leader at Dallara Automobili, shares design ideas with Oxford Brookes Students
FIGURE 2
Strongly
Strongly
Agree
Disagree
15%
15%
Disagree but
could be Agree
convinced 39%
31%
Market survey - Is electric racing the future of motorsport?
FIGURE 3
Modular design allows for ease of maintenance
FIGURE 4
Dallara’s Driver-in-Loop Simulator
Figure 5
Analysis of the weight distribution of the vehicle
Figure 6
CFD analysis of the cooling system feeds the thermal models in DYMOLA
Figure 7
Thermal models of the battery allow individual cell temperatures to be monitored in real-time
Figure 8
Speed [km/h]
Motor I
Motor II
Motor III
Motor IV
Motor V
Time [s]
Speed profiles for various motor choices