The First Combustion Car In 10 Years: SE8
For the 2023/2024 competition cycle, SURTES decided to return to a combustion powertrain for the Class 1 competition. SURTES EC was formed as a new and distinct identity for the Class 1 team, to differentiate from our strong EV roots. This was due to the existing accumulator reaching end-of-life, with a three-year plan formulated to develop a new battery pack carried by the Team SURTES Concept Class 2 team. While work to return to an EV was taking place in the background, a brand-new ICE powertrain concept was developed and the entire car designed and prepared over the 9 months running up to the competition. SE8 was then launched at the FSUK 2024 competition; a reliable, dependable and legally safe basis for the team to develop and push the envelope once experience of running a car was gained.
The main focus was on the development of the powertrain. A Rotax Type 804 parallel twin cylinder motorcycle engine platform was modified with bespoke pistons and cylinder liners to meet the maximum permitted capacity of 709cc, with help from our partner Julian Godfrey Engineering. The compression ratio was raised to take advantage of the greater octane rating of our renewable 85% ethanol fuel. The engine control package used a Syvecs S7Plus ECU and PDUX2B PDM to provide a flexible and capable powertrain control scheme, in order to take advantage of the sensor suite and electronic gear actuator. Fluids and lubricants provided by our partner Ravenol promised to reduce the pumping losses of the combustion engine, increasing overall efficiency. Producing the complex powertrain package within the short timeframe allocated was an incredible feat for the team.
Moving to 13" wheels provided more design freedom for the suspension team to achieve their desired geometry and removed the packaging issues previously experienced with 10" wheels that led to excessive steering torque. The resulting hardpoints resulted in a system that did not require anti-roll bars, reducing the mass and complexity of the system. The team was able to invest in new dampers through a major partner in KW Suspension, providing more repeatability, easier adjustment and improved product support over our previous damper units. The steering system retained the bevel box design used on previous cars, with mass of the overall system reduced by moving to a lighter steering rack. Our title sponsor, Surrey Manufacturing, produced the upright, hub and pedal box assembly components with exceptional precision and care, delivering the parts before the estimated completion date.
The completion of the aerodynamics package was a considerable achievement considering the lack of knowledge at the project start in October 2023. Our composites team managed to build up considerable experience over the project duration, resulting in the production of composite dashboard, floors and aerodynamic devices. The front and rear wings were designed with the goal of maximising efficiency while using common aerofoil profiles to aid manufacturing and reduce cost. Flax fibre provided by Easy Composites was chosen, used with a non-toxic bioresin matrix to form the composite. Flax fibre composites are safer to cut as they are non-carcinogenic, with a lower risk of cuts or splinters when the material is damaged. Therefore, it is ideal for teams lacking extensive composite production facilities.
RS Build Fund
The RS build fund was put towards the electrical system of the car, allowing the team to use motorpsort-quality Deutsch DT and DTM connectors, TE spec 55 wire and Amphenol bulkhead connectors. RS also provided the starter motor solenoid and dashboard indicator lights. The full list of items provided to the team by RS Components is attached at the bottom of the article. By supporting us with items essential to the car build, funds could be re-allocated into more experimental parts, such as the 3D printed, vapour smoothed intake system.
Goals
The major goal for 2023/2024 season was to pass scrutineering and make it through dynamics events; a major challenge for any team. In particular, the team had zero experience in taking an IC car through scrutineering at any competition, with the UK competition renowned for high standards. Previously, SE7 had failed to make it through scrutineering after failing the water ingress test, as well as several delays during technical inspections.
The team was ambitious in aiming to get the car out for dynamic events and compete on track, and set vehicle performance targets at the start of the year. The targets were derived from scratch using simulations and by studying rules, as there was no previous validated car data to reference. The overriding constraint was to produce a moderate-cost, moderate-performance car. The targets agreed included:
- Car Mass - 270 kg
- Acceleration Time - 4.5 seconds
- Lateral Acceleration - 1.5 g
- Turning Radius - 3.2 m
- Fuel Efficiency - 30 kgCO2/100km
Project Management
Effective project management was crucial for the one-season design and build cycle. The team used Gantt charts on both a sub-team and a top level for time management. A critical path analysis was performed to identify key project risks, bottlenecks, and the order of operations. Microsoft Teams was used for resource management and inter-team communications. Procurement was carefully planned using an extensive Spreadsheet to mitigate financial and logistical challenges, ensuring timely acquisition of parts/materials and adherence to the project budget.
Challenges And Limitations
The major challenge for the 2023/2024 SURTES EC project was the transition to a fully student-led project, without academic ties to the course. As a result, the team could no longer rely on the priority status it once had, requiring a change in processes and goals. The team also lost their workshop technician during the project, compounding the loss of knowledge and support available moving forwards. This made moving from producing an all-new car every year to an evolutionary car design process essential, thus SE8 was designed and procured with future-proofing as a core constraint. Ultimately, the extended lead times for internal components extended the car build phase too close to competition to allow a full testing programme. Moving forwards, the team now understands how to overcome these challenges to ensure the car is completed to schedule.
FSUK 2024 And Future Plans
Document Submission and Penalties
The team successfully submitted all required documents on time, avoiding any late penalties. However, a penalty was incurred for the impact attenuator report grade, due to a lack of dynamic testing and the use of the FSAE standard honeycomb part.
IPG Lap Time Simulation
Despite IT issues, the suspension team successfully submitted valid results and a high-quality engineering report for the IPG lap time simulation event.
Cost Score
The cost score was commendable for an all-new team with an all-new car. Documenting every component down to the fasteners was time-consuming and required exceptional engineering understanding, which our cost team demonstrated through the BoM, CBom, DBom, and cost report. However, the supporting materials were insufficient for a higher score, and the team is eager to improve this for future competitions.
Design Event
The design event was both frustrating and insightful. The car was deemed 'incomplete' due to the air intake being removed for scrutineering, resulting in a severe points deduction. Despite this, the car received praise for the innovative powertrain, the addition of an aerodynamics package, design solutions for the suspension corners, and the overall quality of fit and finish.
Business Event
Unfortunately, the business team were unable to attend the business event, resulting in a no-score against a potential 150 points.
Scrutineering
The team managed to pass chassis, technical, safety, fuelling, and tilt test scrutineering inspections. However, the team ran out of time to complete the noise and brake test inspections due to electrical issues with the shutdown circuit and engine control unit. The competition ultimately ended for the team when it was discovered that the ECU was missing the base idle engine map. Although this was a tough end to all the dedicated work over the challenging season, the team could still hold their heads high for all they have achieved, and the strong base built for the future of Team SURTES and SURTES EC.
Future
Despite not completing all dynamic events, the team's achievements in passing several scrutineering stages with a new car was significant. The feedback received and the lessons learned will be invaluable for future development. The car, in its current configuration, is not eligible for FSUK 2025 without a new chassis but is eligible for European competitions, presenting opportunities to promote the University internationally.
The team is considering participating in high-profile European competitions such as FS Netherlands, FS East, FS Austria, FS Spain, FS Portugal, and FS Italy for the 2024/2025 season. This would provide a fantastic opportunity to showcase the University of Surrey on an international stage.
Acknowledgements
We would like to thank the University of Surrey MES and FEPS workshop for their support. Additionally, we thank all our sponsors, alumni, friends and family of the team for their invaluable contributions over the season and beyond.
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