2016 Rules Changes
Michael Royce
Albion Associates, LLC
October 31, 2015
2016 Rules Changes - Summary FSAE-All
Per 2016 FSAE Rules
The rules changed include, but are not limited to, the following:
Rule #
•
•
•
•
•
•
•
•
•
•
•
T3.38
AF5.2
AF7
IC1.7.3
IC1.9.1.b
IC1.11 - IC1.16
IC2.6
IC4.4.4
IC4.6
EV4.2
S4.11.4
System
Anti Intrusion Plate for Monocoque Chassis
Required Submissions
Additional Non Applicable Rules
Recirculation Valves
Fuel Rail Materials
Electronic Throttle Control
Fuel Filler Neck and Sight Tube Clarifications
Lithium Battery
Voltage Limits
Tractive System Active Light
Engine Cost
For 2016 Formula SAE Competitions in United States, the Cost Report Submission process may be
changed. Please refer to the website for additional announcements and information.
2
2016 Rules Changes
2016 Rules Changes - Summary FSAE
All
Rule
Number
•
System
A8.1 & A8.5 Cost Report
Change
PART S - ARTICLE 4: “Cost Report” - Report must comply with
the Cost Event Rules.
*For 2016 Formula SAE Competitions in United States, Cost Report Submission process
may be changed. Please refer to the website for additional announcements and
information.
3
2016 Rules Changes
2016 Rules Change FSAE All
T3.38 Monocoque IA Anti-Intrusion Plate
Rule
Number
Change
•  T3.38.1
Composite AI plates must not fail in a frontal impact. Strength of the AI plate must
be verified by physical testing or a combination of physical testing and analysis. All
physical test results and any analysis completed must be included in the SES.
•  T3.38.2
Strength of composite AI plates may be verified by physical testing under rules
T3.21.2 and T3.21.3.
•  T3.38.3
Strength of composite AI plates may be verified by laminate material testing and
calculations of 3 point bending and perimeter shear analysis. Composite laminate
materials must be tested under T3.30.3 and T3.30.5. Analysis of the AI plate under
3-point bending must show the AI plate does not fail under a static load of 120 kN
distributed over 150mm of length, and perimeter shear analysis must show each
attachment can hold 20 kN in any direction.
4
2016 Rules Changes
2016 Rules Changes – FSAE All
T14.2 Helmets
Rule
Number
•  T14.2
Change
M2000, K2000 & SA200 helmets deleted,
SAH2010 added
M2015, K2015, SA2015 SAH2015 added
FIA 8859-2015 added
Note: This change has not yet been published
5
2016 Rules Changes
2016 Rules Changes – FSAE All
AF Rules
AF5.2 A Nastran analysis deck and supporting documentation must be submitted electronically
with the “Notice of Intent” and SRCF. Nastran does not have to be used for the analysis, but is the
required format for the organizer's to review the analysis input decks.
ARTICLE 7: NON-APPLICABLE RULES: CHASSIS/FRAME
The following rules are not applicable when building a frame to this alternative rule set.
•
AF7.12 T3.33.1 In addition to proving that the strength of the monocoque is adequate, the
monocoque…
•
AF7.13 T3.33.2 The EI of the vertical side of the front bulkhead support structure must be
equivalent…
•
•
•
•
AF7.14 T3.34.1 In the region longitudinally forward of the Main Roll Hoop and aft of the
Front Roll…
AF7.15 T3.34.2 The vertical side impact zone between the upper surface of the floor and
350 mm…
AF7.16 T3.34.3 The vertical side impact zone between the upper surface of the floor and
350 mm…
AF7.17 T3.37 Monocoque Front and Main Hoop Bracing
6
2016 Rules Changes – FSAE IC
IC1.7.3 If pop-off valves, recirculation valves, or heat exchangers (intercoolers) are used, they
may only be positioned in the intake system as shown in IC1.6.1 Figure 2.
7
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC1.9.1.b Fuel Rails
Fuel Rail – The fuel rail must be securely attached to the engine cylinder block, cylinder
head, or intake manifold with mechanical fasteners. This precludes the use of hose clamps,
plastic ties, or safety wire. The threaded fasteners used to secure the fuel rail are considered
critical fasteners and must comply with ARTICLE 11.
The use of fuel rails made from plastic, carbon fiber or rapid prototyping flammable materials is
prohibited. However, the use of unmodified OEM Fuel Rails manufactured from these materials
is acceptable.
8
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC1.11 ETC
•
IC1.11.2 The electronic throttle must automatically close (return to idle) when power is
removed from it.
