Formula Manipal
| Full name | Formula Manipal |
|---|---|
| Base |
Manipal, India 13°21′.95″N 74°47′35.9″E / 13.3502639°N 74.793306°ECoordinates: 13°21′.95″N 74°47′35.9″E / 13.3502639°N 74.793306°E |
| Faculty Advisor |
 Dr. Dayananda K. Pai |
| Team Leader |
Ayush Garg |
| Team Manager |
Rakshith Ramesh |
| Technical Head |
Tushar Singh Jamwal |
| Website |
www |
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www | |
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www | |
| Youtube |
www |
| 2016 Formula Student Season | |
| Chassis | Chromoly 4130 Steel Tubular Space Frame |
| Engine | Honda CBR 600RR PC-37 (599 cc water-cooled inline four-cylinder) |
| Tyres | Hoosier 18 x 7.5 - 10 |
| Formula Student World Championship | |
| Debut | 2008 FSAE Italy |
| Latest race | 2016 Formula Student Germany |
| Competitions |
2x FSAE Italy 1x FS UK 1x FS Austria 3x FS Germany 3x FS Czech Republic 1x Formula Design Challenge |
Formula Manipal started as an abstract idea in 2007, and today has become the biggest and most successful student initiative of Manipal University. The team consists of over thirty inter-disciplinary undergraduates who aim to conceive, design, fabricate, develop and compete with other Formula style vehicles at International Formula Student events.
Formula Manipal has been competing in the international Formula Student competitions for the past six years and made its debut in 2008 at FSAE Italy with the FM08. In the following year, 2009, the team participated in the Formula Student event in UK with the FM09. The team then had a successful participation in FS Austria with the FM-X, the season 2010 car. The year 2011 saw the development of the fourth prototype, the FMXI, which competed in FSAE Italy.
Season 2013 turned out to be the most amazing year for Formula Manipal in its history. For the first time the team successfully participated in two FSAE events in the same calendar year with the FMX3. First, the team went to FS Germany and later to FS Czech Republic.
FMX4, the season 2014 car scaled new heights at the Formula Design Challenge 2015 winning seven trophies in all after commendable performances in the Formula Student Germany and Formula Student Czech Republic 2014.
Currently, the season 2016 team car is back in Manipal after competing in 2 International Formula Student competitions at Germany and Czech Republic. The team is rigorously working on the car to keep it in top shape to compete in Formula Bharat 2017.
Racing Seasons
Season 2007-08
FM08 participated at FSAE Italy in 2008 at the Ferrari Fiorano Circuit in Italy. It was the only Asian team participating at the competition. The car cleared all the static events. The team secured an overall position of 28th and stood 17th in the cost event.
Comments
"A supreme first year performance. I congratulate Formula Manipal".— Luciano Pera, President, ATA
"The fastest Indian FSAE car I have seen…".— Michael Royce, Ex technical Head, Lamborghini
Awards
"Farthest Travelled Team" Award.
Technical Specifications of FM08
| Car Number | •04 (FSAE Italy) |
|---|---|
| Chassis | •FEA optimized mild steel space frame with TIG welding •CNC bending of roll hoops |
| Engine | •HONDA CBR600 F4i. •Four-stroke engine with a capacity of 599 cc |
| Transmission | •Torque biasing Limited slip differential with custom built housing •Chain and sprocket based final drive system designed |
| Suspension | •Unequal non-parallel A-arm suspension push rod actuated •Jupiter V dampers with spring stiffness of 400 pounds/inch (2 way adjustable) |
| Steering | •Customized steering assembly from RANE TRW Steering Systems Ltd. |
| Brakes | •Maximum deceleration 1.2g. •Outboard alloy brake discs actuated by a hydraulic braking system |
| Tyres | •JK racing slicks. •Customized Al alloy wheels. |
| Electrical and Electronics | •DynoJet power commander system used for piggy back re-programmable ECU •Compact RIO implemented with LabVIEW for data acquisition |
| Aerodynamics | •Analysis done by taking the average velocity of the car as 25 m/s •Nose Point 1.457 meters from the front hoops |
| Total Weight | •423 kg |
Season 2008-09
Post season 2008, the team started its plan of action with the review of the last year’s prototype, its shortcomings and its plus points,and setting the goals to be achieved by the technical and management teams. The team put all its efforts in examining the tiniest details to be taken care of, and thus laying a solid foundation for a fruitful year to follow. FM09 was sent to U.K. to ablaze the Silverstone F1 track. The team managed to reduce the wheelbase by 25% and the weight of the car by 16% compared to last year. Every design decision was taken keeping in mind the reliability, cost-effectiveness and ease of manufacturing of the component. The team secured an overall position of 65/88 and 10/88 in the cost event.
