F1 in Schools

2. Meet the team KATE ELTON - MANUFACTURING ENGINEER Kate is responsible for manufacturing part of the project. Kate is the person who machines the cars and maintains the machinery. Kate has a bubbly personality who always has a smile on her face and is a great manufacturing engineer. LAURA COWIE - DESIGN ENGINEER Laura is responsible for the designing of the cars. She is to liaise with the graphic designer to make sure that the colour schemes will work with the design of the car. Laura is always looking on the bright side and has a vibrant design streak running through her. EMILY BLANCH - TEAM MANAGER Emily is responsible for managing the team. She is to make sure that everything is completed on time and to the best that it can be. Emily also picks up the odd jobs that need to be done. Emily is a person full of enthusiasm and has good management and people skills which help her along in her role of Team Manager. SARAH LINNEGAR - RESOURCES MANAGER Sarah is given the job of finding out what resources are available for the team to use. Sarah is also responsible for time management. She is to liaise with the other members of the team to make sure they are running to schedule. Sarah has a bright personality and a resourceful mind, making her perfect for the job. SARAH DEALL - GRAPHIC DESIGNER Sarah is responsible for the artistic side to the project. Sarah works with the colour schemes, marketing material and graphics for the folio. Sarah also needs to liaise with the resource manager for the marketing of the team. Sarah is an energetic person with an artistic eye .

3. Team identity Companies who are not relentlessly trying to differentiate themselves from their competition, position strategically, build brand identity, brand image and total brand equality find themselves hung out to dry. When picking the name for our team we wanted to pick something that represented speed and racing. Team Engine Overload gave us the image of speed and the revving of the engine, hence the use of a revved speedometer for our logo. Also for our name we wanted to steer away from the pink image in our name as pink was used last year in our school’s team name. The name - Team Engine Overload we thought was catchy and a had a certain ring to it. Therefore it would be a memorable name for those who come across us. USE OF ICT – Our graphic designer was responsible for developing our logo design. This was done using a combination of Adobe Illustrator and Photoshop Here you can see our logo which is printed on our shirts

4. sponsorship In order to assist our team in the production of a quality project we wanted to obtain sponsorship so that we could ‘compete’ at a higher level. This year we sought a level one sponsorship of $300 . This money would be used to buy materials such as paint, paper and would go towards are team shirts. Establishing a link Earlier in the year, our team attended the State Manufacturing Forum , which was held at the Superdome. This is where we met Mr Peter Farrel (ResMed). Mr Farrel was very intereted in what we where doing and so we decided to approach ResMed to see if they would be interested in sponsoring our team. Our team manager (Emily) was responsible for pitching our proposal to them. ResMed agreed to be the official sponsor of Team Engine Overload! In return, ResMed would receive free advertising and exposure at the SIDC and their logo would appear throughout our folio and any team marketing material. About ResMed ResMed is a leading respiratory medical device manufacturer , specializing in products for the diagnosis and treatment of sleep disordered breathing (SDB). ResMed operates through direct offices in the United States, the United Kingdom, Switzerland, Sweden, Spain, Singapore, New Zealand, the Netherlands, Malaysia, Japan, Hong Kong, Germany, France, Finland, Australia , and Austria, and through a network of distributors in more than 60 other countries. ResMed's principal manufacturing facilities are located in Sydney, Australia. The manufacturing operations consist primarily of assembly and testing of devices, masks and accessories. Of the numerous raw materials, parts and components purchased for assembly of therapeutic and diagnostic sleep disorder products, most are off-the-shelf items available from multiple vendors. ResMed generally manufactures to its internal sales forecasts and fills orders as received. As a result, the Company generally has no significant backlog of orders for its products. A quality control group performs tests at various steps in the manufacturing cycle to ensure compliance with the Company's specifications.