•
IC1.11.3 The electronic throttle must use at least two (2) sources of energy capable of
returning the throttle to the idle position. One of the sources may be the device that
normally actuates the throttle, e.g. a DC motor, but the other device(s) must be a throttle
return spring that can return the throttle to the idle position in the event of a loss of
actuator power.
NOTE: springs in the TPS are not acceptable throttle return springs
9
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC1.12 ETC-TPS
•
IC1.12.1 The TPS must measure the position of the throttle or the throttle actuator. Throttle
position is defined as percent of travel from fully closed to wide open where 0% is fully
closed and 100% is fully open.
•
IC1.12.2 At least two separate sensors have to be used as TPSs. The TPSs may share the
same supply and reference lines only if effects of supply and/or reference line voltage
offsets can be detected.
•
IC1.12.3 If an implausibility occurs between the values of the two TPSs and persists for more
than 100msec, the power to the electronic throttle must be immediately shut down.
•
IC1.12.4 Implausibility is defined as a deviation of more than 10% throttle position between the
sensors or other failure as defined in IC1.12. Use of larger values may be considered on a case
by case basis and require justification in the FMEA.
•
IC1.12.6 Each TPS must have a separate detachable connector that enables a check of these
functions by unplugging it during Technical Inspection, else, an inline switchable break-out box
must be made available during Technical Inspection that allows disconnection of the each TPS
signal.
10
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC1.13 ETC-APPS
•
IC1.13.1 The APPS must be actuated by a foot pedal. Pedal travel is defined as percent of
travel from a fully released position to a fully applied position where 0% is fully released and
100% is fully applied.
•
IC1.13.2 The foot pedal must return to its original position when not actuated. The foot pedal
must have a positive stop preventing the mounted sensors from being damaged or
overstressed. Two (2) springs must be used to return the throttle pedal to the off position and
each spring must be capable of returning the pedal to the off position with the other
disconnected.
NOTE: The springs in the APPSs are not acceptable pedal return springs.
•
•
IC1.13.3 At least two separate sensors have to be used as APPSs. Separate is defined as not
sharing supply or signal lines.
NOTE: it would be normal for the two sensors to have different transfer functions.
•
IC1.13.4 If implausibility occurs between the values of the two APPSs and persists for more
than 100msec, power to the electronic throttle must be immediately shut down.
11
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC1.13 ETC-APPS-Cont’d
•
IC1.13.5 Implausibility is defined as a deviation of more than 10% pedal travel between
the sensors or other failure as defined in IC1.13. Use of larger values may be considered
on a case by case basis and require justification in the FMEA.
•
IC1.13.6 If three sensors are used, then in the case of an APPS failure, any two APPSs
that agree within 10% pedal travel may be used to define the throttle position target and
the 3rd APPS can be ignored.
•
IC1.13.7 Each APPS must have a separate detachable connector that enables a check of
these functions by unplugging it during Technical Inspection, else, an inline switchable
break-out box must be made available during Technical Inspection that allows
disconnection of the each APPS signal.
•
IC1.13.8 The APPS signals must be sent directly to the throttle controller using an
analogue signal or via a digital data transmission bus such as CAN or FlexRay. Any failure
of the APPSs or APPS wiring must be detectable by the controller and must be treated like
an implausibility.
12
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC1.14-IC1.6. ETC-Cont’d
•
IC1.14.2 The BSE must have a separate detachable connector that enables detection of error states
and the response of the ECU to be checked by unplugging it during Technical Inspection, otherwise
an inline switchable break-out box must be made available during technical inspection that allows
disconnection of each BSE signal.
•
IC1.14.3 The BSE signals must be sent directly to the throttle controller using an analogue signal or
via a digital data transmission bus such as CAN or FlexRay. Any failure of the BSE or BSE wiring that
persists more than 100msec must be detectable by the controller and must be treated like an
implausibility such that power to the electronic throttle is immediately shut down.
•
IC1.15.2 The power to the electronic throttle and the fuel pump must be immediately shut down, if
throttle position differs by more than 10% from the expected target TPS position for more than 1
second. An error in TPS position and the resultant system shutdown must be demonstrated at
Technical Inspection.
•
The electronic throttle and fuel pump shutdown must remain active until the TPS signals indicate the
throttle is at or below the unpowered default position, for at least one (1) second.
13
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC2.6 Fuel Filler & Sight Tube
•
IC2.6.2 At least 125 mm (4.9 inches) vertical height of the fuel filler neck must be above the
top level of the tank, and must be accompanied by a clear fuel resistant sight tube for
reading the fuel level. (Figure 14)
•
IC2.6.3 The sight tube must have at least 125 mm (4.9 inches) of visible vertical height and
a minimum inside diameter of 6 mm (0.25 inches).
