Tuesday, August 16, 2011

Maruti Suzuki Supra SAE India 2011 Exclusive Coverage

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The last weekend was not just another weekend for several auto-fanatic engineering students. It was rather a D-Day because the much awaited Maruti Suzuki Supra SAE INDIA kicked off with much excitement and enthusiasm amidst members of SAE, Maruti Suzuki along with over thousand engineering students at Sriperumbudur race track in Chennai. The formula SAE is an under graduate and post graduate student’s race car event organized across the globe. This event has been taking place from over 23 years now but ironically, it could never happen in India due to lack of support from manufacturers. Although, this time, Maruti Suzuki decided to team-up with SUPRASAE to facilitate this wonderful initiative in India. This project comes forward as another initiative by the company towards aligning itself with the overall Automotive Mission Plan (AMP 2016), a dream to make India an International Automotive Hub. Maruti Suzuki’s vision is to enhance its R&D capability that can work collaboratively with Suzuki to design cars for the global markets. Like SUPRA SAEINDIA Formula-1 car prototype designing, Maruti Suzuki has undertaken several initiatives in the recent past to connect with the youth such as holding guest lectures, offering sponsorships and providing engineering infrastructure support through engine, transmission and other vehicle systems.

This competition encourages all the under graduate and post graduate students to independently design, model and fabricate a formula type racing car. Nearly 1,000 students participated in this grand event as a team of 44 from various engineering colleges in India. These 44 teams then designed a formula type racing car that were later put into various tests by the team of judges (including Dr. V. Krishnamurthy, Former CMD of Maruti Udyog) to pick a winner. The winning car will be now displayed at the Asia Pacific Conference at Chennai in October 2011 and Auto Expo 2012 in January at New Delhi. Primarily, the selected criteria by jury to evaluate a car are to look after the performance in terms of acceleration, braking and handling, while affordable maintenance cost and reliability remains equally important.

Selection process commenced since a year ago to select the finalists, in which 85 teams appeared for the screening on June 2010. After Design review and evaluation, only 44 capable teams were able to make it up to finals. On the D-Day, 1st July 2011, not even the screeching hot summer was a reason to let down the thrill and high expectations which were seen in eyes of all participants. Indeed, it was a sheer pleasure to think about this event that too happened for the first time in India, in Chennai. Maruti Suzuki SUPRASAE India event has certainly paved way to emerging Indian motorsports and young hearts to listen that voice under the hood.


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In MMSC:

Noise of roaring engines was at extreme. Those 40 finalists were already ready with their race car setup. Everybody appeared very busy preparing for the final evaluation. The entire setup had nearly 40 sheds one after the other right from number 1 to 40. Looking at the cars will immediately make you think what kind of engines they have used and how much would be the cost involved?

To answer that, all the 40 finalists were provided a brand new 37bhp Maruti 800 engine and gear box. Total of 1.5 crore rupees have been invested by Maruti in order to successfully organize this event. All the remaining designs, modifications, chassis builds and stuffs are done from the students’ side. One should see it to believe it because the entire modification done by the engineering students in incredibly good. Apart from engine, the teams of students have spent approx. Rs. 1.5 to 2.0 Lakhs to get the job done. Where some managed to build the body using ultra-light fibers, the others preferred to stick with traditional metal sheets. Also, in order to mark safety as the first criteria, rules hold fire extinguisher as the foremost point. Each SAE Car carried fire extinguishers and first aid kits along. In fact, fuel containers were also stored inside a wooden casing to prevent havoc.

So many things one can capture when the stuff comes into a picture. Exhausts, filters, bling-bling alloys, cool stickers and mods are the one to talk about. As we marched towards the final contestants one after the other we were able to get a clear view of the eager teams. Students lifted the engine manually kept it on the chassis. That shows how hard they might have worked. You easily look at the rest in the pictures below.


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The Evaluation Process:

The evaluation process took place in several stages. They are as follows:
  • Static Events
  • Engineering Design
  • Dynamic Events
  • Prototype Acceleration
  • Prototype Braking
  • Prototype Handling
  • Prototype Durability
  • Prototype Fuel economy

Noise Test: All the prototypes are first put into noise test. It does a lot for the next level.
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Leakage Test: No leaks and nothing. All the prototypes are lifted to 45 Degrees and kept for 2 minutes to check if there is any leakage. No leaks will get you to the next level.
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After static tests, the dynamic tests begin. The braking test is a 100m run where you press hard to attain the speed. After crossing 100m the brakes must be immediately applied which should lock all the wheels. If it fails, the team fails. As for the handling test, this picture says it all.
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Rally: A normal rally of 22 Kilometers is done as the final part of this grand event's evaluation process. This rally is not about who finishes first, this rally is all about how reliable the prototype is in the long run.
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And The Award Goes To…

