Formula Student Rules 2024 PDF

Formula Student Rules 2024 C ONTENTS Changelog 3 Abbreviations...

Formula Student Rules 2024 C ONTENTS Changelog 3 Abbreviations 8 A Administrative Regulations 10 A 1 Competition Overview................................... 10 A 2 Vehicle Eligibility..................................... 11 A 3 Rules of Conduct...................................... 12 A 4 General Requirements for Teams & Participants..................... 13 A 5 Documentation & Deadlines................................ 15 A 6 General Rules....................................... 18 T General Technical Requirements 23 T 1 Definitions......................................... 23 T 2 General Design Requirements............................... 26 T 3 General Chassis Design.................................. 29 T 4 Cockpit........................................... 42 T 5 Driver Restraint System.................................. 47 T 6 Brake System....................................... 50 T 7 Powertrain......................................... 51 T 8 Aerodynamic Devices................................... 53 T 9 Compressed Gas Systems and High Pressure Hydraulics................. 54 T 10 Fasteners.......................................... 55 T 11 Electrical Components................................... 56 T 12 Vehicle Identification................................... 62 T 13 Vehicle and Driver Equipment............................... 63 T 14 Autonomous System.................................... 66 T 15 Autonomous System Brake................................ 70 CV Internal Combustion Engine Vehicles 72 CV 1 Internal Combustion Engine Powertrains......................... 72 CV 2 Fuel and Fuel System................................... 75 CV 3 Exhaust System and Noise Control............................ 79 CV 4 Shutdown System..................................... 79 CV 5 Hybrid System....................................... 80 EV Electric Vehicles 82 EV 1 Definitions......................................... 82 EV 2 Electric Powertrain..................................... 82 EV 3 General Requirements................................... 83 EV 4 Tractive System...................................... 84 EV 5 Tractive System Energy Storage.............................. 90 Formula Student Rules 2024 Version: 1.1 1 of 136 Contents EV 6 Shutdown Circuit and Systems.............................. 95 EV 7 Chargers.......................................... 97 EV 8 Tractive System Accumulator Container Hand Cart.................... 98 EV 9 Electrical System Form.................................. 99 IN Technical Inspections 100 IN 1 General........................................... 100 IN 2 Pre-Inspection....................................... 102 IN 3 [EV ONLY ] Accumulator Inspection........................... 103 IN 4 [EV ONLY ] Electrical Inspection............................. 104 IN 5 Mechanical Inspection................................... 105 IN 6 Autonomous System Inspection.............................. 105 IN 7 Tilt Test.......................................... 105 IN 8 Vehicle Weighing..................................... 106 IN 9 [EV ONLY ] Rain Test................................... 106 IN 10 [CV ONLY ] Noise Test.................................. 106 IN 11 Brake Test......................................... 107 IN 12 Post Inspection....................................... 108 S Static Events 109 S1 Business Plan Presentation Event............................. 109 S2 Cost and Manufacturing Event............................... 110 S3 Engineering Design Event................................. 115 D Dynamic Events 118 D 1 Dynamic Events General.................................. 118 D 2 Driving Rules....................................... 118 D 3 Weather Conditions.................................... 121 D 4 Skidpad Event....................................... 122 D 5 Acceleration Event..................................... 125 D 6 Autocross Event...................................... 127 D 7 Endurance and Efficiency Event.............................. 128 D 8 [DC ONLY ] Trackdrive Event............................... 133 D 9 Dynamic Events Penalties................................. 134 Formula Student Rules 2024 Version: 1.1 2 of 136 Formula Student Rules 2024 C HANGELOG Rule Version Change A 1.2.1 1.0 Included CV Hybrid into CV class A 3.7 1.0 Simplified and clarified protest rules A 3.8.1 1.0 Defined minimum penalty for rules violation A 3.8.2 1.0 Defined penalty handling for DC A 4.2.8 1.0 Defined “first competition” A 4.3.8 1.0 Replaced reference to HV by TS A 4.4.2 1.0 Clarified total number of ESOs and ASRs A 5.3.1 1.0 Simplified rule A 5.4 1.0 Extended late submission handling to all deadlines A 5.6.7 1.0 Re-added rule that was accidentally removed A 6.4.6 1.1 Replaced APPS/brake pedal plausibility check by BSPD A 6.7 1.0 Removed rule about the HVD A 6.7.7 1.0 Clarified rule A 6.10 1.0 Added requirements for working on an EV T 1.1.2 1.0 Added definition of bodywork T 1.1.2 1.1 Clarified rule T 1.1.12 1.0 Harmonized impact structures under respective rule T 1.1.16 1.0 Updated definition of rollover protection envelope T 1.1.18 1.0 Updated definition of surface envelope T 1.1.18 1.1 Clarified definition of surface envelope T 2.2.1 1.0 Added restriction for active suspension T 2.3.2 1.0 Added rule about the shape of the bodywork T 2.3.2 1.1 Clarified rule T 2.3.4 1.0 Clarified rule T 2.4.1 1.0 Unified minimum radius for aerodynamic devices and bodywork T 2.4.1 1.1 Clarified rule T 2.6.2 1.0 Clarified rule T 2.8.9 1.0 Prescribed positioning of steering rack T 2.8.9 1.1 Clarified rule T 3.2.1 1.0 Changed value to resolve historical discrepancy with SES and updated T 3.4.4 1.0 Added thickness restriction for asymmetrical lay-ups T 3.5.4 1.0 Added rule to define not quasi-isotropic laminate direction and alignment T 3.15.2 1.0 Added rule to remove inconsistencies between side- and other impact structures T 3.15.3 1.0 Added minimum absorbed energy requirement for two baseline steel tubes and updated rule to remove inconsistencies between side and other impact structures T 3.17.1 1.0 Clarified rule T 3.17.3 1.0 Clarified rule T 3.17.5 1.0 Redefined IA attachment requirements T 3.17.7 1.0 Added minimum adhesive strength requirement for “standard” honeycomb IA Formula Student Rules 2024 Version: 1.1 3 of 136 Contents Rule Version Change T 3.19.1 1.0 Clarified allowance of testing mass and enforcement of rule T 3.19.4 1.0 Added physical testing requirement for non-crushable object(s) located in direct front view of the AIP T 4.8.7 1.1 Require solid layer T 5.5.3 1.0 Clarified rule by separation of bar and bracing T 6.1.8 1.1 Clarified position of the brake system T 6.1.10 1.0 Clarified that brake pedal includes the pedal face T 6.1.11 1.0 Removed [EV ONLY ] label, also valid for HY T 6.2.3 1.0 Changed requirements for BOTS T 6.2.3 1.1 Clarified rule T 6.3.2 1.0 Redefined brake light as system status light to clarify requirements T 7.2.2 1.0 Changed to accomodate HY T 7.2.3 1.0 Clarified wording for heat resistant cover plate positioning T 7.2.7 1.0 Clarified engine and motor(s) cooling specification T 9.1.1 1.0 Added exception for gas springs T 10.1.5 1.0 Added new rule about fasteners T 10.2.3 1.0 Changed wording for snap or retaining rings T 11.1.5 1.0 Added low power control signal voltage limit for HY T 11.4.7 1.0 Added rule that shutdown buttons must be red T 11.5.4 1.0 Clarified wording for inertia switch mounting T 11.7.7 1.0 Applied rule for all HSC, regardless of chemistry type T 11.8.5 1.0 Changed requirements for APPS T 11.9.3 1.0 Moved SCS wording to a separate rule T 11.10.1 1.0 Introduced definition of system status light T 11.11 1.0 Unified wording for electrical component mounting T 12.2.1 1.0 Added hybrid vehicle identification requirements T 13.2.2 1.0 Changed wording for positioning the jacks T 13.2.3 1.0 Changed size of jacks T 13.3.2 1.0 Removed standards that expire after 31.12.2023 T 13.3.3 1.0 Added frontal head restraint system standards T 13.3.10 1.0 Added validity of fire resistant clothing T 13.3.12 1.0 Clarified embroidered driver’s clothing T 13.3.13 1.0 Updated fire resistant material usage in driver’s clothing T 14.2.3 1.0 Added new requirement concerning data logger mounting for CV T 14.9.2 1.0 Added additional logic to transition from AS Finished to AS Emergency T 14.10.3 1.0 Specified requirements on ASSI visibility T 14.10.4 1.0 Redefined ASSI as system status light to clarify requirements T 14.11.3 1.0 Added new requirement concerning mission