This master thesis focuses on design of steering wheel and clutch controller module for Formula Student car, The first part of this thesis is focused on communication protocol CAN and continues with explanation of reasons for development of this solution. Requirements for individual components of system are introduced in next part. At the end of the thesis the final electrical and hardware design is introduced as well as software design. The last part of this thesis is focused on simulation of system in race condition and evaluation of results.

Formula Student is a global engineering competition where university students collaborate to design, construct, and race formula-style cars. Aerodynamics is one aspect in the vehicle design that can improve on-track performance by increasing cornering and straight-line speed. To improve the aerodynamics of KTH Formula Student's DeV18 vehicle, the side structure is being redesigned. The current model, DeV17, features an underperforming tunnel-based side structure. To address this issue, this had the goal to investigate a new multi-element wing design that utilizes ground effect. The design study of the DeV18 vehicle is conducted using Siemens NX 2212 for 3D modelling and Simcenter Star-CCM+ 17.06.008-R8 for airflow simulations. To quickly investigate certain design parameters effect on the results, Design Manager Project inside Simcenter Star-CCM+ is used. The resulting side structure produces a total of 26 N of downforce and 6 N of drag at 40 kph, more than twice that of DeV17’s side structure while also producing less drag. Although this significant improvement compared to DeV17, it is believed that further increases in performance are necessary to compete with top teams. By using a more sophisticated method to optimize the multi-element wing, such as adjoint optimization, the concept could be improved. However, the overall potential of the concept is still considered too limited to achieve the desired performance goals, which is why it will no longer be investigated further.

Diplomová práce se zaměřuje na vypracování návrhu marketingové strategie vybrané organizace. Určuje, jaké jsou klíčové prvky pro vybudování marketingové strategie pro tým Formula Student s důrazem na inovaci v tomto odvětví motoristického sportu. Diplomová práce je rozdělena na tři části. První část se zabývá teoretickými poznatky a důležitými pojmi z oblasti marketingu, druhá část obsahuje základní informace o formulovém týmu a analýzu současného stavu. Poslední část obsahuje návrhy pro formulový tým TU Brno Racing.

Describe entire information about design of respective component in Formula (category Student) braking system is object of this thesis. Processing is divided to four main areas. The first one describes basic components in braking system, which goes on analysis of braking system in present used Formula Student Dragon 1. The second one, more spread part, consists of braking system proportioning for Formula Student Dragon 2, respecting pieces of knowledge from first generation Formula. The third part involves design single components of braking system for second generation Formula. This design is supported by measurements and results of calculations. The conclusion of master thesis involves design of caliper model and its FEM analysis.

Detta kandidatexamensarbete fokuserar på möjligheterna att implementera additiv tillverkning på en styrspindel, en av nyckelkomponenterna i en Formula Student-bil. Målet var att få en inblick i denna tillverkningsteknologi och se om det skulle vara lämpligt att byta KTH Formula Students nuvarande styrspindlar i aluminium (Alumec 89) till att vara gjorda av titan (Ti6AL4V) utan att öka vikten, samt inte förlora styvhet och styrka i konstruktionen. Baserat på den nuvarande geometrin av styrspindeln för KTH Formula Students senaste bil, eV12, designades nya styrspindlar i titan med programmet SolidWorks. Denna process gjordes med hjälp av erfarenhet inom styrspindelskonstruktion och intuition, genom att analysera och förändra designen i en iterativ process. Tre konstruktioner gjordes: en lätt version av den exisisterande, vilken var baserad på den existerande styrspindeln i aluminium, en ihålig version och en okonventionell version som utnyttjar designmöjligheter med additiv tillverkning. För att verifiera de tre olika titankonstruktionerna utfördes det en analys av den existerande styrspindeln. Genom att använda resultatet från denna analys kunde mål för styvhet och maximal spänning sättas för den nya titanstyrspindeln. Ingen av koncepten uppnådde de satte målen fullt ut, men värdefull insikt i design, hållfasthetslära och tillverkningsteknik erhölls. Det faktum att den specifika styvheten för titan är lägre än den för aluminium betyder att skulle vara svårt att göra en fungrande design utan användning av topologioptimeringsmjukvara, om vikt är en av de viktigaste faktorerna. Med mer bearbetningstid skulle dessa konstruktioner troligtvis kunna möta målen. / This bachelor thesis focuses on the possibility to implement additive manufacturing on the upright, one of the key components in a Formula Student car. The goal was to get an insight into this manufacturing technology and to see if it would be suitable to change KTH Formula Student’s current aluminium (Alumec 89) uprights to titanium (Ti6AL4V) ones, without gaining weight and losing stiffness and strength. Based on the current geometry of uprights for KTH Formula Student’s latest car, the eV12, new titanium uprights were designed using SolidWorks. This was done by using experience in upright design and intuition, by analysing and altering the designs in an iterative process. Three designs were made: a lighter version of the existing one, a hollow version and an unconventional version that utilises design possibilities with additive manufacturing. To verify the three different titanium designs, an analysis of the existing aluminium upright was performed. Using the results of this analysis, stiffness and maximum stress goals were set on the new titanium uprights. None of the concepts fully met the set goals, but valuable insight into design, solid mechanics and manufacturing methods was gained. The fact that specific stiffness of titanium is lower than that of aluminium means that it would be hard to make a proper design without the use of topology optimisation software, if weight is one of the most important factors. With more time, the designs would likely meet the set goals.