After three action packed days, All India Shri Sivaji Memorial Society’s Polytechnic from Pune bagged the first position in the 1st Maruti Suzuki Supra SAE 2011 competition. Team Pegasus from PSG College of Technology,Coimbatore and SPCE Racing of Sardar Patel College from New Delhi bagged the second and thirds position respectively. In a closely fought competition, after a rigorous evaluation 33 of the 38 teams could reach the ‘endurance event on the final day. Veteran automobile experts’ shortlisted 33 teams on parameters like safety, robustness, design, cost, performance and marketability at Madras Motorsports Club, Sriperumbudur.


Finally all hard-work pays off. These students had no limit of joy after they were officially announced as the winners.
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Notes About Maruti SUPRA SAE Event:

  • To encourage participation, the company has provided 44 units of Maruti 800 engines and transmission systems to the teams, for use in the prototypes.
  • Incidentally, it is the same trusted, reliable and fuel efficient F8 engine which powers the best seller M-800. It is the smallest engine in MSIL stable responsive and peppy engine is best suited for a racing prototype. The engine delivers superb power and returns high fuel efficiency even on a racing prototype.
  • 4 Maruti Suzuki engineers are part of the technical inspection team of the SUPRA SAEINDIA judges’ panel. In all there are 30 inspectors (SAE, Maruti Suzuki and other automobile companies).
  • In addition, 4 Maruti Suzuki engineers are part of the Cost evaluation panel.
  • Maruti Suzuki engineers on regular intervals have visited and mentored the teams from ITM Gurgaon, Manav Rachna International University, PEC Chandigarh and UPES (University of Petroleum and Energy Studies) from Dehradun.
  • As a market leader, MSIL has to constantly update its products and services in tune with the changing needs and aspirations of the younger consumer. Just in the past five years the average age of its car buyers has seen a sharp drop of 10 years. For these younger customers MSIL makes youthful and energetic cars, while not compromising on the value of fuel efficiency. These initiatives with SAEINDIA helps to reinforce Maruti Suzuki’s strong connect with the youth.
  • More than 50% of India’s population is 25 years of age and are the future customers. With such initiatives Maruti Suzuki is building its brand and aims to capture a mind share of these future customers.

Note of Thanks:

Maruti Suzuki SAEINDIA 2011 will turn out to be a history in the Indian automotive industry. I really enjoyed attending this special event and would like to thank The Automotive India for wholeheartedly offering me this great opportunity.


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Most of the teams installed K&N Airfilters in their hand-made cars.
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To prevent the heat accumulated from exhaust pipe, the teams wrapped it up with metal sheets, ropes and piece of clothes.
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Some students used metal sheets to make the entire body that being quiet cheap. Some students said they used fiber material to reduce the weight to a bit more extent. Looking at the radiator makes me mad about the way these people think and design. Hope this is what has been evaluated all these months for them to come up to this level.
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Even though cost factor is a main thing in consideration, many people preferred alloys rather than steel rims. Some students said that gives their prototype a cool formula car look.
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Tuesday, April 26, 2011

Race Dynamics Contact Info

Contact Info:

Race Dynamics India Pvt Ltd.

97/A Chikayellappa Industrial Layout, Jakkasandra,
Koramangala 1st Block,
Bangalore 560034.
INDIA.

Tele : +91  80 40929292, 40929291

General enquiry : info@racedynamics.in This e-mail address is being protected from spambots. You need JavaScript enabled to view it
Business enquiry : pavan@racedynamics.in This e-mail address is being protected from spambots. You need JavaScript enabled to view it
Mobile : +91 984599 9299

Technical & Product enquiry : sanjay@racedynamics.in This e-mail address is being protected from spambots. You need JavaScript enabled to view it
Mobile : +91 994550 2608

Race Dynamics Dealers

Dealers:


FRK Racing.

No. 6, Dyavasandra Industrial Area, Whitefield road, Bangalore - 560048.
Contact person - Fazal Khan
Telephone number - 091 080 82511093


N1 RACING EQUIPMENTS.
Shop No. 4, Prabha vinayak society, opp. Maratha udyogh bhavan,
New Prabhadevi road, Prabhadevi, Mumbai - 400025.
Contact person – Anant , Anupam
Telephone number - 091 022 24364197.