Comments
"The car is the most well-engineered Indian car I have come across till date. The team has drawn on previous experience and has the potential to excel".— Claude Rouelle, Design Judge
Technical Specifications of FM09
| Car Number | •146 (FS U.K.) |
|---|---|
| Chassis | •Tubes dimensions: 26.7 mm X 2.87 mm •Torsional stiffness : 2400 Nm/degree |
| Engine | •HONDA CBR600 RR. •599 cc (36.6 cu in) liquid-cooled inline four-cylinder |
| Brakes | •Maximum Deceleration-1.2g •Weight Distribution- 61:39 (FRONT:REAR) |
| Suspension and Steering | •Wheelbase- 1700 MM •Front Track Width- 1300mm
|
| Total Weight | •356 kg |
Season 2009-10
The FM-X participated in FS Austria held at Wachauring, Austria in 2010. The design process of FM-X began with the aim of completing all dynamic events with competitive scores. Performance improvements were made with the utilization of facilities like TTC tyre data, extensive dyno tuning and track testing along with an improved data acquisition system. Non-traditional methods like laser cutting and water jet cutting were used extensively for manufacturing components. The team obtained an overall position of 27th and secured the 4th position in the cost event. Also the FM-X was the “Lightest Indian FSAE car” at the competition.
Awards
"Most Motivated Team" Award.
Technical Specifications of FM-X
| Car Number | •99 (FS Austria) |
|---|---|
| CHASSIS | •Front and rear single piece Tubular space frame. •Fusion welding ER70-S6filler. |
| Body | •Carbon Fiber |
| Wheels | •13" Aluminium Rim-Magnesium center Kiezer wheels |
| Tyres | •Hoosier 20.5 x 7 x 13 racing slicks |
| Engine | •2006 model Honda CBR 600 RR. |
| Fuel type | •98 RON gasoline. |
| Power | •79BHP@12000RPM |
| Torque | •57N-m@8000RPM |
| Brakes | •Rotors (Front)-Disc Brake System; PS1 Wilwood Calipers •Rotors (Rear)-Disc Brake System; CP4226 AP Calipers |
| Suspension and Steering | •Suspension type-Double unequal length A-arm and push rod actuated horizontally oriented spring and damper •Wheels-6 inch, 3 pc Al Rim-Mq center, 4.25 inch backspace |
| Ergonomics | •Driver size adjustments-Fixed seat and steering wheel. Pedal adjust fore and aft 25 mm from centre position •Seat(material,padding) -Wet lay-up carbon, padded lumber and knee protection, 60 mm ethafoam head support |
| Total Weight | •266 kg |
Season 2010-11
The team participated at FSAE Italy 2011 held at Riccardo Paletti Circuit, Italy in 2011 with the FMXI. After receiving the award for the ‘Most Motivated Team’ at FS Austria in 2010, the teamed returned to India and began work on the car for season 2011. The design focus was on weight reduction, improving handling and enhancing the overall performance of the car. The team did a lot of tuning and testing on the car and even held several track days. As an outcome of the installation of a new braking system, a reliable DAQ system, improved aerodynamics and testing, the team performed well at the event and stood 16th in the cost event.
Technical Specifications of FMXI
| Car Number | •69 (FSAE Italy) |
|---|---|
| Chassis | •Front and rear single piece Tubular space frame. •Fusion welding ER70-S6filler. |
| Body | •GFRP |
| Wheels | •13" Aluminium Rim-Magnesium center Kiezer wheels |
| Tyres | •Hoosier 20.5 x 7 x 13 racing slicks |
| Engine | •2006 model Honda CBR 600 RR. |
| Fuel type | •98 RON gasoline. |
| Power | •79BHP@12000RPM |
| Torque | •57N-m@8000RPM |
| Brakes | •Rotors (Front)-Disc Brake System; PS1 Wilwood Calipers •Rotors (Rear)-Disc Brake System; PS1 Wilwood Calipers |
| Suspension and Steering | •Suspension type-Double unequal length A-arm and push rod actuated horizontally oriented spring and damper. •Wheels- 6 inch, 3 pc Al Rim-Mq center, 4.25 inch backspace |
| Ergonomics | •Driver size adjustments-Fixed seat and steering wheel. Pedal adjust fore and aft 25 mm from centre position. •Seat(material,padding) -Wet lay-up carbon, padded lumber and knee protection, 60 mm ethafoam head support |
| Total Weight | •276 kg |
Season 2012-13
After the successful season of FMXI, the 2013 Season team decided to take a break for a year to build a light weight, faster and more ergonomic car. The team was able to successfully incorporate electro-pneumatic gear shifting along with a self-designed driveline. The team also improved its data acquisition system and a lot of components for the 2013 car were manufactured in-house.