selection T 15.1 1.0 Removed redundant rule about brake system specifications T 15.1.2 1.0 Clarified allowed locations for parts of ASB T 15.4.2 1.0 Increased requirement on EBS performance CV 1.1.1 1.0 Allowed hybrid powertrains CV 1.3.2 1.0 Harmonized impact structures CV 1.3.2 1.1 Clarified T 3.16 reference CV 2.2 1.0 Removed redundant rule about fuel system parts below the chassis (already defined by EV 4.4.1) CV 2.4.1 1.0 Added temperature rating for fuel lines Formula Student Rules 2024 Version: 1.1 4 of 136 Contents Rule Version Change CV 2.4.2 1.0 Allowed unmodified OEM fuel lines and connectors CV 2.4.3 1.0 Clarified rule CV 3.2 1.0 Moved noise test requirements to IN 10 CV 4.1 1.0 Changed shutdown circuit for HY integration CV 4.1.4 1.0 Added HSC AIR to shutdown circuit CV 5 1.0 Added section for hybrid system restrictions and requirements EV 1.2.1 1.0 Clarified test voltage, added working voltage requirement EV 1.2.1 1.1 Require working voltage only if given in the datasheet EV 2.2.3 1.0 Removed APPS / brake pedal plausibility check EV 3.1.1 1.0 Require solid layer EV 3.1.2 1.0 Added LVS ground measureing point EV 3.2.5 1.0 Relaxed overcurrent protection of motors EV 4.3.6 1.0 Removed PCB spacing exception for integrated circuits EV 4.4 1.0 Removed redundant rule about TS parts below the chassis (already defined by EV 4.4.1) EV 4.4.2 1.0 Harmonized impact structures EV 4.4.2 1.1 Clarified T 3.16 reference and added exception for outboard wheel motors EV 4.5.2 1.0 Moved requirement to different rule EV 4.5.3 1.0 Added requirement from a different rule EV 4.5.13 1.0 Relaxed rule EV 4.5.14 1.0 Clarified rule EV 4.7.5 1.0 Clarified rule EV 4.7.7 1.0 Linked bolted and soldered connections to the high current path requirements EV 4.8.1 1.0 Relaxed rule EV 4.8.2 1.0 Relaxed rule EV 4.10.8 1.0 Defined angle per side EV 4.10.12 1.1 Relaxed rule EV 4.12.1 1.0 Clarified rule EV 5.4.3 1.0 Limited to TSAL’s green light EV 5.4.10 1.0 Defined voltage indicator supply EV 5.5 1.0 Removed redundant rule on joining walls and floor EV 5.5.1 1.0 Harmonized impact structures EV 5.5.2 1.0 Harmonized impact structures EV 5.5.2 1.1 Clarified T 3.16 reference EV 5.5.3 1.0 Require 60 ◦ C for calculations EV 5.5.9 1.0 Require ≥80 % of large surface, extended cell tab requirements EV 5.5.9 1.1 Relaxed rule, loading ≥80 % of one large surface is sufficient EV 5.5.10 1.0 Require testing of friction-based cell mouting EV 5.5.12 1.0 Relaxed AIR and the main fuse separation EV 5.5.14 1.0 Defined max. total cutout area EV 5.5.14 1.1 Clarified rule EV 5.5.15 1.0 Split rule, clarified cooling ducts requirements EV 5.6 1.0 Removed redundant rule about fuse rating EV 5.6.3 1.0 Shortened rule without changing the rule EV 5.7.1 1.0 Changed to voltage at the vehicle side of the AIRs EV 5.8.4 1.0 Clarified rule EV 5.8.12 1.0 Require a single overview showing all values Formula Student Rules 2024 Version: 1.1 5 of 136 Contents Rule Version Change EV 6.3.2 1.0 Added Bender ISOMETER® iso165C-1 EV 6.3.2 1.1 Added Bender A-ISOMETER® iso-F1 IR155-4203 and -4204 EV 7.1.10 1.0 Added charger labeling EV 8.1.6 1.0 Detailed hand cart firewall specification EV 8.1.8 1.0 Added rule that hand cart must be larger than TSAC EV 8.1.10 1.0 Require dedicated label on hand cart EV 8.1.10 1.1 Clarified rule IN 1.5.1 1.0 Allowed installation and removal of protective sensor covers IN 4.1.3 1.0 Move and rephrase BSPD test IN 5.1.1 1.0 Require that test piece and test fixture must be presented at mechanical inspec- tion IN 5.1.1 1.0 Added required items for HY IN 11.2.3 1.0 Increased requirement on EBS performance IN 12.1.3 1.0 Clarified rule S 1.1.1 1.0 Clarified rule S 1.1.3 1.0 Removed redundant information S 1.4.2 1.0 Reduced penalty S 2.4.4 1.0 Moved “fastener” definition to BOM and clarified they should not be listed S 3.4.6 1.0 Changed condition of spare cells S 3.4.8 1.0 Added separate design finals for DC S 3.7.2 1.0 Changed scoring categories for engineering design event D 2.4.1 1.0 Removed distinction between autonomous and manual mode D 2.7.6 1.0 Clarified thar re-runs are granted only for autonomous runs D 2.7.6 1.0 Clarified that officials must be notified before the dynamic event closes D 2.9 1.0 Added new subsection on handling of Re-Runs D 4.4 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 4.5 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 4.6 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 5.1.1 1.0 Removed restriction that cones are not marked D 5.4 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 5.5 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 5.6 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 6.1 1.0 Removed rule about DC autocross using the same track as the trackdrive event D 6.1.3 1.1 DC autocross layout is according to guidelines for trackdrive layout D 6.3 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 6.5 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 7.3.2 1.0 Clarified rule D 7.3.3 1.0 Clarified rule D 7.6.6 1.0 Clarified tire change after puncture D 7.7.4 1.1 Clarified rule D 7.8 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 7.9 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 8.2.2 1.0 Clarified rule D 8.2.3 1.0 Clarified rule D 8.4 1.0 Changed scoring formula to refer to table 3 for maximum number of points D 9.1.6 1.0 Added max. time to enter finish state D 9.2.4 1.0 Clarified rule Formula Student Rules 2024 Version: 1.1 6 of 136 Contents Rule Version Change D 9.2.4 1.0 Added definition of being too slow D 9.2.6 1.0 Added new rule about penalties D 9.4.2 1.0 Clarified that DQ(s) apply to fastest valid run(s) Formula Student Rules 2024 Version: 1.1 7 of 136 Formula Student Rules 2024 A BBREVIATIONS AIP Anti Intrusion Plate EBS Emergency Brake System AIR Accumulator Isolation Relay EDR Engineering Design Report AMI Autonomous Mission Indicator EI Flexural Rigidity AMS Accumulator Management System ESF Electrical System Form APPS Accelerator Pedal Position Sensor ESO Electrical System Officer AS Autonomous System ESOQ Electrical System Officer Qualification ASB Autonomous System Brake ETC Electronic Throttle Control ASF Autonomous System Form EV Electric Vehicle ASMS Autonomous System Master Switch HPI High Pressure Injection ASR Autonomous System Responsible HSC Hybrid Storage Container ASRQ ASR Qualification HSF Hybrid System Form ASSI Autonomous System Status Indicator HV High Voltage BOM Bill of Material HVD High Voltage Disconnect BOTS Brake Over-Travel Switch HY Combustion Hybrid Vehicle BPP Business Plan Presentation Event IA Impact Attenuator BPPV Business Plan Pitch Video IAD Impact Attenuator Data BSPD Brake System Plausibility Device IMD Insulation Monitoring Device CBOM Costed Bill of Material LPI Low Pressure Injection CRD Cost Report Documents LV Low Voltage CV Internal Combustion Engine Vehicle LVMS Low Voltage Master Switch DBOM Detailed Bill of Material LVS Low Voltage System DC Driverless Cup OC Off-Course DI Direct Injection R2D Ready-to-drive DNA Did Not Attempt RES Remote Emergency System DNF Did Not Finish SCS System Critical Signal DOO Down or Out SDC Shutdown Circuit DQ Disqualified SE3D Structural Equivalency 3D Model DSS Design Spec Sheet SES Structural Equivalency Spreadsheet DV Driverless SESA SES Approval Formula Student Rules 2024 Version: 1.1 8 of 136 Abbreviations TPS Throttle Position Sensor TSMP Tractive System Measuring point TS Tractive System TSMS Tractive System Master Switch TSAC Tractive System Accumulator Con- USS Unsafe Stop tainer VSV Vehicle Status Video TSAL Tractive System Active Light Formula Student Rules 2024 Version: 1.1 9 of 136 Formula Student Rules 2024 A A DMINISTRATIVE R EGULATIONS A1 C OMPETITION OVERVIEW A 1.1 Competition Objective A 1.1.1 The competition challenges teams of university students to conceive, design, fabricate, develop and compete with small, formula style, race cars. A 1.2 Competition Procedure A 1.2.1 The competition is split into the following classes: Internal Combustion Engine Vehicle (CV) including Combustion Hybrid Vehicle (HY) Electric Vehicle (EV) A 1.2.2 All vehicles must meet the requirements defined in chapters T and either EV or CV, depend- ing on their drivetrain type. A 1.2.3 The competition starts with a series of technical inspections described in chapter IN to check the vehicle for safety and compliance with the rules. A 1.2.4 The competition is divided into a series of static and dynamic events described in chapters S and D. A 1.2.5 The achievable points in each class are listed in table 3. A 1.2.6 Vehicles of both classes can take