5. sponsorship We made it to the NATIONALS – MORE FUNDS NEEDED! As soon as we found out that we had made It through to the Nationals, we knew that we needed to search for other sponsors to assist us financially and to also allow us to compete competitively in the field. Earlier this year, Sarah (graphic designer) completed a week of work experience at Merlot Constructions Australia, Design and Construction. She acquired some new skills, understanding the design process, and discovering different types of CAD programs used for different roles in the design process. After making contact and giving a brief presentation we were able to secure sponsorship for the Nationals. Merlot Constructions gave us $500 - this money was to be used for our travel expenses to Melbourne. About Merlot Constructions Merlot Constructions, provides new and innovative solutions to the building industry. They have engineered clubs and buildings such as Canley Heights RSL and Sports Club, Carlingford Bowling Club, Fox Hills Golf Club, Mount Lewis Bowling Club, Muirfield Golf Club, Pennant Hills Bowling Club, Terrigal Bowling Club, West Pennant Hills Sports Club, Avalon Beach RSL, Rockdale Tennis Club, Warragamba Workers Club, Albion Park Bowling Club, Corrimal RSL, John Edmondson VC Memorial Club. Merlot have won awards from the Master Builders Association on 7 separate occasions.

7. marketing Marketing is an essential part to our project. Firstly we wanted our marketing to reflect quality – after all our marketing would be a reflection of our team at the end of the day! TARGET MARKETING – We knew that the majority of the teams entering this competition would be males aged between 12 – 17 so we thought that our marketing tools need to be attractive to this demographic. We had the following ideas for the marketing of our team. We came up with many ideas but decisions were made on the suitability of the products and the simplicity of producing the products. When we were choosing how to market our team we wanted to come up with ideas that were original, fun and appealing to young people. These factors influenced our decision in choosing the computer game competition with a model F1 car as the prize . Newsletter Mugs Wristbands Key rings Model F1 prize Computer game competition Stress balls Caps Packs of cards Water bottles Stickers Marketing Ideas

8. marketing An important element of our marketing was to have a quality team uniform. We decided that our team needed a uniform which would assist in marketing and promoting our team. Our sponsorship money would be used to cover the costs of producing our uniform. Our Team Manager (Emily) was responsible for the production of the team uniform. We decided to approach ResMed to see if it would be possible to use their corporate shirts as out team uniform. This was done for two purposes: It would be more cost effective if they could provide us with shirts and secondly by providing us with shirts they would also be promoting their company. We took our shirts to Monograma to have our logo printed onto the front. USE OF ICT – our Graphic Designer produced these designs to show the team members what the uniforms would look like. This was done using both Adobe Illustrator and Adobe Photoshop.

9. marketing We decided to produce some bumper stickers to assist us in marketing our team. This was because bumper stickers are a powerful way to promote our team. They’re like “mini-billboards”, working 24/7 to get our message across. We also decided that we would have a competition on the day so as to attract people to our stand . We came up with the idea of using a computer game to play as we felt this would be best suited to our target market (being teenage boys mainly). We did some hunting around and eventually came up with Geoff Crammonds Grand Prix 4! The competition would be based on the idea of completing a hot lap - fastest time would win a model f1 car (purchased with sponsorship money). Our flyer for the competition – designed in Illustrator A team photo taken at the NSW Finals showing the Ferrari model prize for the competition on display along with our car TEAM NEWSLETTER We decided to create our own team newsletter to help promote our team and also to keep our sponsors informed as to what we had been up to. This is a great way of promoting ourselves. We also emailed this out as an e-zine to help save money in printing!

10. Collaboration COLLABORATION occurred at key points throughout the design process. On a day to day basis, collaboration occurred between team members in the sharing of knowledge, ideas and individual expertise. COLLABORATION WITH OUR SPONSORS - we collaborated with ResMed on a number of issues. We had to talk to them in regards to the reproduction of their company logo (which was supplied to us in the form of an eps file). We also collaborated with ResMed in regards to the production of team shirts. They showed us what their uniform is and provided us with essential information that assisted us in the development of our team uniform. WEBEX ONLINE COLLABORATION TOOL - The internet was a valuable resource in terms of collaboration for this project. On a day to day basis team members communicated to one another through the use of email and msn messenger . This allowed us to communicate as a team when we were not at school. We also used the WEBEX ONLINE COLLABORATION TOOL . This proved to be an extremely useful tool for working on this project during school holidays. Each day we scheduled short meetings to discuss and check up on the progress of our project. Agenda’s were set for each meeting. This was an interesting tool to use and we hope to be using this tool for other projects in the near future COLLABORATION WITH INDUSTRY- We approached Small Parts & Bearings Pty Ltd to see if they could provide us with information for the design of our fixed axle wheel system. They supplied us with valuable information and gave us the idea to use Graphite Powder (a form of lubricant) to assist in the lubrication of the wheels. This company also supplied us with the 1/8” Nickel Plated Brass Wheel Collars, which prevent the wheels from coming off the fixed axle system. COLLABORATION WITH INDUSTRY- We also collaborated with Monograma in regards to the requirements for out team uniforms to be printed. They provided us with valuable information in regards to suitable colours, sizes and files formats to be used.