In 2013, Formula Manipal team aced the registration quiz for Formula Student Germany 2013 by clearing it in less than 72 seconds, thereby becoming the first team in the world to qualify for the event. The event was held at Hockenheimring, Germany in the end of July. The team stood 2nd in the cost report, becoming the first Indian team to get a podium finish in that season. The team cleared technical inspection on the very first day and performed well in the dynamic events. The FMX3 achieved an acceleration timing of 4.62 seconds.The team produced a better result in Formula Student Czech Republic 2013. Here the team created history by becoming the only Indian team to complete the endurance event while incorporating electro-pneumatic gear shifting, fetching an overall rank of 9th in the competition. Furthermore, it was the fastest Indian car in the competition with an acceleration of 4.51 seconds improving its best performance by 0.11 seconds. This was the first time in the history of Formula Manipal that their car participated in and completed all events (Dynamic) at a Formula Student Competition.
Technical Specifications of the FMX3
| Car Number | •96 (FS Germany and FS Czech Republic) |
|---|---|
| Chassis | •Front and rear single piece Tubular space frame. •Fusion welding ER70-S6filler. |
| Body | •GFRP |
| Wheels | •13" Aluminium Rim-Magnesium center Kiezer wheels |
| Tyres | •Hoosier 20.5 x 7 x 13 racing slicks |
| Engine | •2006 model Honda CBR 600 RR PC-37 |
| Engine Displacement | •599 cc |
| Fuel type | •95 RON gasoline. |
| Power | •61BHP@8900RPM (on wheels) |
| Torque | •49N-m@8900RPM (on wheels) |
| Brakes | •Front and rear disc brake system; PS1 Wilwood Calipers |
| Suspension | •Double wishbone unequal length pull rod actuated |
| Steering | •Steering Ratio: 3:1 •Carbon Fibre Steering Wheel |
| Transmission | •Drexler Differential with 3 pairs of torque biasing ratio •Electro-pneumatic gear shifting
|
| Electronics | •Race Dynamics RD0901 ECU •Wireless data acquisition using cRIO 9004 |
| Ergonomics | •Driver visibility- 210 degree side visibility |
| Total Weight | •258 kg |
Season 2013-14
After a podium finish at Formula Student Germany 2013 in the Cost Analysis Event, the season 2014 team successfully completed the registration for both Formula Student Germany and Formula Student Czech Republic 2014. The team headed to Hockenheimring, Germany in the end of July 2014 where they easily cleared the Technical Inspection and the Tilt Test and also competed successfully in all the static events and finished 31st out of the 74 participating teams in the Business Plan Presentation. The FMX4 could not compete in the Dynamic events due to a sudden and unfortunate engine failure which could not be fixed in time. However, the team bought another engine in Germany as it was easily available and more economically feasible. The FMX4 then went to CzechRing, Czech Republic with a new engine aiming to blaze through all events. The team cleared all parts of the Technical Scrutiny with ease and also completed all the static events with commendable results. The car completed the Acceleration event with a timing of 4.81 seconds and Skidpad event with a timing of 8.120s. The car blazed through AutoCross with a timing of 71.710s. Unfortunately, the team could complete only half of the endurance due to a bent suspension bolt in the rear LHS pick-up point. Having competed at two international competitions, the team set about testing the car rigorously after it arrived home.
At the next competition for the 2014 Season, Formula Design Challenge 2015, which was held at Kari Motor Speedway, Coimbatore, Formula Manipal became the first team to complete all parts of the Technical Scrutiny. Their performances in the Static events were commendable having attained a healthy 5th and 6th position in Business Presentation and Cost Analysis events and also bagging a podium in the Engineering Design with a 3rd Place finish. The FMX4 went on to break the existing National Record among all Indian FSAE Teams for Acceleration with a timing of 4.19s. The very next day, FMX4 clocked another great time of 5.76s in Skidpad where all the competitors could only manage 6+ sec. The same day, Formula Manipal finished 3rd in the Autocross event. On the last day for dynamic events, Formula Manipal stood 2nd in the Endurance and Efficiency events becoming the only team at the event to complete all the Static and Dynamic events and also finishing on the podium for all Dynamic events. During Endurance, the FMX4 was also the fastest car on track with the best lap time of 83.95s. Formula Manipal went on to win the most number of trophies, a total of seven and clinched the 2nd Position overall.