part in an additional Driverless Cup (DC). A 1.2.7 The maximum achievable points for the DC are listed in table 3. A 1.2.8 The team with the most overall points will win the competition for its class or the DC, respectively. A 1.3 Competition Information A 1.3.1 The competition specific rules and information are defined in the competition handbook. A 1.3.2 The official language of the competition is English. A 1.3.3 Every organizer of a competition based on this document bares the sole responsibility. Formula Student Rules 2024 Version: 1.1 10 of 136 A 2 Vehicle Eligibility CV & EV DC Static Events: Business Plan Presentation 75 points - Cost and Manufacturing 100 points - Engineering Design 150 points 150 points Dynamic Events: Skidpad 50 points - Driverless (DV) Skidpad 75 points 75 points Acceleration 50 points - Driverless (DV) Acceleration 75 points 75 points Autocross 100 points - Driverless (DV) Autocross - 100 points Endurance 250 points - Efficiency 75 points - Trackdrive - 200 points Overall 1000 points 600 points Table 3: Maximum points awarded A2 V EHICLE E LIGIBILITY A 2.1 Student Competition A 2.1.1 Vehicles entered into the competition must be conceived, designed and maintained by the student team members without direct involvement from external professional engineers, racers, machinists or related professionals. A 2.1.2 The student team may use any information from professionals or from academics as long as the information is given as a discussion of alternatives with their pros and cons. A 2.1.3 Professionals must not make design decisions or drawings. A 2.1.4 Students should perform fabrication tasks where ever possible. A 2.2 First Year Vehicles A 2.2.1 A vehicle may only be used for one year, counting from the first day onsite of its first competition. A 2.2.2 To be classified as new, a vehicle must have at minimum, a newly manufactured chassis with significant changes in the primary structure to its predecessor. Formula Student Rules 2024 Version: 1.1 11 of 136 A 3 Rules of Conduct A3 RULES OF C ONDUCT A 3.1 General Officials Authority A 3.1.1 The officials reserve the right to revise the schedule of the competition and/or interpret or modify the competition rules at any time and in any manner that is, in their sole judgment, required for safe and efficient operation. A 3.1.2 All team members are required to cooperate with, and follow all instructions from the officials. A 3.1.3 Official announcements shall be considered part of these rules. A 3.1.4 All guidelines and clarifications posted in the “Rules and Important Documents” sections on the competition website for the current season including the competition handbook are considered part of these rules. A 3.2 Official Instructions A 3.2.1 Failure of a team member to follow an instruction or command directed specifically to that team or team member results in 25 penalty points being deducted from the team’s overall score. A 3.3 Arguments with Officials A 3.3.1 Argument with, or disobedience to, any official results in the team being eliminated from the competition. A 3.4 Unsportsmanlike Conduct A 3.4.1 In the event of unsportsmanlike conduct, 25 penalty points will be deducted from the team’s overall score. A second violation results in expulsion of the team from the competition. A 3.5 Violations of Intent A 3.5.1 Violation of the intent of a rule will be considered a violation of the rule itself. A 3.5.2 Any parts, devices or software fragments designed with the intent to violate a rule, will be considered as a violation. A 3.6 Questions about the Rules A 3.6.1 Questions about the rules may be asked to the officials. A 3.6.2 The frequently asked questions (FAQ) section on the competition website must be checked before submitting a question. A 3.6.3 The officials will only answer questions that are not already answered in the rules or FAQs or that require new or novel interpretation. Formula Student Rules 2024 Version: 1.1 12 of 136 A 4 General Requirements for Teams & Participants A 3.6.4 Refer to the competition website for specific directions how to submit a rules question. A 3.7 Protests A 3.7.1 A team may protest any rule interpretation, score or official action which they feel has caused some actual, non-trivial, harm to their team, or has had a substantive effect on their score. A 3.7.2 All protests must be submitted in writing as defined in the competition handbook by the team captain within the announced protest period. In order to have a protest considered, a team must post a 25 point protest bond which will be forfeited if their protest is rejected. A 3.7.3 The decision of the officials regarding any protest will be in a written form and is final. A 3.8 Penalties A 3.8.1 Rule violations result in at least 20 penalty points, unless explicitly defined otherwise. The penalty points will be deducted from the team’s overall score. A 3.8.2 Overall penalties apply to CV, EV and DC score, except for penalties concerning events which are not part of the respective class or cup. A4 G ENERAL R EQUIREMENTS FOR T EAMS & PARTICIPANTS A 4.1 Teams per University A 4.1.1 A university can register one CV team and one EV team which both can take part in the DC. A 4.1.2 For the purposes of registering and competing, a university’s CV team and EV team are considered to be separate and independent entities. A 4.1.3 Teams which are formed with members from two or more universities are treated as a single team. A 4.2 Team Members and Participants A 4.2.1 Each participant must provide proof of valid private liability & individual health insurance for the competition. A 4.2.2 All onsite participants must sign a liability waiver upon registering onsite which can be found on the competition website. A 4.2.3 A team member may only be part of one team, work on one vehicle and take part in static and dynamic events for only one team. A 4.2.4 Each team must have one team member identified as the team captain. The team captain is the main contact person for the officials during the registration process and the competition. A 4.2.5 Persons who have previously attended any official event as a judge are not allowed to participate as team members. Formula Student Rules 2024 Version: 1.1 13 of 136 A 4 General Requirements for Teams & Participants A 4.2.6 Team members must be enrolled as degree seeking undergraduate or graduate students in any university. Team members who have graduated within the seven month period prior to the competition remain eligible to participate. A 4.2.7 Students seeking a PhD degree/PhD students or equivalent are not allowed to participate. A 4.2.8 Counting from the year of their first competition, team members can only participate for four additional full years. First competition is defined as the first registration of a team member for a competition by the team captain, irrespective if the team or the team member actually physically participated. A 4.2.9 Team members must be at least 18 years of age. A 4.2.10 Team members who will drive a competition vehicle at any time during a competition must present a valid, government issued driver’s license for passenger cars, containing a photograph. A 4.3 [EV ONLY ] Electrical System Officer A 4.3.1 Every participating team has to appoint one to four ESOs for the competition. A 4.3.2 The ESOs are responsible for all electrical work carried out on the vehicle during the competition. A 4.3.3 The ESOs are the only persons in the team who may declare the vehicle electrically safe, in order for work to be performed on any system of the vehicle by the team. A 4.3.4 The ESOs must be valid team members, i.e. they must have student status, see A 4.2.6. A 4.3.5 The ESOs must be contactable by phone at all times during the competition. A 4.3.6 An ESO must accompany the vehicle whenever it is operated or moved around at the competition site. A 4.3.7 If only one ESO is named by the team, this ESO must not be a driver. A 4.3.8 An appropriate Electrical System Officer Qualification (ESOQ) requires the proof of a practical and theoretical training for working on the TS. Regarding content, the training should be on the basis of DGUV 209-093 stage 2E/3E1 and held by an external expert. A 4.4 Autonomous System Responsible A 4.4.1 To operate the Autonomous System (AS), every participating team must appoint at least one ASR for the competition. This person is responsible for all autonomous operations of the vehicle during the competition which includes any work on the AS as well as racing and testing. A 4.4.2 For vehicles with an electric drivetrain the ASR must fulfill A 4.3 and therefore replaces the ESO. The team may register additional ESOs for accumulator inspection and work on Tractive System (TS) only. The sum of registered ASRs and ESOs must not exceed four persons. 