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STEP 2 - RESEARCH & INVESTIGATE


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STEP 2 - RESEARCH & INVESTIGATE

Its important to research and investigate the various Test Driver Challenge Car design requirements along with understanding the manufacturing processes before you start working on your own car design. It will also be beneficial to have reviewed previous F1 in Schools car designs to help provide you with inspiration. This section will help guide you through the important things to investigate and research...

Test Driver Challenge - How it fits in the UAE Competition Matrix

There are 3 categories that students can choose to enter in the U.A.E. F1 in Schools National Competition

1. Test Driver Challenge

  • Optional Beginner level
  • Simple Come and try / taster style category
  • Car must be designed around the Test Driver Car Template
  • No need to form a team
  • Competition prizes and awards, but there is no World Finals qualification

2. Rookie Category

  • Novice level
  • Must be first time Rookie entrant and 15 years of age or under
  • Must enter as a team of 3-6 students
  • Must use F1 in Schools standard wheel system plus other car design restrictions
  • National Final winning team qualifies for the World Finals

3. Professional Category

  • As the name suggests, this is the F1 in Schools Pro level
  • For over 15 years old or previous Rookie or Pro entrants
  • Must enter as a team of 3-6 students
  • Greater freedom with car design and complexity
  • National Final winning team qualifies for the World Finals

The F1 Model Block - What is it?

All F1 in Schools cars must have their car bodies CNC machined and manufactured from the official F1 Model block. This effectively means that all of the car body, and optionally the wings if to be made from Model Block material, must be designed to fit within the physical dimensions of the model block. You can easily check if your design fits within the block using Fusion 360. The Model Block is made from a polyurethane material that is very light and easy top machine with good surface finishing.

F1 Model Block.PNG

The above illustration shows the F1 Model Block. The left side image is with the bottom surface including pre-machined tether line slot facing up. The pre-drilled CO2 Canister Chamber hole can also be seen. The right side image shows the F1 Model Block right way up and again the CO2 Canister Chamber hole on the rear / back end of the block. The specific dimensions of the F1 Model block are shown on the illustration below:

image.png

So looking at the above dimensions it can be seen that no car body can be wider than 65mm or taller than 50mm. Whilst the model block is 223mm long, the maximum length of an F1 in Schools car is actually limited to 210mm.

To learn more about the technical specification and physical properties of the model block material, download the - F1 Model Block Technical Data Sheet 29.6.15.pdf

 

The Test Driver Car Design Template

All Test Driver Challenge cars MUST be designed around the official Test Driver Car Template. The template is provided by Yas in Schools and can be downloaded as a Fusion 360 assembly file. The template download link can be found at STEP 3 - DESIGN YOUR OWN CAR. The template assembly also includes the F1 Model block as a separate component so that you can check your design fits within the block dimensions.

Review the below diagram and related information to learn more about how the Test Driver Car Template is used...

image.png

  1. Car Body Core - Shown in green above. When designing your own car, you can only add material to this body core shape. NO MATERIAL CAN BE REMOVED FROM THE BODY CORE SHAPE. Typically designers would add material to the sides and top surface to form a more aerodynamic car body design. Note that the bottom surface of this Car body core is aligned to the bottom surface of the F1 Model block, so therefore, you can not add material to the bottom surface. The Car Body core includes the pre-machined and drilled tether line slot and CO2 Canister chamber hole.
  2. Wheels - The official F1 in Schools wheels are supplied by Yas in Schools. All Test Driver Challenge Cars MUST USE these wheels unmodified, you are not allowed to design and manufacture your own wheels.
  3. Axle Guides - These parts insert into the car body to provide a very efficient and low friction support for the axles. The hole which these axle guides insert into is drilled during the CNC machining process. Designers are allowed to make the body wider where the axle guides insert, but you are NOT ALLOWED to change their position by moving forward, rearward or in the vertical direction
  4. Axles - The standard axles are provided along with the wheels and axle guide parts. The axles in the Test Driver Car Template are modeled at the maximum full standard length. You ARE ALLOWED to change the length of the axles ie. make them shorter so your wheel track becomes narrower if required.
  5. Tether Guides -  The Test Driver Car Template assembly model includes two standard tether line guides. F1 in Schools car are tethered to the race track via a thin nylon line that runs the length of each track lane. The tether line is passed through the tether guides to attach the car. You ARE ALLOWED to change the position of where the tether guides are located.

For more technical detail related to the Test Driver Car Template, download the Technical Drawing here - Test Driver Car Template Technical Drawing.pdf

 

Test Driver Challenge Car Design Rules

Following is a BASIC SUMMARY of the design rules for the Test Driver Challenge category. The detailed design rules are explained in the Test Driver Challenge Technical and Competition Regulations document.

Download the Test Driver Technical and Competition Regulations here:

 

Test Driver Design Rules Summary

  • Car Body - The body of the car must consist only of the model block material and be designed around the Car Body Core included with the Test Driver Car Template.
  • Rear Wing - Test Driver Challenge Cars must include a rear wing that is completely visible from the top view. The rear wing must be manufactured from the F1 model block material. The rear wing must be designed to comply with the various minimum dimensions mentioned in the Technical and Competition Regulations. 
  • CNC Machining Restrictions - Test Driver Challenge car body & rear wing will only be manufactured using CNC machining of both the left and right side of the car. This means that all surfaces of the car body and rear wing must be visible in the left and right side views.
  • Front Wing - The front wing should be manufactured as a separate 3D printed part. The front wing must be designed to comply with the various minimum dimensions mentioned in the Technical and Competition Regulations. 
  • Wheels - Test Driver Cars must use the standard F1 in Schools wheels. The vertical and horizontal position of the wheels must remain unchanged from their position set in the Test Driver Car Template. The wheel 'track' can optionally be made narrower. For example: the Test Driver Car Template includes the axles at their maximum length. Designers may choose to shorten the axle length so that the wheels sit closer to the car body they designed.
  • Car Weight - Test Driver Challenge Cars when fully assembled and submitted for racing, must weigh a minimum of 55 grams. You can learn how to analyse the weight of your design in Step 3 - Design Your Own Car
  • Surface Finishing - Unlike Rookie and Professional entries, Test Driver Challenge Cars do not have to be painted. Painting or other surface finishing is optional for Test Driver Challenge Cars

Example Test Driver Challenge Car Design

Exploded Iso Annotated.PNG

In the above example of a typical test driver challenge car you can see that and front wing has been designed for separate 3D printing and material has been added to the car body core in the following areas:

  • Rear Wing - added to each side of the Co2 canister chamber hole area
  • Sides - material added as side pod features to improve aerodynamics between front and rear wheels
  • Top - material added forward of the Co2 canister chamber hole to improve aerodynamics
  • Front Wing joint - a lip and step feature that mates with the front wing has been created to improve the joint strength when the wing is glued to the car body
  • Front wing - designed as a separate part that will be 3D printed

CNC Manufacturing Limitations to Consider

All F1 in Schools Car Bodies must be CNC machined from the F1 Model Block. This usually done using a 3 axis CNC Router. There are some limitations to consider in terms of how certain shapes can and cannot be machined using a 3 axis CNC machine. These limitations wont impact your creativity too much, but you do need to understand them. To get a better understanding of how 3 axis CNC machining works, visit the page linked below:

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