Pro Auto Mods.
No. C 106/107, sector II, Noida - 201301,
Contact person - Harsh and Samarth
Telephone number - 091 9971404274

Racing Heights.
No. 2-4-96/97,  Ramagopalpet,
Secundrabad, Andhra Pradesh.
Contact person - Harshit, Vishal or Sandeep.
Telephone number - 091 040 27811434.

Race Dynamics Products

Engine  Management  System:










Engine Management System EMS / ECU determines the quantity of fuel, ignition timing and other parameters by monitoring the engine through sensors, and reading values from multidimensional maps. The Race Dynamics ECU has the tag of being one of the most , reliable, versatile and cost effective ones around the world. With its success in the Indian Motorsports it has also proven to comprehensively enhance the performance of the vehicle and provide the customer with the best setup to run basic to extreme modifications. The Race Dynamics ECU has received tremendous encouragement and interest from the racing fraternity ever since introduction in 2004. Subsequently due to the continuous development program undertaken at Race Dynamics we have been introducing newer and advanced products with greater flexibility.


The RD ECU has been developed and prototyped completely in-house, from its facility located in Bangalore, India. We undertake extensive testing of the hardware and firmware using state of the art automotive and electronic validating systems before launching the products in the market. Extreme emphasis on Quality has led to development of systems that deliver when put through the toughest of working environments. We use advanced and latest microprocessor technology, which gives the RD ECU unmatched real time accuracy. The unique patented architecture provides the basic framework for development of new products and easy troubleshooting.

PETROL/GASOLINE:



Race Dynamics has vast experience in developing standalone, piggyback and auxiliary engine control and management units based on 32, 16 and 8 bit processor platforms. Our range spans from low cost single cylinder engine control to full-fledged race specific 12 cylinder sequential control. Our systems offer the best of performance at unbeatable prices. A host of plug-in modules like data loggers and visual display units are available as accessories for our ECU range.





-RD0901:






Our new series of ECUs, the RD0901 integrated the latest technologies in semiconductors and control strategies with  techniques and specifications acquired by our vast experience with RD0601. High on capability, incorporating a 1 to 12 cylinder  sequential complete engine control with many motorsport-centric  features such as flat shift, launch control, self-calibrating,  anti-lag, etc. setting standards in refinement, reliability, versatility and cost.




RD0601:






The RD0601 series of engine management systems are designed to be simple to install, tune and use. A highly optimized and robust architecture allows it to precisely control all engine parameters supported with a very high degree of compatibility with most original-equipment engine, sensors, actuators and other systems. This system has been extensively used all over and is vouched for by the entire Indian Racing fraternity. The hugely successful ECU that set the ball rolling. Tried, tested and improvised in the harshest of conditions from the deserts of Rajasthan to the ice-cold peaks of the Himalayas. A very versatile programmable system that set standards for things to come.


Features:


•  Standard one’s support 4 injectors and 4 cylinder ignition modules, can be upgraded to 8 injectors and 6 cylinder ignition  systems.
• Injection sequence programmable to fully sequential, semi-sequential or batched mode. • Supports up to 10000 RPM, upgradable  to 15000
• Switchable between original ECU mode and Race Dynamics performance ECU mode anytime on the move via dashboard mounted toggle  switch.
• Correction maps for fuel and ignition based on:
-Air temperature
-Engine temperature
-Battery voltage
-Altitude
-Lambda sensor feedback
-Throttle movement.
• Battery voltage based ignition dwell time corrections.
• 20 X 16 tuning tables for fuel and ignition.
• Programmable Rev Limit
• Optional programmable Launch control
• VTEC / MIVEC control.
• Programmable Idle control
• Idle correction based on:
-Air temperature.
-Engine temperature.
-Cranking conditions.
-Throttle acceleration / deceleration.
-Air-conditioning
-Altitude.
• Acceleration enrichment correction based on:
-Rate of Throttle variation of  RPM’s
-Load Points
• Lockable ECU Maps.



Data Logging System



XDL-500:






Data-Logging systems with GPS integration that can record up to 20 analog signals and 10-bit digital signals at 200Hz to on-board flash, accelerometers and memory cards. A compact and easy-to-use package.




Driver Analysis System:



XDA-500:






An extended version, with a focus on enhancing driver techniques. This system can capture, derive, evaluate and store driver-centric information and indicate probable corrective actions that can be adopted to enhance driving performance.




