Introduction

The Department of Structures within Redback Racing are primarily involved with designing and manufacturing a vehicular frame and its dependent peripherals. Structures therefore remains at the forefront of the Design Process of RB21-E, by providing a foundation for other Departments to carry out their projects. Due to this, the specific design choices made by Structures can be seen to have a domino effect on other Technical Departments, such as through the introduction of spacial constraints. Owing to a recent Restructuring of internal departments, Structures has shifted from being made up of 2 sub-departments to now being comprised of 4 distinct sub-departments

Departments - An Overview

Driver Safety

The sub-department of Driver Safety transcends what the name implies, being in charge of driver ergonomics in addition to direct safety components. Members are involved with designing, manufacturing, and testing safety components such as:

• Anti-Intrusion Plate (AIP)/Impact Attenuator (IA)
• Firewall
• Steering Wheel Housing
• Pedal Box
• Seat

Most manufactured components are static in nature and remain so during normal testing and competition use. But, the AIP/IA can be considered as dynamic due to the nature of crashes resulting in these components deforming in order to provide protection from injury alongside aiding in the deceleration of the Car. The design and manufacturing of components draws upon the existing hierarchy of experienced members. Some components are only required by FSAE-A rules to withstand a single force value, therefore, testing can sometimes be completed with the aid of a screwdriver, force gauge, and elbow grease. Other components like the IA and AIP have more restrictions and specific rules requiring more specialised equipment such as an Instron (a machine that crushes components and provides output data). Testing remains a fluid situation dependent upon the rules associated with differing components. Driver Safety is closely inter-linked with other Redback Racing Departments of Dynamics, Electrics, and the Drivers themselves.

The ergonomics associated with indirect safety components the Driver comes into contact with also greatly contribute to increased driver safety. For example, the placement of the Pedal Box on a slide rail help account for non-uniform variables such as height differences and preferences between Drivers. Ultimately, the focus is upon minimising distractions and designing intuitive smart features.

Chassis

Chassis as a sub-department is responsible for the design, verification, and construction of the chassis for the Car. In order to inform design choices, research is also carried out with regards to suitable materials that can be incorporated into the chassis such as Fibreglass and Carbon Fibre.

Chassis mainly concern themselves with the tasks of designing and manufacturing the frame of the Car, and Cockpit closeouts. With regards to testing, the main test for the frame itself is torsion testing. This is carried out by modelling the frame and analysing it in ANSYS (a simulation software) and through subsequent physical testing. Simulated and physical results are compared to inform future development and design choices. Chassis also account for Systems Packaging (specifications set forth by FSAE-A must be met) by communicating with the Departments of Aerodynamics and Electrics, resulting in a collaborative effort to ensure all Redback Department components can fit within the Car.

Mounts

Mounts are involved with the design and manufacturing of mounts which enable for other components of the Car to remain in their required orientation and position. These components can be electrical components, Motor, and Carbon Fibre body just to name a few. Mounts was a part of Ancillaries Pre-Restructure, and now work on:

• Electrical Components - master switch, brake light, LV battery, accumulator, inverter, motor, tractive enclosure, etc.
• Dynamic Components - pump, side-pods, radiator, catch can, motor controller, suspension, pedal box, under-tray etc.
• Chassis Components - impact attenuator, headrest, firewall, seat, etc.

Due to their involvement with a large set of components, Mounts find it difficult to carry out physical testing, instead relying upon FEA simulations. Mounts work with all Technical Departments, especially Electrics and Dynamics. New members are looking forward to the start of a new Design Cycle for RB22-E in Term 3, and can expect to make further contributions starting then.

Linkages

The sub-department of Linkages is involved with designing and manufacturing components related to the suspension of the car. Linkages work on:

• Anti-roll bar
• Control arms
• Uprights
• Wheel cubs
• Pushrods
• Tie-rods
• Dampers
• Bell-cranks

In a Formula SAE vehicle, the suspension's role is to control each wheel's angle, position, and velocity to maintain a high value of mechanical grip while transmitting the forces generated by the tyres to the chassis. Efficient designs result in greater performance as well as a better overall drive in terms of comfort.