1 https://fsg.one/4i5SP Formula Student Rules 2024 Version: 1.1 14 of 136 A 5 Documentation & Deadlines A 4.4.3 The ASR is the only person in the team who is allowed to declare the AS safe, so that the vehicle may be operated in manual or autonomous mode. A 4.4.4 The ASR must be a valid team member, i.e. they must have student status, see A 4.2.6. A 4.4.5 The ASR must accompany the vehicle whenever it is operated or moved around at the competition site. A 4.4.6 If only one ASR is named by the team, this ASR must not be a driver. A 4.4.7 The ASR must be properly qualified to handle the AS and to understand and deal with problems and failures. As ASR Qualification (ASRQ), a bachelor degree in computer science, electrical engineering, mechatronics, automation engineering, robotics or similar , i.e. comparable study content or progress, is a sufficient qualification. The qualification certificate needs to be an official university document and contain information on completed courses. A5 D OCUMENTATION & D EADLINES A 5.1 Required Documents and Forms A 5.1.1 Several documents and forms must be submitted by the action deadlines defined in the competition handbook. A 5.2 Submission A 5.2.1 Submitted documents may only be viewed by members of the submitting team, authorized judges and officials. A 5.2.2 By submitting documents via the competition website, the team agrees that they may be reproduced and distributed by the officials, in both complete and edited versions, for educational purpose. A 5.2.3 Documents or videos that are largely incomplete or not readable/viewable will be considered as not submitted. A 5.3 Correction Requests A 5.3.1 If the officials request a correction for a document, the corrected version has to be submitted within 168 hours (7 days) following the request. A 5.3.2 Separate requests for different parts within one document or form will be treated indepen- dently. A 5.3.3 If the corrected version of the document does not completely contain all requested corrections, the team will be de-registered from the competition. Formula Student Rules 2024 Version: 1.1 15 of 136 A 5 Documentation & Deadlines A 5.4 Late Submission or Non-Submission A 5.4.1 For each submission later than the respective deadline 10 penalty points are deducted from the team’s overall score. A 5.4.2 Teams that do not submit documents until 24 hours (1 day) after the respective deadline will be de-registered from the competition. A 5.5 De-registration A 5.5.1 A team which is de-registered from the competition has a single chance to apply for a place on the waiting list. A 5.5.2 To apply, the team must complete the following within 24 hours after the de-registration notification Submit an informal application to the officials Correct the reason for de-registration (e.g. submission of a document) A 5.5.3 If the application is positively confirmed by the officials, the team will: Be placed at the end of the waiting list. Receive 20 penalty points. A 5.5.4 Applications will be declined if the rework is inadequate or de-registration was caused by misbehavior of the team. A 5.6 Vehicle Status Video A 5.6.1 All teams must submit a video showing the vehicle driving prior to the competition. The video must be submitted before the deadline specified in the competition handbook. A 5.6.2 The video must show the following sequences in the described order: Standing still 360◦ video around the vehicle (close up, may overlap with the following two bullet points) [EV ONLY ] Activate TS [CV ONLY ] Start engine Straight driving, minimum distance is 30 m, minimum speed is 10 km/h for vehicles with driver Full stop (not needed for [DC ONLY ] video) 180◦ cornering Straight driving back to start point, minimum speed is 10 km/h for vehicles with driver [DC ONLY ] At the end of the VSV, the vehicle must be stopped by an emergency brake maneuver (see T 15). Standing still Formula Student Rules 2024 Version: 1.1 16 of 136 A 5 Documentation & Deadlines A 5.6.3 The video must fulfill the following criteria: Continuous video from a third person view - no assembled sequences Vehicle must be clearly visible (light, video resolution, frames and frequency) Vehicle must run under its own power Driving must follow A 6.4.6 Vehicle must be presented in ready-to-race conditions incl. body work No crossing in front of the vehicle after [EV ONLY ] TS activated / [CV ONLY ] engine started [EV ONLY ] Tractive System Active Light (TSAL), [DC ONLY ] Autonomous System Status Indicator (ASSI), and brake light, must be clearly visible in the video [EV ONLY ] Ready-to-drive (R2D) sound must be audible in the video [DC ONLY ] Vehicle must drive without a driver [DC ONLY ] In addition to the third person view, an onboard view and a visualization of the vehicle’s environment perception and path planning must be shown in split screen. All parts must be time synchronized. Must not exceed a length of 60 seconds. File size may be limited, see the competition handbook. File format must be common e.g. avi, mpg, mp4, wmv A 5.6.4 The VSV will be reviewed in order of submission. A review may take up to two weeks. A 5.6.5 If a team receives a “fail” for its video prior to the VSV deadline, the video will be treated as not submitted. A new submission is possible afterwards. In all other situations A 5.4 and A 5.3 apply. A 5.6.6 If a team fails only the [DC ONLY ] part, it will only be de-registered from the DC. A 5.6.7 A team which uploads a VSV with a previous year vehicle will be de-registered from the competition. A 5.7 SES Approval A 5.7.1 Teams using a monocoque must submit a SESA as one document, in addition to the SES deadline. The SESA template will be available on the competition website. A 5.7.2 The Structural Equivalency Spreadsheet (SES) must be checked and approved by a graduated engineer with appropriate expertise. A 5.7.3 Once the SES has been approved, the SESA form should be filled out, signed and submitted until the SESA deadline. A 5.7.4 If any changes to the original SES become necessary due to the approval process, the updated final SES must be submitted again on the competition website. A 5.7.5 The changelog with details of all changes made from the “Version History” tab of the SES form must be attached to the SESA document and must also be signed by the SES reviewer. Formula Student Rules 2024 Version: 1.1 17 of 136 A 6 General Rules A 5.7.6 The officials will randomly double check submitted SESA with their respective submitted SES. A6 G ENERAL RULES A 6.1 Removing the Vehicle from the Site A 6.1.1 Teams who remove their vehicle ([EV ONLY ] or TS accumulator) from the competition site after the competition has begun will be disqualified from the competition. A 6.2 Forfeit for Non-Appearance A 6.2.1 It is the responsibility of each team to be in the right place at the right time. A 6.2.2 If a team is not present and ready to compete at the scheduled time, they forfeit their attempt at that event. A 6.3 Team Briefing A 6.3.1 All team captains and drivers on a particular day must attend the team briefing for that day. A 6.3.2 All ASRs are required to attend the team briefing. A 6.4 Testing and Work Safety A 6.4.1 Competition organizers are not responsible for the use of the vehicles outside of their competition. A 6.4.2 The competition officials disassociate themselves from all activities of the teams besides their own competition and associated events. A 6.4.3 All teams are advised to follow common practices and common sense when working on the vehicle and when operating the vehicle, before, during and after a competition. A 6.4.4 The vehicles must not participate in events not suitable for this type of vehicles like hill climbs, drag races or similar. A 6.4.5 Teams must never use their vehicles for wheel-to-wheel races. A 6.4.6 The following listed requirements are considered the minimum for a testing/operating environment to qualify as safe. Following these guidelines does not guarantee safety under all circumstances: Driver wearing full protection gear according to T 13.3 Working TSAL, IMD, AMS, ASSI, RES, EBS, BSPD, APPS, and ETC plausibility check if applicable Rules compliant chassis and mounted Impact Attenuator (IA) No other passenger cars, trucks etc. being parked or driven on the same premise at the same time, unless the areas are clearly separated Formula Student Rules 2024 Version: 1.1 18 