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Formula SAE: an insider's look at Detroit's international competition (part 1)

3 juin 2008

par Mathieu Lapointe, Auto123.com


-PART II (click here)

A couple of months ago, I joined a team of students from Montreal's École de Technologie supérieure who are participating in the Formula SAE Championship. I witnessed first-hand the development of their machine as well as their track tests. From May 13 to 18, they took part in an annual competition at the Michigan International Speedway.


Over 100 teams from many different countries flew to Detroit: the United States (including Hawaii), Canada, Brazil, the Netherlands, Japan, Austria, Australia, England, etc. They all had their own spot in the pit area, inside the famous oval speedway, with bleachers totaling 186,000 seats.

A springboard for graduate students
Aside from the actual race and various contests, this event allows students to meet with potential employers. Before the competition even started, Jude and Sébastien, who worked on the car's suspension at the ETS, were offered jobs at Arvin Meritor, a renowned auto engineering company.

Participating in the Formula SAE Championship encourages students to work extra hard, not only for personal reasons but also for the team's success. Therefore, by hiring a student who's involved in Formula SAE, business executives are making sure-fire selections.

Claude Rouelle, an engineer with 30+ years of experience in auto racing, both in NASCAR and Formula One, told me that a competition like Detroit's is "a golden recruiting pool; I see the best and I try to hire them." Why? "Because they're highly motivated and knowledgeable and also because they're full of enthusiasm, energy, creativeness and camaraderie," he explains.

Time to go!
Back in Montreal, everyone was excited, including myself. The team was scheduled to leave for Detroit at 4 a.m. Upon entering the ETS facilities, I saw team captain Jude sleeping on a couch. A few feet away, the car was still on blocks, with two people working underneath.



Our departure had to be delayed for a while because the engine broke down just before leaving and needed immediate repair. Everyone, except those working on the engine, seemed rather calm; they were busy packing their gear and tools inside the trailer.

The engine was ready for a start at 7:30. Upon ignition, I noticed white smoke coming from the dashboard. Stop! Students in charge of electronics made a close inspection to find out what went wrong. François and Maxime had their hands full. Two hours later, the problem was identified and corrected, although it made the dashboard non-operational for the competition.


We arrived at the hotel around midnight -- 6 hours behind schedule. We were all very tired so we immediately headed to our rooms for a good night's sleep. The morning registration was just a few hours away.

The first two days were dedicated to stationary tests: weigh-in, design presentation, braking, inclinometer, etc. Prior to that was a thorough mechanical inspection... at the end of a 3-hour wait. The tension was palpable among the team; should officials find a problem requiring more than 20 minutes to repair, the car had to be taken back for modifications, which would further delay the inspection.

The car had to meet multiple standards with regard to ground clearance, engine specifications, driving position, etc. Three inspectors scrutinized the machine and one of them actually found something: certain bolts were too short. Fortunately, the issue was solved in a matter of minutes and it was on to the next step. Every student who would drive the car had to be able to get out of it in under 5 seconds. No problem here. End of Day 2.



On Thursday morning, the last couple of tests were completed. It was also time for the design evaluation. Students had 20 minutes to impress the jury and show them how their car stands out from the rest. Judges wanted to know every little detail about the design and components. Expectations were high as the ETS usually shines in this part of the competition. When it was all over, Jude confessed that he was a little disappointed by the lack of reactions from the jury, which made him fear the worst. Would they qualify for the semi-finals?


At the weigh-in, the result was 335 pounds, which surprised Steven Fox, one of the judges who had over 35 years of experience in auto racing. "It's easily one of the lightest vehicles I've seen in this competition," he said. In fact, only a team from the Netherlands, TU Delft, managed to create a lighter car. ETS students were excited, especially considering that weight reduction was a key objective throughout the development process.

Then, the exhaust system had to be checked out to ensure it wasn't louder than 110 decibels. Everyone from the ETS knew that their car was noisy. The first result indicated 114 decibels, so a special exhaust tip was added. Now, the decibelmeter read 109.9! Perfect. Braking tests were the only thing standing between the team and the track.

Of course, there was also a marketing presentation, in which students had to make a business case for their machine in hope of attracting potential investors. Then, they needed to submit a detailed account of all the design and production costs. In order to be mass-produced, a car had to retail for $25,000 or less. Again, no problem here.

The stationary tests were now completed and the team felt really exhausted. Most of them went back to the hotel, while others spent time repairing a scary-looking crack. The next day would be even more demanding with the start of the action on the track.

Stay connected for Part 2...