University of Aberdeen and Dundee scoop
awards at Europe's biggest student motorsport event  

Budding engineers in the University of Aberdeen and University of Dundee teams are celebrating after picking up the Shell Award for the Most Fuel Efficient Car and E.ON UK Safety Award respectively after competing at the Institution of Mechanical Engineers' Formula Student (FS) 2010 event.  The Scottish teams were awarded the prizes for the cars they designed and built from scratch, putting them in good stead when applying for jobs. 

 FS is Europe's biggest student motorsport event and was attended by more than 2,500 students from around 30 countries between 15-18 July at Silverstone.  The University of Aberdeen's car (pictured below) was given the award for the second year running, while the University of Dundee collected its award for the best crash avoidance or impact mitigation system. 
 
All cars underwent a number of dynamic and static tests at the four-day event.  The fuel efficiency of the cars was measured during the 22km endurance event which focused on both speed and fuel economy. Fuel consumption was calculated accurately by recording how much refuelling was required after the lengthy course.
  
Daniel Ahrens, Project Manager of the Aberdeen team, said: "With fuel efficiency fast becoming an important selling point of vehicles, we carefully designed our car to maximise its power.  After considering engine type and size, the team opted for a carburettor 450cc engine, while concentrating on keeping the car's weight down to 210kg.  We were really pleased as we managed to reduce the 2010 car's weight by an impressive 45kg from the University's 2009 car."  Dan is now in the USA enjoying a well deserved break before coming back to the UK.  

The team ran on the least amount of fuel out of all the cars that completed the endurance test, won by TU Munich of Germany. The endurance test is won by the fastest car completing the event, but Aberdeen's car finished with just half the fuel used by TU Munich. The UK team consumed only 1.793 litres of petrol to complete the 22km course which was also nearly a third less than the second most fuel efficient car. It also clocked up a cool 35mpg.     

Nick Brown, Marketing Manager, Graduate Recruitment, UK & Ireland at Shell International said: "Increasing the efficiency of energy use in the 21^st Century will play a significant role in meeting societies growing energy needs in an economically, environmentally and socially responsible manner."

"Shell is proud to support an event that encourages young engineers to develop qualities and skills vital to meeting this challenge, such as creativity, collaboration and resilience. These are qualities at the heart of Shell's graduate recruitment process and why we gain such value in our partnership with FS," added Brown.

The University of Dundee impressed judges by creating a 'novel design' using aluminium honeycomb for energy absorption.  Its manual tests of the effects of an impact won the team the safety award for the first year.   

All teams were required to present crash test results looking at the energy absorbed and how much the vehicle was deformed by an impact.  This was done either via manual testing or virtually using computer aided systems.    
 
FS 2010 also encouraged students to use sustainable and low impact materials and processes.  This year the University of Central Lancashire team used balsalt fibre, derived from volcanic rock, throughout the manufacture of their car due to the sustainability of the material in comparison to other composites such as carbon.  The University of Warwick team made an eco-seat for its car made from coconut husk, bamboo strand fabric and natural forming latex.           

Formula Student is run by the Institution of Mechanical Engineers and is Europe's biggest student motorsport event. It is in its 13th year and is open to university teams around the world. Its Patron is Ross Brawn, Team Principal, MERCEDES GP PETRONAS Formula One Team. FS usually forms part of the students' academic studies, and culminates in a competition where teams from all over the world come together to race and compete against each other. Restrictions are placed on the car frame and engine so the students' knowledge, creativity, and imagination are tested.

The IMechE Formula Student event uses the same rules as the Formula SAE series (with some minor changes) and this means student teams can enter their cars in the Formula SAE events, including those in the US, Australia and Germany. Visit www.formulastudent.com for more information.

The following partners supported FS 2010: Airbus in the UK, Autodesk, Cenex, E.ON UK, The MathWorks, Mercedes-Benz HighPerformanceEngines, National Instruments and Shell. 

For further information,  view websites: www.mxawards.org www.formulastudent.com and www.imeche.org

Powertrain developments cut fuel consumption and CO2 by 10 per cent

A brand new concept vehicle, the CO2ncept-10%, is the result of a powertrain friction reduction development project between The Schaeffler Group and Porsche.

The development project involved the use of novel, optimised engine components, which when combined, achieve an overall 10 per cent reduction in fuel consumption and CO2 emissions.
 
CO2ncept-10% is a CO2 demonstration vehicle based on a Porsche Cayenne with a V8 engine. In addition to tried and tested, optimised engine components, the vehicle is also equipped with several new powertrain and chassis components supplied by Schaeffler. These components help to significantly reduce the car's fuel consumption compared to existing production models.