•
IC2.6.6 Fuel Level Line - A permanent, non-moveable fuel level line must be located
between 12.7 mm and 25.4 mm (0.5 inch and 1 inch) below the top of the visible portion of
the sight tube. This line will be used as the fill line for the Tilt Test (Rule T8.5), and before
and after the Endurance Test to measure the amount of fuel used during the Endurance
Event.
14
2016 Rules Changes
2016 Rules Changes – FSAE IC
IC4.4.4 Lithium Batteries
•
•
•
2016 Rule:
IC4.4.4 Battery packs based on Lithium Chemistry:
a. Must have overcurrent protection that trips at or below the maximum
specified discharge current of the cells.
b. Must have a rigid, sturdy and fire retardant casing.
c. Must be separated from the driver by a firewall as specified in T4.5
The 2015 Rule was:
IC4.4.4 Battery packs based on Lithium Chemistry:
a. must be commercially manufactured items
b. must have over voltage, under voltage, short circuit and over temperature
cell protection
c. must be separated from the driver by a firewall
15
2016 Rules Changes
2016 Rules Changes – FSAE-E
EV4.12 TSAL
EV4.12 Tractive-system-active light (TSAL)
•
EV4.12.1 The vehicles must include a single Tractive Systems Active Light (TSAL) that
must illuminate when the tractive system is active. The TSAL must not perform any
other functions.
•
EV4.12.2 The tractive system is active when any of the following are true:
a. An accumulator isolation relay is closed.
b. The voltage outside the accumulator containers exceeds 60V DC or 25V AC RMS.
•
EV4.12.3 The TSAL itself must:
a. Be directly controlled by the voltage present within the tractive system using hard wired
electronics. Software control is not permitted.
b. Be red in color.
c. Flash continuously with a frequency between 2Hz and 5Hz when illuminated.
16
2016 Rules Changes
2016 Rules Changes – FSAE-E
EV4.12 TSAL-Cont’d
•
EV4.12.4 The TSAL mounting location must:
a. Be near the main roll hoop at the highest point of the vehicle.
b. Be mounted lower than the highest point of the main roll hoop.
c. Be no lower than 150 mm from the highest point of the roll hoop.
d. Not allow contact with the driver’s helmet in any circumstances.
e. Not be in proximity to other lights.
•
EV4.12.5 The TSAL must be visible:
a. From every horizontal direction, except small angles which are blocked by the main roll hoop.
b. From a point 1.6m vertically from ground level, within a 3m horizontal radius from the TSAL.
c. In direct sunlight.
17
2016 Rules Changes
2016 Rules Changes - Summary FSAE
All
Rule
Number
•
System
A8.1 & A8.5 Cost Report
Change
PART S - ARTICLE 4: “Cost Report” - Report must comply with
the Cost Event Rules.
*For 2016 Formula SAE Competitions in United States, Cost Report Submission process
may be changed. Please refer to the website for additional announcements and
information.
18
2016 Rules Changes
2016 Rules Changes – FSAE IC
Cost Report
•
Engine cost includes transmission (whether integral or not by design),
components used to transmit power between engine and transmission and all
components necessary to run including spark plugs, coils, wires, oil filter, etc.
with the exception of the air induction and fuel system components.
•  Any driveline component downstream of the transmission output gear/shaft is
not included.
•  Cost includes engine as received by manufacturer but not custom parts such
as drysump pans, PCV changes, etc.
•  Fully internal engine changes are free.
•  If covers or other parts are removed disassembly labor must be included in
labor cost.
19
2016 Rules Changes
2016 Rules Changes – Summary
Formula Hybrid
For the benefit of the teams, below is a summary of the major rules changes for the 2014 Formula SAE
competitions. It is not a complete list and is not binding. If there are any differences between this summary and the
official rules, the Rules will prevail. Therefore, it is the responsibility of the competitors to read the published Rules
thoroughly.
Rule
Number
Section
A1.2.3
Battery Capacity
Change
Added description of capacity calculations
A7.5
A9.3
Multiple year vehicles
Late submissions
Allowed, but caveats on expectations and scoring.
Several changes to late penalties
A9.4
T2.1.2
Early submissions
Definition of Open Wheel
New section! Bonus points for early SES approvals
Aligned with 2015 FSAE definition
T4.1.1
T4.1.2
Cockpit Opening Template
Cockpit Cross Section Templt
Movement of template allowed (as FSAE)
Added note on vertical movement
T5.1.2(e)
T6.5.5
Driver’s Harness Lap Belt
Rear Wheel Steer
Added recommendation for 2 tilt lock adjusters
Now allowed
T7.4
T8.1.2
Brake Light
Cooling Fluids
Aligned with 2015 FSAE rules
“Opticool” approved as electrical system coolant
20
2016 Rules Changes
2016 Rules Changes – Summary
Formula Hybrid (Cont’d)
Rule
Number
System
Change
EV2.2.1
Accelerator Error Checking
If in motor controller, no extra circuits required.
