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PAINTING THE FOAM F1 MODEL BLOCK

Find tips and hints for painting the new F1 Model Block in this PDF produced by F1 in Schools - F1 Model Block Paint Guidance.pdf

Finished your car design - What next?

Before making a request to have your design manufactured by Yas Marina Circuit there are some important things to do and consider:

1. Check that the design complies with the Technical Regulations - most commonly students will design cars which are too long, too wide or too tall. It is important to check the maximum permitted car length in the regulations. Car bodies are not permitted to be as long as the actual Foam Model Block. This is because a portion of the Foam Block is held via a clamp during the actual CNC machining process.
2. Ensure that no part of the body or other features such as wings which ARE to be made from foam block protrude beyond the model block dimensions width of 65mm and block height of 50mm
3. Wings designed to be manufactured from the foam block which are less than 3mm in thickness could break off during manufacturing and will be more prone to breakage during racing.
4. Only features to be made from the foam model block should be included in the .STL file that is submitted for CNC machining manufacture. Don't save the STL file including wheels or any wing parts that are being 3D printed. These parts need to be saved as separate STL files.
5. The final step in Autodesk Inventor, in preparation for manufacture, is to add a manufacturing reference plate to the rear of the car. Instructions for this are presented below. The car body with reference plate added must be saved in .STL (stereo lithography) file extension format. This file format is required for compatibility for use with the CAM (Computer Aided Manufacture) software used by us to generate the machining code. 

ADDING A MACHINING REFERENCE PLATE - PROFESSIONAL TEAMS ONLY

• Add the manufacturing reference plate | save as .STL | upload the .STL when submitting your manufacturing request to YMC F1 in Schools

If you are a Professional team, the final step before uploading your manufacturing request and completed design is to add a manufacturing reference plate as per the instructions document linked below. The reference plate is used during the CAM process to accurately locate your car model relative to the pre-machined C02 cartridge hole in the actual foam F1 Model block.

• Fusion 360 CAD - Adding Manufacturing Reference Plate: F1iS - Fursion 360 - Add Manufacture Reference Plate.pdf
• Inventor CAD - Adding Manufacturing Reference Plate: AD Inventor-Add-reference plate guide.pdf

EXPORTING THE CAR BODY INCLUDING REFERENCE PLATE AS A .STL FILE

The following linked PDF explains how to export your design as an STL correctly. It is important to check this document as it explains how to export the file in the correct dimensional format.

Autodesk STL Saving.pdf

If you have any questions or suggestions, please post them here by replying to this topic...

Computer Numeric Control (CNC) Manufacturing of F1 in Schools Cars - An Overview

• Standard machining = AED 185 (inc VAT) per car (this includes all resources and full standard car wheel and axle kit)
• Additional machining operations = approx AED 50 each per operation. (Some Professional Category team designs will require additional machining to create detail on the top or bottom of the car that isn't accessible through standard side machining. Don't worry, the team at Yas in Schools will check for this and inform you if it is required)

Stage 1 - Prepare Final Design for Manufacture in CAD / Fusion 360 (Done by the students)

• Check design for rules compliance
• REMEMBER - Your part to be machined must fit within the dimensions of the standard Foam F1 Model block. The dimensions can be found in the Technical Regulations document.
• Add a machining reference plate to the 3D design. See details by clicking > Here
• Save your design as a .STL file in Autodesk Inventor and email to F1 in Schools

Stage 2 - Submit a Manufacturing Request to YMC

• Find the online link (CLICK HERE). Fill the form and upload your car body (with reference plate attached) STL file

Stage 3 - Computer Aided Manufacture using QuickCAM Pro (Done by the manufacturing centre)

• The 3D car model is converted to machining code. This is known as G-Code and includes all of the X,Y and Z co-ordinates that describe the profile of the car along with cutting speed, feeds and other instructions for the machine cutting operation to follow. Click the thumbnail below for an example of what this code looks like.

Stage 4 - CNC Machining (Done by the Yas in Schools manufacturing centre)

• Cars are machined on a DENFORD 3D CNC Router see this link for more information about these machines - http://www.denfordat...ompact-1000.pdf
• The Foam F1 Model blank is mounted in a special F1 in Schools Machining fixture
• Standard Machining, with the car oriented on its side commences via material being removed leaving behind the profile of the car design
• Here is a video of a typical F1 in schools car machining operation....

Stage 5 - We deliver the completed car body/s and wheel kits to your school!

We will be developing more detailed classroom friendly resources that help explain the Design through to Manufacture soon.

If you have any suggestions or comments, please reply to this post...

This one page guide is very useful for helping machine operators remember the basic steps involved in set up and procedure when using a DENFORD 3D Router for manufacturing CO2 cars (F1 or Bloodhound). Post a reply here if you have any suggestions.

DENFORD ROUTER - CO2 Quick Start.pdf

We have created a special spreadsheet to help schools run a successful internal competition day. The spreadsheet is designed for input of all event scoring data, including race times based around the judging and racing criteria specified in the Competition Regulations.

When your event is complete and all scoring data has been entered, you can even instantly see which teams should win the outright and category awards!

The spreadsheet includes separate tabs/sheets for each F1 in Schools Secondary competition division, the first tab 'INSTRUCTIONS' is where you should start! (Click the thumbnail below to see where these are located)

Download the spreadsheet using the link below.

