Hybrid Safety and
Fatigue Reduction
BY: BRANDON CHURCHES AND SETH KLEIN
FACULTY ADVISOR: DR. ERIC MEYER, DR. NASIR
TECHNICAL ADVISOR: DR. ROBERT FLETCHER (ME)
Need Statement:
● Needs Statement
o
There is a need to improve the safety and reduce fatigue for the hybrid car drivers.
● Overview:
o
By understanding the biomechanics of the driver and safety concerns, we can
create a seating package that is both safer for the driver and reduces the fatigue
they feel during the race.
SAE Formula Hybrid
●
International Competition started
by Dartmouth College in 2006
●
Competition at New Hampshire
Motor Speedway at the end of April
●
Students Design and build a electric
hybrid car
SAE Formula Hybrid
Types of Testing done at the Competition
● Dynamic
○
Acceleration
○
Autocross
○
Endurance
● Design
Design Parameters
● Seat at 120 Degree
Angle
● Speeds up to 50 Mph
● Allow car to be worked
on
● Light Weight
Design Parameters
● Rules of Competition
o
Head Clearance
o
Driver Egress
Driver Egress
●
Exit the Car in 5 seconds
Seat
● Limit movement of
driver
● Using Carbon
Composite
o
Working with Plasan Carbon
Composites
● 6 point harness
Preliminary Quantification
● Pressurestat Paper
o
o
Pressure Point Quantification
Static Test
● Sensor Kinetics
o
o
Phone app
Measures Movement
Figure 1: Sensor Kinetics, Google Play store
Possible Quantification
●
Tekscan
http://www.tekscan.com/
Wrist Biomechanics
●
Wrist Average Range of motion
o
Radial 20°
o
Ulnar 35°
o
Extension 70°
o
Flexion 75°
Figure 1: Normal Range of Motion Reference Values
Wrist Biomechanics
● Wrist Straps
● Will cause Fatigue in the
wrists and forearms
Head/Neck Support
Injury Distribution for 605 Belted Drivers
● Neck injuries are the
most common injury
type
o
605 belted drivers
Graph 1: Lunduell 1998
Head/Neck Support
With Head Restraint
Without Head Restraint
“Graph 2: “Melvin 2004”
Graph 3: “Melvin 2004”
The Left graph shows Right Front crash with a Hans Head restraint while the right has no Head Restraint
Quantification
● Using Triax Sim-G to
test the effectiveness
of a head restraint.
Figure 2: https://www.triaxtec.com/sim-g/
Budget
Aspect:
Seat
Materials:
Cost:
Use:
Source:
CFC
Donated
Seat
Plasan
Padding:
$40
Force
Reductio
n
Plywood
Donated
Mock ups
Seat Belt
Donated
Safety
Mold
$200
Seat
$89
Safety
$6 - 2
copies
Data
Head
Restraint
Data
Total:
Phone
App
$335
Takata
Google
Play Store
Market Analysis
● 15 Profession Formula
sanctioned racing
bodies
● Over 70 circuits
worldwide that have
held a Formula One
Race
Project Timelines
Dates:
Senior Projectes Task:
Dates:
Internal Team
Deadlines:
December 17- January 12th
Mock Up Complete
January 12th
Rolling Chassis
January 12th - January 26th
Pressure Testing
January 26th - February
17th
Finish Carbon Fiber Seat
February 17th - 28th
Finalize attachment and
Quick release method.
March 16th
Running Car
March - April
Testing
April 4th
20 hours of Drive Time
Blue Devil Unveiling
April 20th - 24th
Final Presentation
April 28th - May 2nd
Competition
April 28th
Competition
Hybrid Competition Timeline
Milestone:
Deadline:
Project Management Plan, Section S3.2.1
12.22.14
Structural Equivalency Spreadsheet (SES), Section T3.8
01.28.15
Fuel Request, Section IC2.1.3 (no official form)
01.28.15
Program Submission, Section A10
02.11.15
Interim Project Report, Section S3.2.2
02.18.15
Impact Attenuator Data (IA), Section T3.21
02.18.15
Site Pre-Registration, Section A10(j)
03.04.15
Electrical System Form (ESF), Article EV9
03.18.15
Failure Modes and Effects Analysis (FMEA), Article EV9
03.18.15
Design Report, Section S4.2.1
03.25.15
Sustainability Report, Section S4.2.2
03.25.15
Design Specifications Sheet, Section S4.2.3
03.25.15
Electrical Pre-Inspection, Section S2.3
04.17.15
Major Tasks/Team
●
●
Key Tasks:
o
Cockpit Mock Up
o
Carbon Fiber Mold
o
Carbon Fiber Seat
o
Data Acquisition
Brandon Churches:
o
●
Responsibilities: Presentation Design, Research, Solidworks, Cockpit Mock Up, Mold,
Carbon Fiber Seat
Seth Klein
o
Responsibilities: Written Report Design, Research, Data Acquisition and Analysis,
Cockpit Mock Up, Mold, Carbon Fiber Seat
References
1. "2015 Formula Hybrid Rules." N.p., 15 Oct. 2014. Web. 5 Nov. 2014.
2. "About Formula Hybrid." Formula Hybrid RSS2. N.p., n.d. Web. 06 Oct. 2014.
3. Lundell, Bjorn, Lotta Jakobsson, Bo Alfredsson, and Clas Jernstrom. "Guidelines for and
the Design of a Car Seat Concept for Improved Protection Against Neck Injuries in
Rear End Car Impacts." (n.d.): n. pag. SAE International. Web. 02 Dec. 2014
4. Melvin, John W., Paul C. Begeman, and Craig D. Foster. "Sled Test Evaluation of Racecar
Head/Neck Restraints Revisited." SAE International. N.p., 3 Dec. 2004. Web. 6 Dec.
2014.
5. "Normal Range of Motion Reference Values." Normal Range of Motion Reference
Values. American Society for Surgery of the Hand, n.d. Web. 10 Dec. 2014.
Questions?