of 136 A 6 General Rules No running under low visibility conditions No running at speeds above typical event speeds No running in areas where crashing into obstacles at the height of the driver’s head is possible, such that parts of the vehicle may pass below an obstacle, but the driver’s head can be trapped between the obstacle and the main hoop for example A 6.4.7 Organizers reserve the right to disqualify a team registered for their competition in case of unsafe driving behavior, especially if the reputation of the competition, sponsors and other teams is compromised. A 6.5 Onsite Working Safety A 6.5.1 Everyone in the dynamic area and everybody working on the vehicle must wear appropriate, closed-toed shoes. A 6.5.2 Appropriate personal protective equipment must be used. A 6.5.3 Any operation producing litter or debris, e.g. cutting of carbon fiber, should not be performed in the pits. A 6.5.4 When jacking up the vehicle a safe and stable support device rated for the load must be used. A 6.6 Alcohol and Illegal Material A 6.6.1 Alcohol, illegal drugs, weapons or other illegal material are prohibited on the competition site during the competition. A 6.6.2 If any team member is tested with an alcohol level higher than 0.0 ‰, he or she will be immediately disqualified for the rest of the competition. A second team member being found to have an alcohol level higher than 0.0 ‰ results in the entire team being disqualified immediately. A 6.7 Vehicle Movement A 6.7.1 Vehicles must not move under their own power anywhere other than on the practice or competition tracks. A 6.7.2 [EV ONLY ] The detachable handle or key of the Tractive System Master Switch (TSMS) must be completely removed and kept by an ESO. The lockout/tagout function of the TSMS, see EV 6.2.2, must be used. A 6.7.3 Vehicles must also have their AS, see T 14.6, deactivated when being moved around the paddock. The ASR must ensure no unauthorized activation of the Autonomous System Master Switch (ASMS) following T 14.6.8. A 6.7.4 Vehicles must be pushed at a normal walking pace by means of a “push bar”, see T 13.1, and with a team member in the cockpit wearing the required driver equipment as defined in T 13.3 except for helmet, arm restraints and balaclava. A 6.7.5 The team member in the cockpit must have full control of steering and braking. Formula Student Rules 2024 Version: 1.1 19 of 136 A 6 General Rules A 6.7.6 When the push bar is attached to the vehicle, the engine/TS must remain switched off. A 6.7.7 Vehicles with wings are required to have two team members walking on either side of the front wing whenever the vehicle is being pushed. A 6.8 [CV ONLY ] Engine Running A 6.8.1 Running engines is not allowed in the pits. A 6.8.2 Engine running is allowed in the engine test area and in the dynamic area, when the following conditions are met: The vehicle must have passed mechanical inspection. The vehicle must be jacked using the jacks, see T 13.2. A driver, wearing required driver equipment, see T 13.3, must be seated in the cockpit. A fire extinguisher must be immediately available. Driven wheels can only remain fitted to the vehicle if they will not rotate. No one is allowed under the vehicle while the engine is running. A 6.8.3 Cranking engines in the pits is allowed, when the following conditions are met: The vehicle has passed mechanical inspection. The driven axles are securely jacked up. Gearbox is in neutral. All driven wheels are removed. Connectors to all injectors and ignition coils are detached. A fire extinguisher must be placed next to the engine. A 6.9 Fueling and Oil A 6.9.1 Fueling may only take place at the fuel station and must be conducted by officials only. A 6.9.2 Open fuel containers are not permitted at the competition. A 6.9.3 Waste oil must be taken to the fuel station for disposal. A 6.10 [EV ONLY ] Working on the Vehicle A 6.10.1 All activities require the TSAL to be green. A 6.10.2 A prominent manual sign indicating the “TSAL green” state must be present whenever the LVS is switched off and the requirements for an only green TSAL according to EV 4.10 are met. A 6.10.3 All activities on the vehicle, except when working on an active TS, require the High Voltage Disconnect (HVD) to be removed. Formula Student Rules 2024 Version: 1.1 20 of 136 A 6 General Rules A 6.11 [EV ONLY ] Working on the Tractive System A 6.11.1 Activities on the TS, except for the accumulator, see A 6.12, must take place in the pit. A 6.11.2 All activities require the attendance of the ESO. A 6.11.3 For activities on the inactive TS, the following procedure must be carried out: The vehicle must be barred from anyone not involved in the work, by using barrier tape. The Tractive System Master Switch (TSMS) must be switched off. It must be assured that the TS cannot be activated by, at a minimum, using the lockout/tag out of the TSMS. A check for zero-potential must be carried out. A sign that declares the vehicle is electrically safe must be installed. The name of the ESO who is supervising the activities must be noted on the sign. This ESO is the only person who may remove the sign and the barrier. A 6.11.4 In case of measurements on the active TS or an activation of the TS in the pit for testing purposes, the following steps must be followed: The vehicle must be barred from anyone not involved in the work, by using barrier tape. The vehicle must be jacked up and the driven wheels removed. One team member must be prepared to push a shutdown button at any time. The TS must only be activated for as long as necessary. Appropriate insulated tools and equipment must be used. Safety glasses with side shields and compliant safety gloves must be worn by all participating team members when parts of the TS are exposed. No other work on the vehicle is permitted when the TS is active. A 6.11.5 If the TSAL is flashing red or malfunctioning, the TS is considered as active. A 6.11.6 There must be at least one team member present, who is not directly involved in the work, but who could assist in case of an incident. A 6.12 [EV ONLY ] Working on Tractive System Accumulators A 6.12.1 Opening or working on Tractive System Accumulator Containers (TSACs) is only allowed in the provided work places in the charging area, see A 6.13. A 6.12.2 All activities require the attendance of an ESO. A 6.12.3 Whenever the TSACs are opened, the cell segments must be separated with the maintenance plugs, see EV 5.4.4. A 6.12.4 Appropriate insulated tools and equipment must be used. A 6.12.5 Safety glasses with side shields and compliant safety gloves must be worn by all participating team members. Formula Student Rules 2024 Version: 1.1 21 of 136 A 6 General Rules A 6.12.6 There must be at least one team member present, who is not directly involved in the work conducted on the accumulator, but who could assist in case of an incident. A 6.12.7 Moving accumulator cells and/or accumulator segment(s) around at the competition site is only permitted if they are inside a completely closed TSAC. A 6.12.8 All parts and modules of the TSAC that are not currently being worked on must be covered at least according to IPxxB while working on the accumulator container. A 6.12.9 Additional safety measures may be included in the respective competition handbook. A 6.13 [EV ONLY ] Charging A 6.13.1 There will be a separated charging area on the competition site. Charging TS accumulators is only allowed inside this area. A 6.13.2 Accumulators must be removed from the vehicle and placed on the TSAC hand cart, see EV 8.1, for charging. A 6.13.3 The label EV 5.3.8 or an additional label according to EV 5.3.8 must be visible during charging. A 6.13.4 No grinding, drilling, etc. is allowed in the charging area. A 6.13.5 At least one team member who has knowledge of the charging process must stay with the accumulator(s) during charging. Formula Student Rules 2024 Version: 1.1 22 of 136 Formula Student Rules 2024 T G ENERAL T ECHNICAL R EQUIREMENTS T1 D EFINITIONS T 1.1 Chassis Definitions T 1.1.1 Chassis – the fabricated structural assembly that supports all functional vehicle systems. This assembly may be a single welded structure, multiple welded structures or a combination of composite and welded structures. T 1.1.2 Bodywork – the outermost surface of the chassis or any fairing parts and covers. T 1.1.3 Cockpit – the volume which accommodates the driver which is defined by the top of the vehicle, the floor closeout, the inner side of the bodywork, the front bulkhead and the firewall. T 1.1.4 Chassis member – a minimum representative single piece of