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STEP 2 - RESEARCH & INVESTIGATE


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STEP 2 - RESEARCH & INVESTIGATE

Its important to conduct some research and investigation before designing any product. The activities below will help you understand the Test Driver Challenge Car design rules and various other facts which are important to know about before you start working on your 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 research and investigate...

    IMPORTANT - The Test Driver Challenge Car Design Rules

    Below 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 Regulations document.

    Download the Test Driver Technical and Competition Regulations  now > F1iS-UAE-Test-Driver_Regs-2021-22.pdf

    Test Driver Design Rules Summary

    • Car Body - The body of the car must consist only of the F1 Model Block material (see below) and be designed around the Car Body Core included with the Test Driver Car Template (see below). No material can be removed from the templates car body core
    • Rear Wing - Test Driver Challenge Cars must include a rear wing that is completely visible from the top view. The rear wing must be designed as part of the F1 model block material. The wing must be designed to comply with the rear wing dimension rules explained in the Technical Regulations document. 
    • Front Wing - The front wing should be designed so it can be manufactured as a separate 3D printed part. The front wing must be designed to comply with the front wing dimension rules explained in the Technical and Regulations document. 
    • Wheels - Test Driver Cars must use the standard F1 in Schools wheels. The position of the wheel 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 not weigh less than 55 grams. Our Fusion 360 tutorial will show you how you can calculate the weight of your car using 3D CAD tools.
    • 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. Learn more about the CNC machining process below
    • Surface Finishing - Unlike Rookie and Professional entries, Test Driver Challenge Cars do not have to be painted. Painting or other surface finishing is not required for Test Driver Challenge cars

    The F1 Model Block - What is it?

    The F1 Model block is the block of raw material used to make F1 in Schools car bodies from. All Test Driver F1 in Schools cars must have their car bodies and rear wings designed to fit within the size of the F1 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 to machine and hand finish.

    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 circular pre-drilled CO2 Canister Chamber hole can also be seen. The right side image shows the F1 Model Block with the top facing up. The dimensions of the F1 Model block are shown on the illustration below:

    image.png

    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 data sheet here > 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 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 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. 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 of the core. The Car Body core includes the pre-machined and drilled tether line slot and CO2 Canister chamber hole.
    2. Wheels - The 'real' 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. The position of the wheel center lines can not be changed and must remain located as set up in the template.
    3. Axle Guides - These parts insert into the car body to provide a very efficient and low friction support for the axles. The hole in the model block which the 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 / attached to the race track via a thin nylon line that runs the length of each track lane. The tether line is passed through the hole in the tether guides to attach the car. You ARE ALLOWED to change the position of where the tether guides are located on the underside of your car.

    For more detail related to the Test Driver Car Template you can download the Technical Drawing here >Test Driver Template Drawing Rev02.pdf

    Example Completed 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 will be attached by using super glue. In terms of the car body, 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 matches with the front wing has been created to improve the joint strength when the wing is glued to the car body

    CNC Manufacturing Limitations to Consider

    All F1 in Schools Car Bodies must be CNC machined from the F1 Model Block. This is 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 its good practice to understand them. To get a better understanding of how 3 axis CNC machining works, visit the page linked below:

    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 - the category you are participating in...

    • Optional Beginner level
    • Simple Come and try / taster style category
    • Car must be designed around the Test Driver Car Template
    • You can enter on your own or work with a maximum of two friends
    • 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

    Now go to STEP 3 - DESIGN YOUR OWN CAR

    BACK TO TEST DRIVER CHALLENGE MAIN MENU

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