EV2.3
Accelerator Signal Isolation
Must be galvanically isolated from TS and bonded
to GLV ground.
EV3.3
Accumulator Housings
New section, “Virtual Accumulator Housings”
EV3.4.4
SMD Lockout
Removed padlock at a locking means
EV3.4.7
Accumulator Voltage Indicator
Now applies to removable containers only
EV3.5.8
Accumulator Openings
Cooling openings “reasonable size”, no completely
open side pods
EV3.6.3
Isolation Relays
Clarified (now includes no TSV to IMD)
EV3.7.8
AMS Shutdown
Clarified that some GLV systems can stay active.
EV3.7.10
AMS Test Port
Updated Test Connector Wiring drawing, Fig. 28
EV3.7.10.a AMS Test Port
Changed Banana Jack spacing (now 0.75” was 1.0”)
21
2016 Rules Changes
2016 Rules Changes – Summary
Formula Hybrid (Cont’d)
Rule
Number
System
Change
EV3.9
Pouch Cells
MAJOR CHANGES!
EV4.3.2
Grounding
Max resistance changed to 100 ohms (was 5 ohms)
EV4.4.6
TSMP Protection
Fuses no longer permitted.
EV4.7.4
HVD Lockout
Removed padlock as a locking device.
EV4.10
TESL Indicator
All references to TSAL changed to TSEL
EV4.10.2
TESL Indicator
Required color changed from red to amber.
EV5.1
Shutdown Circuits
Shutdown Button (BRB) sections clarified &
reorganized.
EV5.2
Master Switches
Section rewritten & reorganized.
EV5.5.6
Elect. w/Internal Power
Was a note, now a rule.
EV5.6.1
Side Mounted S/Down Buttons
Location clarified
22
2016 Rules Changes
2016 Rules Changes – Summary
Formula Hybrid (Cont’d)
Rule
Number
System
Change
EV5.9.4
IMD Shutdown
Some GLV systems may remain energized.
EV8.2.2
Charging
Chassis/frame must be grounded while charging.
EV8.4
Required Equipment
Updated list. Was EV8.3.6.
EV9.1.4
ESF
Must now include MSDS sheets for accumulator
cells.
S1
Pre-Event Peer Review
Rewritten.
23
2016 Rules Changes
2016 FH Rules Changes
S1 Peer Review
•
S1.1.1 The first inspection of a vehicles electrical systems will take place at the
team’s home institution approximately three (3) weeks before the competition.
The review will be performed by volunteer Electrical Engineers from the IEEE or
by other qualified professionals.
Note: The electrical reviewers are professionals who have volunteered their time to
assist your team meet the Formula Hybrid electrical rules requirements. For the
review to be effective, the vehicle ESF and schematics must be complete and as
accurate as possible. Asking these engineers to review your vehicle with
incomplete system documentation could be seen as disrespectful.
•  S1.1.3 Teams will be contacted by the organizers approximately one month before
the competition to schedule the technical reviews.
24
2016 Rules Changes
2016 FH Rules Changes
S1 Peer Review - (Cont’d)
•
Vehicles should be presented in a condition that will allow an inspection of its
electrical systems.
•
At a minimum this would be:
-  Major electrical components mounted in their final locations within the vehicle.
-  GLV control wiring in place and functional
-  TSV wiring in place with conduit and strain relief where required.
-  TSV protective covers mounted in their final positions.
-  Accumulator enclosures finished and mounted to the vehicle structure with
conduit, strain relief etc. in place.
Note: Accumulator devices do not need to be installed for the PEER inspection.
However the AIRs should be located in their final positions and should be functional,
with all TSV wiring outboard of the AIRs in place. AMS sense wiring should be
complete up to where they would connect to the accumulator cells.
25
2016 Rules Changes
2016 Rules Changes – Summary
Formula Hybrid (Cont’d)
Rule
Number
System
Change
S2.3
Inspection Condition
Waived for HIP and SEO vehicles.
S3
Project Management
Reorganized and many clarifications
S4.10.2
Static Events Only (SEO)
Rule rewritten and clarified.
D5.4.2
Acceleration Event
Order of runs restriction removed for hybrids
Appendix J
Firewall Flame Test
Required torch changed from Mapp gas to Propane
26
2016 Rules Changes
Formula SAE Workshop
Copyright © 2015 Michael J. Royce.
All rights reserved.