We are one the few teams in the Formula SAE competition that design and manufacture a completely custom brake system. Composed of self-designed brake calipers, pedalbox and brake rotors, the custom components are optimized for our unique application. All components see thorough structural analysis to minimize weight. Brake pads and rotors are dynamometer tested for ideal operation.
Interacting with almost every system on the car, the chassis is designed to withstand all vehicle loading cases, minimize overall weight, and meet stiffness goals.
The suspension is designed for the demands of autocross, including quick maneuvering and changes in speed. Optimal handling is achieved with double unequal length non-parallel A-arms with adjustable anti roll bars.
The team starts with a dirtbike engine, then designs a fuel-injection system, the intake and exhaust systems, and a forced induction system utilizing a turbocharger. The designs are then tested and the engine is tuned on our in-house dynamometer. This group also designs the auxiliary systems for the engine including fuel, cooling, and shifting.
The Drivetrain system is responsible for transmitting all of the power from the engine to the wheels. At the heart of the drivetrain system is a Drexler Formula Student LSD with adjustable torque bias ratio. Transmitting that torque to the wheels is accomplished with carbon fiber half-shafts that weigh 40% less than steel equivalents. Power is transmitted from the engine by a custom 7075 aluminum alloy rear sprocket using a 520 class chain.
A full aerodynamics package is designed and analyzed to maximize downforce while reducing the effects of drag. The aero package consists of the rear wing, front wing, and undertray. Components from other systems of the car are also analyzed, such as the throttle, intake system, and cooling ducts.
This group is devoted to getting the car to perform in the best way. This all begins in the design phase with suspension geometry; the designers also decide on spring, damper, and tire combinations that best suit the vehicle. Once the car is built, the vehicle dynamics group is responsible for the organization and coordination of testing in order to better tune the vehicle.
RIT uses multiple custom Printed Circuit Boards which communicate over a CAN bus. These boards are used as the interface between different car systems. The sensor hub reads engine sensor data and pushes it onto the CAN bus. This information is then used by the engine controller, as well as the dash indicator and steering wheel boards to deliver pertinent information to the driver.
Most parts are made in house by the Fabriaction and CNC groups. Fabrication is responsible for all hand-made parts, constructing pieces on engine lathes, speed lathes, and vertical mills. They then sand and polish the parts and assist with the final assembly of the car.
We have access to two vertical machining centers and three turning centers. The CNC group is responsible for the maintenance, set up, and operation of these machines. After programing the tool paths in Mastercam, the 3D model is brought to life as an accurate, functional, and one of a kind part.
To reduce weight and increase strength and stiffness of the car, our team incorporates carbon fiber and other composite materials into the design. The chassis is constructed from carbon fiber, as are the steering wheel, aerodynamic undertray, gas pedal and muffler to name a few. Every major system on the car incorporates carbon fiber in some fashion.