Dash Displays:



XDIS-500






These graphic display modules are compatible with all Race Dynamics gasoline ECUs, the systems are designed to display all real-time data with user programmable shift-lights, RPM sensitivity and vehicle calibrations.
Race Dynamics through continuous and sustained  research and development is able to provide race car drivers and racing teams with complete engine management, data acquisition and display solutions. Call us to know more.
The VDL500 display system replaces all your analogue gauges with one single digital display screen, sourcing all its information directly from the RD ECU via a simple serial cable. It is the perfect data centre for all race enthusiasts. The VDL500 shows various essential engine parameters like RPM, CAM, CKP, MAP, TPS, IPW, IGN, AFR, etc... The primary features include selectable shift light RPM limit including RPM limits for individual LEDs,  RPM bar sensitivity, various sensor calibration, custom information to be displayed at the bottom( owner name, race team name ), adjustable contrast and brightness, etc…

Tuesday, March 29, 2011

McLaren Electronics

 (Basic Architecture of the MaLaren Electronics solution created and deployed using the Microsoft Application Platform)


(SQL Server Data displayed in Office Excel) 



Understanding the ECU (Engine Control Unit)

    First things first, to understand the ECU, you need to know why it was developed. Computers have been used for many years to develop F1 cars and to gather data from them to transmit back to the garages during a race. The FIA invited manufacturers of automotive electronics in 2006 to come up with a single design of the ECU for all teams across the whole of Formula One to use. The chosen design by McLaren Electronics and Microsoft, with its SQL Server 2008 database, supplied all competing F1 teams in both 2008 and 2009, and will continue to do so for 2010. The contract supplies all teams with the ECU, the ATLAS (Advanced Telemetry Linked Analysis System) Server and the ATLAS Client.
The ECU is the onboard device that gathers the data from the car’s engine, suspension system, transmission, and frame components through many sensors, encrypting it to transmit to the ATLAS Server. This then decodes the data and sends it to the ATLAS Client, which allows support teams to access the real time data on their laptops in the back of their garages. The teams can then monitor the performance of the car and inform the driver of any issues. For the top teams, such as McLaren and Ferrari, there can be several engineers constantly analysing the data which is generated by the ECU, with some of them focusing on the transmission feeds, and others on the telemetry from the engine and suspension.
Ok, so this all seems rather confusing, and unless you are an engineer, a simple fan of the sport may not feel like they need to know all this. But actually, when you peel away the in depth analysis and explanations into how it all works, it is incredibly fascinating.
So… That’s what McLaren Electronics and Microsoft provides for the current Formula One teams, and now we also know that it’s because the FIA asked for it, but why, and what does it achieve that makes it so important?
The FIA originally invited manufacturers to design a single ECU, for that simple reason: it would be the sole ECU. This ultimately meant that there would be a level playing field between all the teams, and it would also be a way to control costs within the sport. Apart from that, the ECU maintains safety, and these were the key reasons why the FIA challenged a design. It was McLaren Electronics that ultimately saw the potential of the FILESTREAM feature of the Microsoft SQL Server 2008 database software and after testing its efficiency through a proof of concept test, McLaren Electronics were able to put it into production as their solution to a single ECU that would provide a database that could handle and store a high volume of data for quick and easy access. As teams generate a high volume of data from wind tunnels, simulations, and previous races and practice and test sessions, the SQL Server 2008, is able to gain the same performance from historical data such as the above examples, as well as that of real time data during the race itself, something that previous databases were unable to achieve.
So what are the benefits? One benefit of the ECU is that it saves the teams from having to conduct additional tests to gather data, as if it is already on the database, whether it is from earlier in the day, from the same circuit the year before, or from simulations, they can access it and analyse it, without having to repeat a test, and this ultimately saves money. Immediate access to historical data is another benefit. This enables the teams to access data from previous years at a specific track and from simulations in order to help them with their set up for the car over that particular weekend. The immediate access of data also enables teams to determine what may need to be changed on the car when a driver pits if he has been complaining that the car is not performing as it should be.
During a race, one to two gigabytes of data is gathered on just one car, and over the course of a year, with free practice and qualifying included, up to two to three terabytes is eventually gathered. Therefore the solution provided by McLaren Electronics is vital in terms of speed in accessing the data, and it’s also vital in terms of accurate storage. In other words, making sure no data gets lost is crucial to a Formula One team, as before the SQL Server 2008, lost data would have to have been retrieved from the car after the race: lost data that could have ultimately been needed during the race. Teams need to be able to make immediate decisions during the race, after all a lot can happen in a lap, and waiting to make the decision could be crucial to the outcome of the final standings. The endless amounts of data gathered during the race itself, through previous races at the same track, and through simulations, all being accessed immediately upon request, all helps towards the engineers being able to make swift decisions.
There is also another key benefit: the ability to work offline. The SQL Server 2008 Express enables team members to work alone away from the central database. This is important when one single engineer is working alone, perhaps with a driver, on a test rig, or while testing new equipment with a supplier. While out alone an engineer will still need to be able to access the database just like he would as part of the trackside team, and the benefit of the SQL Server 2008 Express, which can be downloaded for free, means he can access the full database wherever he is. This benefit alone shows how advanced this piece of technology is, and altogether, the solution provided by McLaren Electronics, enables all Formula One teams to constantly develop their cars, constantly improving their performance