The engineering competition Formula Student has introduced a Driverless Vehicle (DV)class, which requires the students to develop a car that can autonomously make its wayaround a cone track. To ensure the safety of such a vehicle, an Emergency Brake System(EBS) is required. The EBS shall ensure transition to safe state for detection of a singlefailure mode. This thesis work covers the design of the EBS for KTH Formula Student(KTH FS).Due to the safety critical character of this system, the software part of the EBS, calledEBS Supervisor, has been analyzed in accordance with the safety standard ISO 26262 tosee if an improved safety could be achieved. The analysis has been perform according toPart 3: Concept phase of ISO 26262 with an item definition, Hazard Analysis and RiskAssessment (HARA), Functional Safety Concept (FSC) and Technical Safety Concept(TSC).The result of the analysis showed that the EBS Supervisor requires extensive redundanciesin order to follow ISO 26262. This includes an additional CPU as well as signal checksof inputs and outputs. Due to limited resources in terms of money and time within theKTH FS team, these redundancies will not be implemented. The process of working withthe safety standard did however inspire an increased safety mindset. / Ingenjörstävlingen Formula Student har introducerat en förarlös tävlingsklass (eng:Driverless Vehicle) som innebär att studenterna ska utveckla en bil som autonomt kan tasig runt en konbana. För att försäkra sig om säkerheten för ett sådant fordon krävs ettnödbromssystem (eng: Emergency Brake System (EBS)). EBS:en skall försäkra att enövergång till ett säkert tillstånd sker då ett singulärt fel upptäcks. Det här examensarbetetbehandlar designen av EBS:en för KTH Formula Student.På grund av den säkerhetskritiska karaktären hos detta system har mjukvarudelen avEBS:en, kallad EBS Supervisor, blivit analyserad utifrån säkerhetsstandarden ISO 26262för att se om en förbättrad säkerhet kunde uppnås. Analysen har blivit genomfördenligt Del 3: Konceptfas av ISO 26262 med item definition, Hazard Analysis and RiskAssessment, Functional Safety Concept och Technical Safety Concept.Resultatet av analysen visade att EBS Supervisor kräver omfattande redundanser föratt uppfylla ISO 26262. Detta inkluderar en extra CPU såväl som kontroller av inochutsignaler. På grund av begränsade resurser i form av pengar och tid inom KTHFS, valdes dessa redundanser att inte implementeras. Processen av att arbeta medsäkerhetsstandarden har dock inspirerat ett ökat säkerhetstänk.

The topic of this master degree thesis is Formula Car Steering System Design. The thesis analyses principles connected with the steering system, such as aligning torque, camber variation from steering or spindle height change, as well as the influence of the steering wheel geometry on these principles. The main part of this thesis is steering system designing for practical purposes in international competitions of university teams. The simulation of parts is processed by finite element method. Also included are the load transfer and the tyre data sets topics. The thesis concludes with a list of several examples of car setup for cornering.