uncut, continuous tubing or equivalent structure. T 1.1.5 Front bulkhead – a planar structure that defines the forward plane of the chassis and provides protection for the driver’s feet (in front view, together with the Anti Intrusion Plate (AIP), covers the driver’s feet). T 1.1.6 Front bulkhead support – a structure that defines the side of the chassis from the front bulkhead back to the top of the upper side impact structure and the bottom of the front hoop. T 1.1.7 Front hoop – a roll bar located above the driver’s legs, in proximity to the steering wheel. T 1.1.8 Impact Attenuator (IA) – a deformable, energy absorbing device located forward of the front bulkhead. T 1.1.9 Main hoop – a roll bar located alongside or just behind the driver’s torso. T 1.1.10 Monocoque – a chassis made of composite material. T 1.1.11 Node-to-node triangulation – an arrangement of chassis members projected onto a plane, where a co-planar load applied in any direction, at any node, results in only tensile or compressive forces in the chassis members as shown in figure 1. T 1.1.12 Primary structure – the primary structure is comprised of the following components: Main hoop Front hoop Roll hoop braces and supports Impact structures as mentioned under T 3.15 Front bulkhead Formula Student Rules 2024 Version: 1.1 23 of 136 T 1 Definitions Figure 1: Node-to-node triangulation of chassis members (left correct and right incorrect). Front bulkhead support system All chassis members, guides and supports that transfer load from the driver’s restraint system into the above mentioned components of the primary structure T 1.1.13 Roll hoops – both the front hoop and the main hoop are classified as “roll hoops” T 1.1.14 Roll hoop bracing – the structure from a roll hoop to the roll hoop bracing support. T 1.1.15 Roll hoop bracing supports – the structure from the lower end of the roll hoop bracing back to the roll hoop(s). T 1.1.16 Rollover protection envelope – the union of the primary structure and any additional structures fixed to the primary structure which meet the minimum specification defined in T 3.2 or equivalent the plane from the top of the main hoop to the top of the front hoop the plane from the top of the main hoop to the rearmost structure according to T 3.2 or equivalent Example depicted in figure 2. T 1.1.17 Side impact structure – the area of the side of the chassis between the front hoop and the main hoop and from the chassis floor to the height as required in T 3.15 above the lowest inside chassis point between front hoop and main hoop. T 1.1.18 Surface envelope – the surface envelope is the surface of the union of the rollover protection envelope, see T 1.1.16, and the volume defined by the top of the main hoop and the outside edges of the four tires a plane from the top of the main hoop to the top of the front bulkhead a plane from the top of the main hoop to the the rearmost structure according to T 3.2 or equivalent a projection in side view of the lower boundaries of the rollover protection envelope Example depicted in figure 3. Formula Student Rules 2024 Version: 1.1 24 of 136 T 1 Definitions Figure 2: Rollover protection envelope T 1.1.16, thick lines are primary structure members according to T 3.2 Figure 3: Surface Envelope T 1.1.18 T 1.2 Material Definitions T 1.2.1 Fire Retardant – a material meeting one of the following standards: UL94 V-0 for the minimum used material thickness FAR 25.853(a)(1)(i) Equivalent standards are only accepted, if the team shows equivalence and this is approved by the officials prior to the event. T 1.2.2 Coolant – a substance used for heat transfer by convection. T 1.3 Electrical Definitions T 1.3.1 Direct Connection – two devices or circuits are directly connected if the connection is not routed through any common PCB and does not include any devices or functionality other than overcurrent protection or connectors. T 1.4 Driving Mode Definitions T 1.4.1 Manual Mode – a vehicle is in manual mode when driven by a human driver. In this case the ASMS must be off (AS deactivated). T 1.4.2 Autonomous Mode – a vehicle is in autonomous mode when the AS is activated. When a vehicle is in autonomous mode, there must be no person inside the vehicle. Formula Student Rules 2024 Version: 1.1 25 of 136 T 2 General Design Requirements T2 G ENERAL D ESIGN R EQUIREMENTS T 2.1 Vehicle Configuration T 2.1.1 The vehicle must be designed and fabricated in accordance with good engineering practices. T 2.1.2 The vehicle must be open-wheeled, single seat and open cockpit (a formula style body) with four wheels that are not in a straight line. T 2.1.3 Open wheel vehicles must satisfy the following (see also figure 4): The wheel/tire assembly must be unobstructed when viewed from the side. No part of the vehicle may enter a keep-out-zone defined by two lines extending vertically from positions 75 mm in front of and 75 mm behind the outer diameter of the front and rear tires in the side view of the vehicle, with steering straight ahead. This keep-out zone extends laterally from the outside plane of the wheel/tire to the inboard plane of the wheel/tire assembly. 75 mm 75 mm 75 mm 75 mm No Parts allowed in this Area View on this Surface must be unobstructed Figure 4: Keep-out-zones for the definition of an open-wheeled vehicle. T 2.2 Ground Clearance T 2.2.1 The minimum static ground clearance of any portion of the vehicle, other than the tires, including a driver, must be 30 mm. If an active suspension system is installed, the static ground clearance is measured in the lowest adjustable position. T 2.2.2 Sliding skirts or other aerodynamic devices that by design, fabrication or as a consequence of moving, contact the track surface are prohibited. Formula Student Rules 2024 Version: 1.1 26 of 136 T 2 General Design Requirements T 2.3 Bodywork T 2.3.1 There must be no openings through the bodywork into the cockpit other than that required for the cockpit opening. Minimal openings around the front suspension and steering system components are allowed. T 2.3.2 In any side view in front of the cockpit opening and outside the area defined in T 8.2 all parts of the bodywork must have no external concave radii of curvatures. Any gaps between bodywork and other parts must be reduced to a minimum. T 2.3.3 Enclosed chassis structures and structures between the chassis and the ground must have two venting holes of at least 25 mm diameter in the lowest part of the structure to prevent accumulation of liquids. Additional holes are required when multiple local lowest parts exist in the structure. T 2.3.4 The bodywork in front of the front wheels with the tangent of surface above 45◦ relative to the forward direction must have a radius of at least 38 mm along the top, sides and bottom of all affected edges. T 2.4 Minimum Edge Radii of Bodywork and Aerodynamic Devices T 2.4.1 For all edges that could come into contact with any standing pedestrian without reaching to the vehicle, the minimum radius of the bodywork and aerodynamic devices is 3 mm for all forward facing edges and 1 mm for all other edges. T 2.5 Suspension T 2.5.1 The vehicle must be equipped with fully operational front and rear suspension systems including shock absorbers and a usable wheel travel of at least 50 mm and a minimum jounce of 25 mm with driver seated. T 2.5.2 All suspension mounting points must be visible at technical inspection, either by direct view or by removing any covers. T 2.6 Wheels T 2.6.1 Any wheel mounting system that uses a single retaining nut must incorporate a device to prevent loosening of the nut and the wheel. A second nut (“jam nut”) does not meet these requirements. T 2.6.2 Wheel lug bolts, drive pegs and studs must be made of steel or titanium. The team must be able to show good engineering practice and providing adequate strength by calculations. Wheel lug bolts, drive pegs and studs must not be hollow. T 2.6.3 Aluminium wheel nuts may be used, but they must be hard anodized and in pristine condition. T 2.7 Tires T 2.7.1 Vehicles must have two types of tires as follows: Formula Student Rules 2024 Version: 1.1 27 of 136 T 2 General Design Requirements Dry tires - The tires on the vehicle when it is presented for technical inspection are defined as its “dry tires”. Wet tires - Wet tires may be any size or type of treaded or grooved tire provided: – The tread pattern or grooves were molded in by the tire manufacturer or were cut by the tire manufacturer or their appointed agent. Any grooves that have been cut must have documentary proof that it was done in accordance with these