In the joint development project, Schaeffler was responsible for the design and testing of components, while Porsche managed system coordination and validation for the entire vehicle.
 
The reductions in fuel consumption and CO2 emissions were verified theoretically through complex simulation calculations at Schaeffler, and practically via extensive bench testing at Porsche. The calculation standard used was the Standardised New European Driving Cycle (NEDC).
 
The engine accounts for 5.8% of the optimised fuel consumption and associated CO2 emissions. Most of this (4.1%) comes from modification of the VarioCam Plus valve control system, by replacing hydraulic cam timers with electromechanical equivalents, as well as the use of optimised switching tappets on the intake side. An extra 1.7% reduction can be achieved through minimising frictional losses, by cross-system optimisation of valve train, belt drive and chain drive components.
 
Schaeffler's double-row angular contact ball bearings that are installed in the front and rear axle differentials generated a further 1.1% in fuel savings. These TwinTandem bearings, which replaced the existing tapered roller bearings, reduce frictional resistance significantly when compared to conventional transmission systems. This reduction amounts to 35% in the front axle transmission and 42% in the rear axle transmission.
 
Fuel consumption can also be reduced via the chassis. By replacing the hydraulic roll stabiliser with an electromechanically controlled equivalent and using smooth running wheel bearings, a 3.2% reduction in fuel consumption is achieved. "As is the case with cam timers, electrically-operated components make such an important contribution because they only require energy when they are operating," explained Dr. Robert Plank, Manager of Corporate Engineering for the Schaeffler Group. "In hydraulically-controlled systems, the pumps need to maintain pressure at all times, resulting in much higher energy requirements."
 
"This project is a good example of successful cooperation between an automobile manufacturer and supplier. This cooperation reduces development times, avoids extensive redundancies and makes an important contribution to competitive ability," commented Dr. Plank. "To us, the CO2ncept-10% is clear proof of the continuing optimisation potential that is also closely related to volume production. This is not the end of the line though. CO2ncept-10% is the sum of its components, and these components are just a few from Schaeffler's portfolio that enable similar levels of energy efficiency optimisation to be reached for vehicles from other industry sectors."

For further information on Schaeffler's range of automotive engine components, view website: www.schaeffler.co.uk   Refer to page 46

Fiat selects Stanyl Diablo for charge air duct resonator

As a tribute to 100 years of Alfa Romeo, Fiat Automobiles Group has launched a 2010 Alfa Romeo Giulietta. In the 1950s, the Alfa Romeo Giulietta caught the imagination of car enthusiasts throughout the world for the first time. Now, the Alfa Romeo Style Centre has produced a new Giulietta, using sophisticated material solutions and manufacturing technologies in line with the needs of today.

Automotive Tier1 supplier Hutchinson, selected Stanyl® Diablo OCD2100 for the Turbo charge air duct resonator on the Alfa Giulietta 1.6 L Multijet 105 Hp Euro 5 Turbo Diesel engine. The resonator acts to dampen noise in the charge air system.

According to Maurizio Servetti, responsible for Group Materials Labs Plastic unit of Fiat Group, this is one of the first Turbo resonator of its kind made in plastic for a FIAT Group Automobiles engine platform: "At Fiat we are committed to increasing the level of acoustic comfort , while at the same time protecting the environment by decreasing noise and increasing fuel economy. We found that thanks to its unique long time high heat ageing performance, Stanyl Diablo OCD2100 was the only material we could approve for temperatures above 200°C for 3000 hours."

Stanyl Diablo OCD2100 is the first grade of a next generation family of Stanyl PA46 grades that offer a revolutionary improvement in long term thermal stability. This technology, developed and patented by DSM, extends the functional life of components well beyond the limits of other high temperature polyamides. By limiting thermal oxidative breakdown, Stanyl Diablo withstands more than 5,000 hours temperature exposure up to 220°C with less than 15% loss in mechanical properties.

Hutchinson technical team says: "Thanks to the combination of superior mechanical and fatigue properties at very high temperatures and its welding retention, Stanyl Diablo OCD 2100 was one of few engineering plastic that could meet the Fiat technical requirements while at the same time offering a cost advantage compared to current metal solutions."

Ton Vet , Application Development Manager for DSM Engineering Plastics adds: "Stanyl Diablo OCD2100 outperforms current high heat resins on high temperature stability, but also on weldability, weld strength and the weld's long term heat stability. Part design and function can be reached more easily and, more importantly, under-the-bonnet part reliability can be guaranteed for the lifetime required."

DSM's Stanyl materials are easy to process. During injection molding, tool temperatures of 80°C and melt temperatures around 300°C are normally used. Short cycle

times can be achieved to reduce system costs.

For further information, e-mail: sandra.coolen@dsm.com  Refer to page 78