In this thesis the requirements for a rear wheel steering mechanism aimed to be implementedon KTH:s Formula Student car were evaluated. The requirements were obtainedby using already known loads, an analysis of how the quickly the driver turns the steeringwheel during track driving from video material and the Formula Student rulebook whichthe car is designed after. After the requirements were produced a number of concepts wereproduced and evaluated against each other. The concept that was given the highest scorewas a rack and pinion concept with a rotary actuator which was developed further.The design was made by first selecting an actuator with a planetary gearbox that couldfulfill the speed and load requirements and afterwards with CAD a design that could beintegrated on the car was made. The concept weighed around 1,7 kg and was compatiblewith the requirements. / I detta arbete undersöktes kraven som ställs på ett bakhjulsstyrningssystem för implementering på KTH:s Formula Student bil. Kraven togs fram genom att använda redan kända laster, en analys av hur snabbt föraren svänger utifrån videomaterial samt regelboken som alla formulastudentbilar är konstruerade efter. Efter att kraven tagits fram utvärderades ett antal koncept där det bästa konceptet, kuggstångsmekanism med ett roterande ställdon utvecklades vidare. Prototypdesignen gjordes genom att först välja ett ställdon med planetväxellåda som skulle klara av kraven och därefter med hjälp av CAD skapa en integrerbar design. Det färdiga konceptet väger ca 1,7 kg och klarar alla ställda krav.

Composite monocoque frames are becoming increasingly more popular inperformance cars. Compared to their steel and aluminum counterparts theyprovide additional torsional stiffness at the cost of less weight. This thesiscovers the complex optimization process of a monocoque applied within theregulations of a Formula Student competition. It aims to give the reader a goodunderstanding of the rules and how they affect the optimization process whilegenerating an optimized design used in the competition of Formula StudentGermany -21 by KTH Formula Student. The rules of Formula Student dictate the structural requirements on themonocoque based on a steel space frame. All materials except low carbon steelused in the structure require proof of equivalence through regulated testingmethods. However, this thesis shows that the regulated setup can severelyaffect results through a deep analysis of the testing methodology.The torsional stiffness of the monocoque is analyzed and optimized accordingto the results of a free-size optimization. Both through slight adjustmentsin chassis geometry and the laminate, resulting in a theoretical torsionalstiffness of 9.9 kNm/deg, more than five times as much as the old space frame.Weighing in at 20 kg, a significant weight reduction of about 10 kg, eventhough it was larger, with a surface area of about 4.2 m2. This design will be the first monocoque manufactured within KTH FormulaStudent since 2010. Therefore, a lot of focus was put on analyzing the rulesand lay the ground for future development by conducting tests on optimizedpanels. These results have the potential to further reduce the weight of a futuremonocoque with a different geometry. / Allt fler sportbilar använder självbärande karosser i komposit. Till skillnadfrån deras stål och aluminium motsvarighet så tillåter kompositkonstruktionenen styvare konstruktion för samma vikt. Denna rapport går igenom denkomplicerade optimeringsprocessen för en självbärande kaross i kolfiber appliceratinom tävlingen Formula Student. Målet med rapporten är att läsaren ska fåen bättre förståelse av reglerna och dess påverkan på optimeringsprocessensamtidigt som en optimerad design presenteras för användandet i “FormulaStudent Germany -21” åt KTH Formula Student. Reglerna inom Formula Student ställer strukturella krav på den självbärandekarossen baserat på en standard för stålrörsramar. Alla material förutomlåg kols stål som används i strukturen kräver att ekvivalens bevisas genomspecifika tester. Denna rapport visar att dessa tester kan generera olika resultatgenom en djup analys av metodiken. Torsions styvheten av karossen analyseras och optimeras enligt reglernagenom en så kallad free-size optimization". Genom att variera geometri ochkomposit utvecklades en kaross som var mer än 5 gånger så styv som dentidigare stålrörsramen med en teoretisk torsions styvhet på 9.9kNm/deg. Meden vikt på 20 kg reducerades även vikten 10 kg, även om den var större, ochhade en area på cirka 4.2m2. Denna design kommer att vara den första självbärande komposit karossentillverkad inom KTH Formula Student sedan 2010. Efter den djupa analysen avreglerna, testas då de optimerade panelerna, vilket lägger grunden för framtidautvecklingen. Dessa resultat har potential att reducera vikten ytterligare av enframtida kaross, genom ändringar i geometrin.

The Master’s thesis deals with the design and production of a composite chassis of the new formula Dragon X. The carbon prepreg used for manufacturing of the monocoque was to be operated at high temperatures. Therefore, this thesis deals with the application of composites structures in the high temperature environment. The thesis addresses the torsional stiffness problematics and it was not only physically tested, but also simulated by FEM analysis and the results were compared.