rules. – There is a minimum tread depth of 2.4 mm. T 2.7.2 Tires on the same axle must have the same manufacturer, size and compound. T 2.7.3 Tire warmers are not allowed. T 2.7.4 Special agents that increase traction must not be added to the tires or track surface. T 2.8 Steering T 2.8.1 Steering systems using cables or belts for actuation are prohibited. This does not apply for autonomous steering actuators. T 2.8.2 The steering wheel must directly mechanically actuate the front wheels. T 2.8.3 The steering system must have positive steering stops that prevent the steering linkages from locking up. The stops must be placed on the rack and must prevent the tires and rims from contacting any other parts. Steering actuation must be possible during standstill. T 2.8.4 Allowable steering system free play is limited to a total of 7◦ measured at the steering wheel. T 2.8.5 The steering wheel must be attached to the column with a quick disconnect. The driver must be able to operate the quick disconnect while in the normal driving position with gloves on. T 2.8.6 The steering wheel must be no more than 250 mm rearward of the front hoop. This distance is measured horizontally, on the vehicle centerline, from the rear surface of the front hoop to the forward most surface of the steering wheel with the steering in any position. T 2.8.7 The steering wheel must have a continuous perimeter that is near circular or near oval. The outer perimeter profile may have some straight sections, but no concave sections. T 2.8.8 In any angular position, the top of the steering wheel must be no higher than the top-most surface of the front hoop. T 2.8.9 The steering rack must be mechanically attached to the primary structure and all stationary parts must be within the rollover protection envelope, see T 1.1.16. T 2.8.10 Joints between all components attaching the steering wheel to the steering rack must be mechanical and visible at technical inspection. Bonded joints are allowed in accordance with T 3.2.8. T 2.8.11 Rear wheel steering, which can be electrically actuated, is permitted if mechanical stops limit the range of angular movement of the rear wheels to a maximum of 6◦. This must be demonstrated with a driver in the vehicle and the team must provide the equipment for the steering angle range to be verified at technical inspection. Formula Student Rules 2024 Version: 1.1 28 of 136 T 3 General Chassis Design T 2.9 Wheelbase T 2.9.1 The vehicle must have a wheelbase of at least 1525 mm. T 2.10 Track and Rollover Stability T 2.10.1 The smaller track of the vehicle (front or rear) must be no less than 75 % of the larger track. T 2.10.2 The track and center of gravity of the vehicle must combine to provide adequate rollover stability. T3 G ENERAL C HASSIS D ESIGN T 3.1 General Requirements T 3.1.1 Among other requirements, the vehicle’s structure must include: Two roll hoops that are braced A front bulkhead with support system and IA Side impact structures T 3.2 Minimum Material Requirements T 3.2.1 Table 4 shows the minimum requirements for the members of the primary structure if made from steel tubing. Item or application Minimum Minimum cross Minimum area wall thickness sectional area moment of inertia Main and front hoops, 2.0 mm 173 mm2 11 320 mm4 shoulder harness mounting bar Impact structures, 1.2 mm 119 mm2 8509 mm4 front bulkhead, roll hoop bracing, driver’s restraint harness attachment (except as noted above) Front bulkhead support, 1.2 mm 91 mm2 6695 mm4 main hoop bracing supports Table 4: Minimum Material Requirements T 3.2.2 Steel tubing has to be made from unalloyed carbon steel with a maximum content of 0.3 % carbon, 1.7 % manganese and 0.6 % of any other element. All other steel grades are considered alternative materials and require additional testing and documentation (see T 3.3). T 3.2.3 Except for inspection holes, any holes drilled in any part which is a member of the primary structure must be considered in the SES. Formula Student Rules 2024 Version: 1.1 29 of 136 T 3 General Chassis Design T 3.2.4 The steel properties used for the calculations in the SES must be: Non-welded strength for continuous material calculations: Young’s Modulus (E) = 200 GPa Yield Strength (Sy ) = 305 MPa Ultimate Strength (Su ) = 365 MPa Welded strength for discontinuous material such as joint calculations: Yield Strength (Sy ) = 180 MPa Ultimate Strength (Su ) = 300 MPa T 3.2.5 Any tubing with a wall thickness less than 1.2 mm or a minimum area moment of inertia less than 6695 mm4 is considered non-structural and will be ignored when assessing compliance to any rule regarding the vehicle structure. T 3.2.6 If a member of the primary structure (except for the roll hoops) is a bent tube or made from multiple tubes an additional tube must support it. This support tube must: Have its attachment point at the position along the bend tube where it deviates farthest from a straight line connecting both ends. Be of the same dimension as the supported tube(s). Terminate at a node of the primary structure. Be angled no more than 30◦ from the plane of the supported tube(s). T 3.2.7 Any welded seams shape must not be mechanically altered in any way. T 3.2.8 Where bonded joints are applicable and governed by the rules, a 50 % reduction shall be applied to all nominal and tested adhesive values. Bonded joints in the primary structure must be documented in the SES. T 3.3 Alternative Materials T 3.3.1 Alternative materials may be used for all parts of the primary structure and the TSAC with the following exceptions: The main hoop and the main hoop bracing must be steel The front hoop must be metal Any welded structures of the primary structure must be steel However, the front hoop may be an aluminium welded structure T 3.3.2 If any other materials than steel tubing are used in the primary structure or the TSAC, physical testing is required to show equivalency to the minimum material properties for steel in T 3.2. T 3.3.3 If alloyed steel as defined by T 3.2.2 is used, the team has to include tests and documentation in the SES to show structural equivalency. This may include, but is not limited to: Formula Student Rules 2024 Version: 1.1 30 of 136 T 3 General Chassis Design Receipts and data sheets of the used tubing materials Documentation about welding processes and filler materials Documentation about heat treatments Tests showing adequate strength and elongation at break in the welded condition T 3.4 Composite Structures T 3.4.1 If composite structures are used in the primary structure or the TSAC, the Flexural Rigidity (EI) of that structure must be calculated with the tools and formulas in the SES. The actual geometry and curvature of the panel may be taken into account for the main hoop bracing support, the front hoop bracing, the front bulkhead support structure, the shoulder harness bar, the TS and TSAC protective structure. For all other areas the EI must be calculated as the EI of a flat panel about its neutral axis. This panel must have the same composition as the structure used in the primary structure or the TSAC. T 3.4.2 If composite materials are used in the primary structure or the TSAC the SES must include: Material type(s) Cloth weights Resin type Fiber orientation Number of layers Core material Lay-up technique 3-point-bend test and shear test data T 3.4.3 For any laminate in the primary structure or the TSAC, the maximum weight content of parallel fibers, relative to the weight of all fibers in the laminate, is 50 %. All fibers laid within any orientation +/-10◦ count as parallel in this case. T 3.4.4 If an asymmetrical lay-up is used in the primary structure, the thinner skin must have a thickness of at least 40 % of the thicker skin. T 3.4.5 Wherever backing plates are required, they must be fully supported by the structure they are attached to. T 3.4.6 Backing plates must have a continuous perimeter that is near circular or near oval. The outer perimeter profile may have some straight sections, but no concave sections. Backing plates must not have any cut-outs within their outside perimeter except for the holes for bolts. T 3.5 Laminate Testing T 3.5.1 If composite materials are used for any part of the primary structure or the TSAC the team must: Build a representative test panel which must measure exactly 275 mm × 500 mm that has the same design, laminate and fabrication method as used for the respective part of Formula Student Rules 2024 Version: 1.1 31 of 136 T 3 General Chassis Design the primary structure represented as a flat panel. The sides of the test panel must not be