11. Research – existing designs Overall Evaluation: The Toyota has a complicated yet aerodynamically efficient design. The design allows for the car to travel at high speed whilst maintaining contact with the track due to the use of wings which provide downforce. The car has a striking livery of contrasting colours. The wings are easily adjusted to suit different driving styles and tracks. A very nice machine!

12. Design concepts This was our first CATIA design – we felt it was a bit basic so we decided to have another go! This car gave us valuable experience in learning how to use the CAD software.

13. Design concepts This was our second design – a bit more radical, reminds us of the bat mobile! Lightweight and mean looking!!!!!!!! This design has a cut out on the bottom to reduce the weight.

14. Design concepts This was our third design – we all thought this was the best as it looked the most aerodynamic. We also added air scoops to the pods and wing tips to allow the air to pass cleanly through the car. We LIKE IT!!!! This was the car that got us to the NATIONALS

15. Design concepts This is the assembly of our car showing how it will look once manufactured. This is a CATIA PRODUCT

16. Design concepts Use of ICT - PENGUIN Our CATIA file was saved as an IGS file and then imported into RHINO and then rendered using PENGUIN NON PHOTOREALISTIC RENDERER . This rendering software allowed us to produce designs that look as though they have been hand rendered! What is Penguin? Penguin is a conceptual, sketch and cartoon, non-photometric scan line renderer. With Penguin you can create stylized images of your models with an artistic look for enhanced graphic and visual appeal.

17. Nsw car – livery design This was the livery design for the car that got us to the Nationals. The car in the blue ResMed colour but we have added some stripes to improve its attitude – we think it looks pretty cool!

19. innovation We decided that in order to make our car stand out from the crowd we needed to give it a POINT OF DIFFERENCE . We looked at the wing design of many formula 1 cars. These wings are designed to provide DOWNFORCE , however we thought of using the wings to give the car some lift so as to reduce the amount of friction created between the wheels and the track. From what we have seen all cars in the SIDC are using downforce – LETS TRY SOMETHING DIFFERENT! We looked at the wing design on planes. The angle at which a plane wing is tilted is known as “ ANGLE OF ATTACK ”. If we were to use a conventional wing design on our car, we would affectively be creating more friction between the wheels and the track, this is the reason for having our front wing designed more like those on a plane. It was important that the angle of attack not be too large so as not to have a major affect on the aerodynamics of the car. a = ANGLE OF ATTACK ANGLE OF ATTACK Angle of attack is a term used in aerodynamics to describe the angle between the wing's chord and the direction of the relative wind , effectively the direction in which the aircraft is currently moving. The amount of lift generated by a wing is directly related to the angle of attack, with greater angles generating more lift. GREATER ANGLE = GREATER LIFT

20. innovation We decided that in order to make our car stand out from the crowd we needed to give it a POINT OF DIFFERENCE . We looked at the wing design of many formula 1 cars. These wings are designed to provide DOWNFORCE , however we thought of using the wings to give the car some lift so as to reduce the amount of friction created between the wheels and the track. From what we have seen all cars in the SIDC are using downforce – LETS TRY SOMETHING DIFFERENT! We looked at the wing design on planes. The angle at which a plane wing is tilted is known as “ ANGLE OF ATTACK ”. If we were to use a conventional wing design on our car, we would affectively be creating more friction between the wheels and the track, this is the reason for having our front wing designed more like those on a plane. It was important that the angle of attack not be too large so as not to have a major affect on the aerodynamics of the car. a = ANGLE OF ATTACK ANGLE OF ATTACK Angle of attack is a term used in aerodynamics to describe the angle between the wing's chord and the direction of the relative wind , effectively the direction in which the aircraft is currently moving. The amount of lift generated by a wing is directly related to the angle of attack, with greater angles generating more lift. GREATER ANGLE = GREATER LIFT

21. Nationals – livery design This is the livery design for our Nationals car. We tried to keep the livery design similar to our previous car so that people would recognise it as being ours As you can see the front wing is designed to give the car some lift. The car was designed to be as light as possible – approx 65grams.