Technical Specifications of the FMX4
| Car Number | •96 (FS Germany and FS Czech Republic 2014)
•77 (FDC India 2015) |
|---|---|
| Chassis | •Front and rear single piece Tubular space frame. •Fusion welding ER70-S6filler. |
| Body | •CFRP |
| Wheels | •13 inches Aluminium Rim-Magnesium center Kiezer wheels |
| Tyres | •Hoosier 20.5 x 7 x 13 racing slicks |
| Engine | •2006 model Honda CBR 600 RR PC-37 |
| Engine Displacement | •599 cc |
| Fuel type | •98 RON gasoline. |
| Power | •79BHP@12000RPM (on wheels) |
| Torque | •57N-m@8000RPM (on wheels) |
| Brakes | •Front and rear disc brake system; PS1 Wilwood Calipers |
| Suspension | •Double wishbone unequal length pull rod actuated |
| Steering | •Steering Rack Ratio: 6.33:1 •Aluminium Steering Wheel |
| Transmission | •Drexler Limited slip Clutch Type Differential with 3 pairs of torque biasing ratio •Electro-pneumatic gear shifting
|
| Electronics | •Race Dynamics RD0901 ECU •Wireless data acquisition using MyRio |
| Ergonomics | •Driver visibility- 210 degree side visibility |
| Total Weight | •250 kg |
Season 2016
After taking a break for Season 2015, and having won many laurels at the Formula Design Challenge 2015, Formula Manipal's next car, the FMX6 participated in Formula Student Czech Republic 2016 and Formula Student Germany 2016. The FMX6 design wise was far superior to its predecessors, having switched to 10 inch rims and successfully successfully implemented a self-designed, Aluminum Honeycomb Impact Attenuator and dry sump lubrication system.
The competition in Czech started out very well with Formula Manipal clearing the technical inspection and completing all static events successfully. In the Autocross event, there was an unfortunate complication with an engine causing it to fail. This resulted in the FMX6 not being able to compete in the autocross and endurance events. The team was the best Indian team in the competition securing an overall position of 16th in the competition with 5th place in the cost event.
The problem was quickly solved and the car was up and running in time for Formula Student Germany. Formula Manipal showed commendable performances in all static events, technical inspection, autocross and acceleration. Unfortunately, competing in the endurance eluded the FMX6 again as a fuel leak that came to notice during the pre-endurance inspection couldn't be fixed in time.
The team is currently back in Manipal working on the car to compete in Formula Bharat 2017.
Technical Specifications of the FMX6
| Car Number | • 296 (FS Germany 2016)
• 96 (FS Czech Republic 2016) |
|---|---|
| Chassis | • Steel tubular space-frame chassis. • AISI - 1018 round steel tubing • TIG welded with ER70-S2 low carbon alloy steel filler. |
| Body | • CFRP |
| Wheels | • 10 inch Aluminium Alloy Rim 6061 T6 Kiezer wheels with Aluminium 7075 self designed wheel centers |
| Tyres | • Hoosier 18 x 7.5 - 10 racing slicks |
| Engine | • 2006 model Honda CBR 600 RR PC-37 |
| Engine Displacement | • 599.36 cc |
| Fuel type | • 98 RON Gasoline |
| Power | • 80BHP@10000RPM |
| Torque | • 57N-m@8000RPM |
| Brakes | • Front and rear disc brake system with ISR 4 Piston and Wilwood PS1 2 Piston Calipers |
| Suspension | • Double unequal wishbone. front-pullrod and rear-pushrod actuated shocks with blade adjustable anti roll-bar |
| Steering | • Steering Rack Ratio: 6.33:1 |
| Transmission | • Drexler Clutch Type Limited slip Differential with 3 pairs of torque biasing ratio
• Final Drive ratio of 34:11, titanium half shafts, DID 520 series X-ring chain and linear chain tensioning mechanism
• Electro-pneumatic gear shifting for better shift time |
| Electronics | • Motec M400 ECU
• NI MyRio used in cojuction with AiM EVO4 for wireless data logging |
| Ergonomics | • Driver visibility- 210 degree side visibility |
| Total Weight | • 203 kg |
Citations
References
- http://articles.timesofindia.indiatimes.com/2012-12-26/mangalore/36007043_1_mit-students-manipal-university-first-car
- http://articles.timesofindia.indiatimes.com/2012-11-09/mangalore/35015949_1_manipal-university-formula-style-ferrari-fiorano
- http://www.hindu.com/2008/09/05/stories/2008090550310200.htm
- http://www.hindu.com/2010/11/13/stories/2010111356580200.htm
- http://www.daijiworld.com/news/news_disp.asp?n_id=65181&n_tit=Formula+Manipal+-+Aiming+to+EnForce+India+%3F+%3A+by+Divvy+Kant+Upadhyay
- http://mangaloretoday.com/mt/index.php?action=mn&type=1966