Program Overview

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Program Overview

The NUS Formula SAE (FSAE) team brings together students from various disciplines to build and drive an electric Formula-style race car to compete annually against teams around the globe at the Formula SAE Michigan competition. Students who aspire to be part of the FSAE team need to complete a training programme before they are selected for the main competition team.

Course Description

This course is designed for the FSAE trainees to provide them with exposure to the basics of automotive engineering that are essential for building a race car. At the end of this course, students should be able to:

• Understand the basic components and subsystems of a race car.
• Create prototypes of components and subsystems using appropriate fabrication methods.
• Adopt good technical documentation and housekeeping practices.

Course Details

• Workload: 4 units (graded on CS/CU basis)
• Note: This course is only available for students who are selected for the FSAE training programme.

Course Syllabus

Introduction to FSAE Competition

• Competition format
• Rules
• NUS FSAE team format
• Roles and responsibilities

Chassis

• Function of chassis
• Different types of chassis
• Chassis loading
• Cockpit ergonomics
• Pedals, steering wheel, seat, and harness
• Composite theory

Suspension

• Function of suspension
• Different types of suspension systems
• Tyre data
• Suspension geometry
• Suspension loading

Aerodynamics

• Effects of aerodynamics
• Different types of aerodynamics devices
• Drag, lift, and aerodynamics balance

Drivetrain

• Introduction to gears and clutch
• Different types of drive
• Function of differentials
• Different types of differentials
• Different types of joints and half shafts

Electric Drive

• Control theory
• Different types of motor controllers
• Different types of motors

Electrical and Electronics

• FSAE rules for electrical
• Basic schematics for FSAE cars
• Function of major subsystems in FSAE cars
• Basics of CAN bus
• Connectors, wire gauge, and shielding

Engine

• Different types of engines
• Introduction to wave dynamics
• Intake and exhaust
• Cooling and lubrication
• Forced induction
• Hybrid drive

Sensors

• Different types of sensors on FSAE cars
• Sensor calibration
• Introduction to datalogging

Race Car Reliability / Failure

• Material fatigue
• Force calculation
• Testing and validation
• Case study

CAD Training

• Basic SolidWorks training
• CAD good practices
• Design for prototyping
• Advanced SolidWorks training

Finite Element Analysis

• Introduction to finite element analysis
• Ansys Static Structural GUI and setup
• Ansys Fluent GUI and setup
• Case study

Fabrication

• Manufacturing methods
• Milling training
• Lathe training
• Composite training

Safety

• Risk assessment
• Introduction to tools and equipment

Institution

The course is offered by the Engineering Design and Innovation Centre at the National University of Singapore.