22. Final render This render was done using FLAMINGO . Flamingo is a photorealistic renderer which allows you to produce a realistic image of what your design would look like. Flamingo is a PLUGIN for RHINO3D , another CAD package that we used to assist us in producing high quality renders.

23. Testing - design specs Aim: To check that our cars would comply with the design specifications and rules as set by REA Method: We needed to check our cars against the specifications during the design stage and also during the manufacturing. CATIA was used to check our car met all the dimensional requirements. We factored in a tolerance of +/- 0.5mm for sanding after manufacture. MEASURE INERTIA – this allowed us to check the weight of our car assembly in CATIA (SHOWN BOTTOM RIGHT) ASSEMBLY DESIGN – this allowed us to check if anything would clash when assembled ie the front wing and the wheels. CATIA PROCESS – this allowed us to check the simulation of the machining process to ensure that our car could be manufactured on the CNC machine. MANUAL TESTING AFTER MANUFACTURE – Emily was responsible for checking the car dimensions after manufacture to ensure that it met all the requirements. Emily manually checking the dimensions of the car

24. Testing – reaction times Aim: To find the team member with the fastest reaction time. Method: In order to find the team driver we needed to test each member of the team to see who had the quickest reaction times. This was done by using a simple online reaction time tester. This test was similar to the Christmas tree setup as found on the race system. The traffic light turned from red to green. You had to press the mouse button as soon as you saw the green light show. Each team member would have 5 turns – the average reaction time overall was then calculated. All of us in the team practiced using this test. A screen shot of the tester can be seen to the right: Results: The average reaction times for each team member are show below: Conclusion: Kate has the fastest reaction time so she will be the team driver. A screen shot of the online Reaction Tester 0.2186 0.2252 0.2436 0.2055 0.2126 Laura Sarah D Sarah L Kate Emily

25. Testing – machine process Aim: To check that our cars could be machined from the balsa blank Method: We used the NC MANUFACTURE feature in CATIA to produce the NC CODE for the MICROROUTER . This process converts our design into numeric code so that the router knows exactly where to machine. These images show the toolpath that is used to machine our cars out of the balsa blank. It even allows us to see the actual finish of the car when we zoom in! Emily manually checking the dimensions of the car

26. Testing – wind tunnel Aim: To test the aerodynamic efficiency of the cars we designed. Method: Our cars were placed in the WIND TUNNEL and hooked up to the internal sensor. The wind tunnel was then turned on. Drag was determined by the amount that the air pushed against the car's surface. The greater the push the air made on the car, the more the car moved backward. The backward motion of the car pulled on the sensor. This sensor gave a reading of drag in grams. The lower the number the better the aerodynamics. Results All of the the tests involved some vibrating, which caused the readings to rise and fall. Human judgment was used to determine the mean of those high and low values. We noticed that the National Final car vibrated in the tests when the tunnel was at its highest wind speed (120kph) NSW Final Car = 39g of drag National Final Car = 32g of drag Conclusion: It was clear that our new car was the most aerodynamic Kate and Emily conducting wind tunnel tests

27. manufacture This is the first stage in the manufacturing process. The balsa blank is loaded into the Microrouter MANUFACTURING STAGE 1 The second stage is to open your NC file which was created in CATIA. VR MILLING is used to control the router MANUFACTURING STAGE 2 Here you can see the car being machined inside the Microrouter. This process takes approx 25 minutes. MANUFACTURING STAGE 3

28. manufacture Here you can see our car just after being taken out of the machine. You can also see the fixture still attached. MANUFACTURING STAGE 4 Here you can see our manufacturing engineer using the bandsaw to cut the car free from the balsa blank MANUFACTURING STAGE 5 Our team manager helping to sand our cars before paint is applied MANUFACTURING STAGE 6

29. manufacture MANUFACTURING STAGE 6 Here you can see our car after being sprayed metallic blue. The car was first primed and then rubbed back before the top coat was applied. Kate our manufacturing engineer assembles the cars and works on the wheel systems. MANUFACTURING STAGE 7 MANUFACTURING STAGE 6 Here you can see one of our cars being finished. The last thing to do is apply all the sponsors stickers.

31. THE END QUESTION TIME THANKS FOR THE EXPERIENCE