What is Formula SAE Electric? (Fast, Fun, Future)

Summary

This video explores the exciting world of Formula SAE Electric, showcasing the innovative designs and rigorous challenges faced by student teams in this prestigious competition. Teams from around the world gather to test their electric race cars, which are built under strict regulations and rules. The competition spans several events, including acceleration, autocross, and endurance, with an emphasis on simplicity and efficiency in car design. The video highlights various team approaches, from single-motor rear-wheel setups to advanced quad-motor systems, and celebrates the dedication and ingenuity of the next generation of engineers, culminating in the victory of the Rochester Institute of Technology.

Takeaways

• 😀 SAE (Society of Automotive Engineers) hosts student competitions like Formula SAE and Baja SAE to help develop engineering talent and improve the automotive industry.
• 😀 Formula SAE Electric is one of the most exciting student racing events, attracting teams from around the world, with a focus on electric vehicle technology and zero-emission racing.
• 😀 Teams compete in multiple events, including acceleration, autocross, endurance, and design presentations, requiring significant planning and innovation.
• 😀 Newer teams are advised to focus on a simple, functional design, typically starting with a tubular space frame before upgrading to a carbon fiber monocoque as experience grows.
• 😀 Power regulations limit the amount of energy that can be sent to the motors, and teams must choose the most effective motor configuration for their design, like rear-wheel drive with a single motor or all-wheel drive with hub motors.
• 😀 Axial flux motors, often used by teams, are powerful for their size and are different from the more common longitudinal flux motors seen in commercial EVs.
• 😀 Battery capacity is typically between 5 and 6 kWh, with designs needing to balance energy needs for endurance events while keeping weight and size manageable.
• 😀 Regenerative braking (regen) is a feature more common in advanced teams with multiple motors but is not recommended for beginners.
• 😀 Industry sponsors, including major automakers like Ford and GM, and aerospace companies like SpaceX, actively participate in these events to recruit top engineering talent.
• 😀 The design and safety inspections for each car are critical, with teams needing to pass mechanical, electrical, and driver egress tests before competing, marking a huge achievement in the process.
• 😀 At the end of the event, awards are given to the top performers, with teams like the Rochester Institute of Technology being recognized for their excellent performance.

Q & A

What is the purpose of the Society of Automotive Engineers (SAE) in the automotive industry?

The SAE helps the automotive industry by creating specifications for components like charging couplers (e.g., J1772, J3400), and also hosts student competitions like Baja SAE and Formula SAE, which encourage innovation and practical learning.

When did Formula SAE begin and how has it evolved?

Formula SAE officially started in 1981 and has evolved to offer three different racing series: the original gasoline-powered series, a hybrid racing series, and the electric Formula SAE series.

What makes the Formula SAE Electric event unique?

Formula SAE Electric is unique because it focuses on zero-tailpipe-emission electric vehicles. It also features a highly competitive event with strict rules and requirements that teams must navigate in designing their race cars.

Why is it important for teams to 'keep it simple' in their designs?

Newer teams are encouraged to focus on creating a 'minimum viable product' rather than over-complicating their design. The goal is to gain experience and gradually improve through each event, rather than attempting to win in the first year.

What is the main difference between a tubular space frame and a carbon fiber monocoque design?

A tubular space frame is typically used by newer teams due to its simpler design, while a carbon fiber monocoque offers a lighter, more advanced design that is often used by teams with more experience.

How do the power regulations affect the design choices in Formula SAE Electric?

Power regulations limit the amount of electrical energy that can be sent to the motors, ensuring fair competition. Teams typically use a single motor setup for rear-wheel drive or, in some cases, a quad motor setup for all-wheel drive.

What is the advantage of using an axial flux motor in Formula SAE Electric cars?

Axial flux motors, often referred to as 'pancake motors,' are compact and powerful for their size, offering high performance in a small package. This design is used by companies like McLaren in their plug-in hybrids.

What is the role of the 'accumulator' in Formula SAE Electric cars?

The accumulator refers to the battery system in the car, which must include battery management, cooling, and an enclosure for safety. The size of the battery is primarily determined by the endurance event's requirements.

What is the purpose of the driver egress requirement in the Formula SAE inspections?

The driver egress requirement ensures that the driver can exit the car in under 5 seconds in the event of an emergency. It's a crucial safety measure that every team must pass to be eligible to race.

How do the acceleration and autocross events test a Formula SAE Electric car's performance?

The acceleration event tests how quickly the car can go from a standstill to top speed, while the autocross event involves timed individual laps on a closed course. Both events assess the car's power delivery, handling, and overall performance in a competitive environment.