Please come back here to post any questions or comments you may have about using the spreadsheet

http://f1-in-schools-torque.invisionzone.com/index.php?/files/file/13-%7B?%7D/

Thanks for letting us know the outcome - cheers

A great way to get started with students or to promote the project within your school is to use the PowerPoint presentation available for download from the link below.

DOWNLOAD HERE > F1inSchools-Overiew-V2.ppsx

The presentation includes several videos, streamed directly from YouTube, therefore it is necessary to be internet connected to view these. 

_{We need to inspect the carbon brushes for the spindle motor. It is normal for these brushes to wear over time and need replacing. I'm not sure of how many hours of operation is expected before replacement is normally due.}

_{The PDF below provides a complete schematic for two Kress motor models. I'm not sure which one you have. Dissassembly from the top of the unit to reach the carbon brushes should be relatively straight forward, but we recommend that you only proceed if you or one of your schools technicians is confident in being able to perform this without damaging any components. (You will see the carbon brush part numbers listed in the legend with the schematic.)}

_{During dissassembly you should be able to inspect the ability of the brush wear state and relative ability to contact the armateur.}

Kress parts and diagram.pdf

_{Once you have the brushes removed please upload a photograph and supply your comments / findings.}

QUESTION FROM A SCHOOL...

We've got a problem, the motor will not run for the spindle.

It stopped during a job after cutting for 40mins through bolsa wood using a 6mm ball nose cutter. It ran fine then stopped, starting twice for a sec before stopping completely. All other motors and switches are still working.

The relay kicks in and there is an 230V ac output from the board. But the spindle motor is unresponsive.

Thoughts?

1. Check on / off switch on Kress motor has not tripped to the off position.
   
2. Take the Kress motor out of the MRC 40 and plug directly in to 240v mains supply, will the motor power up.
   

I've had the motor out and checked the switch, which is locked in the on position. Then tried a mains straight to it and nothing.

I would say it's only had 35hr run time of which the maximum single cycle has been 45min.

I'm a little cautious of opening up the motor in case it voids the warranty. The spindle is free to move and there is no grating sound which makes me think it might just be a dry solder or lose wire.

Thoughts?

I wasn't cutting a car at the time. It was after an area clearance with 5 mm step down and the feedrate nothing more than it should be able to cut in balsa (it wasn't struggling).

Thank you for your swift reply.

Visit our Gallery to view sample F1 in Schools Secondary Design Portfolios to help with ideas for your teams. Below is a direct link to team BlackBirdX, Indian High School design portfolio from the 2012 World Finals. You will find many more sample portfolios in the gallery.

F1 in Schools - MAKE

Used to convert your F1 in Schools car body CAD model into special code to enable manufacturing on a CNC router. QuickCAM Pro is an advanced, yet simple to use, wizard based CAM package, which is used to create cutter paths for machining 3D parts on a CNC milling machine or CNC Router. See pdf for more detail and contact us f1inschools@ymc.ae for purchasing enquiries.

quickcam-pro.pdf

At Yas Marina Circuit we offer a pathway of STEM and 21st Century Skills programs for students from ages 8 - 19 years of age under the banner of YAS in SCHOOLS. Yas in Schools uses the world of motorsports to provide schools with exciting and relevant team project based classroom learning experiences related to STEM and 21st Century Skills

There are three programs for schools that we run throughout the UAE and Middle East region:

1. Formula Ethara - Paper Race Cars Team Challenge for PRIMARY SCHOOLS

2. F1 in Schools™ - The Formula 1 Technology Challenge (High Schools Grades 7 - 11)

3. Land Rover 4x4 in Schools Technology Challenge for (High Schools Grades 9 - 12)

There are forums within the 'Yas in Schools Torque" website dedicated to supporting each of these programs.

Each season we run National Competitions and a National Final for each program... The champion teams from the F1 in Schools™ and 4x4 in Schools Challenges are invited to represent the UAE at each programs respective World Finals.

F1 IN SCHOOLS REGULATIONS

There are two types of Regulations for each U.A.E. F1 in Schools Competition Category

1. Technical Regulations - details all of the F1 in Schools car design rules
2. Competition Regulations - details and explains all of the competition judging activities, requirements and includes the judging scorecards.

2021/ 22 TECHNICAL REGULATION DOCUMENT DOWNLOADS

The Technical Regulation documents cover the car design rules.

A. Test Driver Challenge Category

For individuals and teams designing cars to enter the Test Driver Challenge category

1. 2021/22 TEST DRIVER TECHNICAL REGULATIONS  - DOWNLOAD >  F1iS-UAE-Test-Driver_Regs-2021-22.pdf

B. Rookie and Professional Categories

For teams entering either the U.A.E. Rookie or Professional categories

1. 2021/22 PROFESSIONAL & ROOKIE TECHNICAL REGULATIONS - DOWNLOAD >  F1iS-UAE-Tech_Regs-2021-22-V1.pdf

2021/22 COMPETITION REGULATION DOCUMENT DOWNLOAD

2. ALL COMPETITON CATEGOIRIES DOWNLOAD > UAE F1iS-2021-22 Competition-Regulations-V1.pdf

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