Toyota on Formula One electronics

To even a casual observer, it is clear a Formula One car would be largely useless without tyres, a chassis or an engine - but what about electronics? You may not think you see electronics at work when the drivers hit the track, but without such technical wizardry, the cars would not even leave the garage.

"If you removed the electronics from the car, it would not even start," explains Ludwig Zeller, Toyota’s senior manager electric and electronic. "It would not run; there would be no action. You could look at the car; you could push the car - but nothing else."

An electronic control unit (ECU) monitors and manages all aspects of the Toyota TF108's electrical systems and it is this device which is fundamental to simply starting the engine, let alone getting the best possible performance from it lap after lap. "The ECU in the car is like the nerve centre for your body," explains Zeller. "Basically it is controlling all of the functions."

Electronics in a Formula One car can be roughly divided into two categories; those that control aspects of the car, and those that monitor the car's behaviour.

There are around 250 sensors on the TF108, giving feedback on approximately 1,300 different parameters. The data from these sensors can be studied back in the garage and it is used to advise the driver what settings to change on his car; an action he can complete whilst driving flat-out.

Like a road car, the TF108 draws its electricity from an alternator and stores it in a battery under the driver's seat, although these specialised alternators are significantly smaller and lighter, while the battery is designed to be resistant to the vibrations which come with driving at over 300km/h.

From the ultra high-tech seamless shift, semi-automatic gearbox and settings on the 2.4litre V8 engine right through to the driver's drinks bottle, many aspects of the TF108 are controlled by electronics on the steering wheel.

"The steering wheel is the most important interface for the driver," Zeller says. "From the steering wheel he can change almost everything. If there is a change in conditions, for example if the weather changes from dry to wet, he has to adapt all his settings for the brakes, for the engine, for the differential, for the gearshift. He really can control the car."

Formula One rules place strict limits on what can be done electronically, so it is not possible to alter any aspect of the car's behaviour remotely from the pit garage. However, using dials and switches on his steering wheel, a driver can still make significant adjustments himself. One major aspect the driver can influence from his steering wheel is the fuel economy of his engine.

While it may seem that a Formula One car is flat-out at all times, there are times when reduced fuel consumption will not negatively affect overall performance but could provide a strategic advantage, when stuck behind a slower rival or behind a safety car for example.

Toyota’s senior general manager engine Luca Marmorini reveals: "There are two switches for engine control on the steering wheel. In particular one allows the driver to change the engine map, allowing him to choose one of several options - each one corresponds to a different fuelling of the engine. Typically number one is the performance fuelling map, and he has then four other possible maps where he can save fuel during the lap. Sometimes it's very important to save fuel for delaying a pit stop, for example."

With such a vital role played by electronics, these systems - like everything else on the car - must be tested thoroughly to get the best possible performance, and for this a specialised testing unit, called a 'hardware in the loop' (HIL) system, has been developed.

This unit contains all the TF108's electronic systems and allows engineers to run through laps of a circuit in specific situations to ensure maximum performance; without needing a TF108 or its engine. Zeller adds: "The HIL simulation is basically our car. We can simulate everything, we can play back track data and we can simulate problems for our car."

Formula One racing's electronic rules became stricter at the start of 2008 when a standard ECU was introduced, meaning all teams must use the same part with no modifications, greatly reducing the freedom given to the electronic experts at Toyota. As a consequence, so-called driver aids such as traction control, engine braking and launch control have been eliminated.

But that does not mean Toyota’s electronics specialists in Cologne have an easy life this season, far from it. The HIL system has been particularly valuable in understanding the standard ECU and streamlining how it is used within the TF108.

Marmorini says: "You never stop learning how an ECU works because each time you need to check the reaction of your driver, of your car, and to tune all your parameters to do the best job. So I would say we are definitely still learning about it. The team did an excellent job to adapt and since the beginning of the year we have been well prepared, even if the learning process is continuous."

The removal of driver aids and the introduction of a standard ECU may have taken Formula One electronics out of the spotlight, but those rule changes have not diminished the fundamental importance of electronics to the performance of the cars. Whenever the cars line up on the grid, remember, it is not just the atmosphere which is electric.