laminated (core material must be visible). Perform a 3-point bending test on this panel The data from these tests and pictures of the test samples and test setup must be included in the SES. In the pictures, the following must be identifiable: distance between the two supports, dimensions of the load applicator and test sample marking as per T 3.5.5. The test results must be used to derive strength and stiffness properties used in the SES formula for all laminate panels. Representative test panels for parts of the TSAC may use smaller dimensions, provided that the panel core thickness is 5 mm or smaller. This representative test panel must then measure 150 mm × 275 mm. In this case, the distance between the two test panel supports must be at least 200 mm and the load applicator must have a radius of at least 5 mm. T 3.5.6 and T 3.5.7 do not apply. T 3.5.2 If a panel represents side impact structure it must be proven that it has at least the same properties as two steel tubes meeting the requirements for side impact structure tubes for buckling modulus, yield strength and absorbed energy. T 3.5.3 Composite structures with different core thicknesses but otherwise identical construction may use material properties derived from a single test panel. The panel with the thicker core must be tested and the structure using derived material properties must not use a core thickness of less than 66 % of the tested panel. T 3.5.4 When a laminate is not quasi-isotropic, i.e. has equal strength and stiffness in the 0◦ , 90◦ and ±45◦ direction, the results from the 3 point bending test will be assigned to the 0◦ lay-up direction. To show equivalence in the SES, the 0◦ lay-up direction must be used and oriented accordingly in the chassis. T 3.5.5 The test samples must be presented at technical inspection. All samples must be marked with the following non-removable (e.g.: permanent marker or engraving, but no sticker) information: laminated structure acronym and date of testing. T 3.5.6 The distance between the two test panel supports must be at least 400 mm. T 3.5.7 The load applicator used to test any panel or tube must be metallic and have a radius of 50 mm. T 3.5.8 The load applicator must overhang the test piece to prevent edge loading. T 3.5.9 There must be no material between the load applicator and the test piece. T 3.5.10 Perimeter shear tests must be completed which measure the force required to push or pull a 25 mm diameter flat punch through a flat laminate sample. The sample must be at least 100 mm × 100 mm. Core and skin thicknesses must be identical to those used in the actual primary structure and be manufactured using the same materials and processes. T 3.5.11 The test fixture must support the entire sample, except for a 32 mm hole aligned co-axially with the punch. The sample must not be clamped to the fixture. Formula Student Rules 2024 Version: 1.1 32 of 136 T 3 General Chassis Design T 3.6 Structural Documentation T 3.6.1 All teams must submit a Structural Equivalency Spreadsheet (SES) and Structural Equiva- lency 3D Model (SE3D). T 3.6.2 The SES spreadsheet form can be downloaded from the competition website. T 3.6.3 The SE3D must contain a three dimensional CAD model of the chassis including all members of the primary structure and all mechanical attachment details of the hoops and hoop braces in “IGES” file format not larger than 40 MB. [EV ONLY ] The TSAC(s) and attachment must also be included. T 3.6.4 Vehicles must be fabricated in accordance with the materials and processes described in the SES. T 3.6.5 Teams must bring a copy of the approved SES to technical inspection. T 3.7 Roll Hoops T 3.7.1 Both roll hoops must be securely integrated to the primary structure using node-to-node triangulation or equivalent joining methods. T 3.7.2 The minimum radius of any bend, measured at the tube centerline, must be at least three times the tube outside diameter. Bends must be smooth and continuous with no evidence of crimping or wall failure. The minimum area moment of inertia, see T 3.2, must be maintained in all areas, including the bends of the manufactured tubes. T 3.7.3 In a plane perpendicular to the longitudinal axis of the vehicle and through the lower endpoints of the roll hoop, no part of the primary structure may lie below 30 mm of the endpoints of the roll hoop. T 3.7.4 Roll hoops attached to a composite primary structure must be mechanically attached at the top and bottom of both sides of that structure and at intermediate locations if needed to show equivalency. The lower roll hoop tubing attachment points must be within 50 mm of the endpoints of the roll hoop. T 3.7.5 Mounting plates welded to the roll hoops must be at least 2 mm thick steel or 3 mm thick aluminium, dependent of the roll hoop material. T 3.7.6 Both roll hoops must have one 4.5 mm inspection hole in a non-critical straight location and its surface at this point must be unobstructed for at least 180◦. T 3.8 Main Hoop T 3.8.1 The main hoop must be constructed of a single piece of uncut, continuous, closed section steel tubing. T 3.8.2 In side view the portion of the main hoop which is above its upper attachment point to the side impact structure must be inclined less than 10◦ from vertical. T 3.8.3 In side view any bends in the main hoop above its upper attachment point to the primary structure must be braced to a node of the main hoop bracing support structure with tubing meeting the requirements of main hoop bracing. Formula Student Rules 2024 Version: 1.1 33 of 136 T 3 General Chassis Design T 3.8.4 In side view any portion lower than the upper attachment point to the side impact structure must be inclined either forward or not more than 10◦ rearward. T 3.9 Front Hoop T 3.9.1 The front hoop must be constructed of a continuous and closed section. T 3.9.2 If the front hoop is made from more than one piece it must be supported by node-to-node triangulation or an equivalent construction. T 3.9.3 In side view, no part of the front hoop can be inclined more than 20◦ from vertical. T 3.9.4 If the front hoop is a welded construction made from multiple aluminium profiles, the equivalent yield strength must be considered in the as-welded condition unless the team demonstrates and shows proof that it has been properly solution heat treated and artificially aged. The team must supply sufficient documentation proving the appropriate heat treatment process was performed. T 3.9.5 The front hoop requires six attachment points, two on each side connecting to the front bulkhead support structures and two connecting to the front hoop bracing, and must therefore show equivalency to 180 kN, as follows from T 3.16.1 and T 3.11.4. T 3.9.6 Fully laminating the front hoop to the monocoque is acceptable. Fully laminating means that the hoop has to be encapsulated with laminate around its whole circumference, see figure 5. Equivalence to T 3.7.4 must be shown in the SES. The laminate encapsulating the front hoop must overlap by at least 25 mm on each side. It must have the same lay-up as the laminate that it is connecting to. Figure 5: Front hoop laminating requirements T 3.10 Main Hoop Bracing T 3.10.1 The main hoop must be supported to the front or the rear by bracing tubes on each side of the main hoop. T 3.10.2 In side view the main hoop and the main hoop braces must not lie on the same side of a vertical line coincident with the top of the main hoop. T 3.10.3 The main hoop braces must be attached to the main hoop no lower than 160 mm below the top-most surface of the main hoop. The included angle formed by the main hoop and the main hoop braces must be at least 30◦. Formula Student Rules 2024 Version: 1.1 34 of 136 T 3 General Chassis Design T 3.10.4 The main hoop braces must be straight. T 3.10.5 The lower ends of the main hoop braces must be supported back to the upper attachment point of the main hoop to the side impact structure and to the lower attachment point of the main hoop to the side impact structure by a node-to-node triangulated structure or equivalent composite structure. T 3.10.6 If any item which extends outside of the primary structure is attached to the main hoop braces, additional bracing is required to prevent bending loads in a rollover situation. T 3.11 Front Hoop Bracing T 3.11.1 The front hoop bracing attaches on each side of the front hoop as well as the structure forward of the driver’s feet. A minimum of two tubes without any bends must be straight on a line in side view of the frame and must have a minimum distance of 100 mm between each other at the front hoop. T 3.11.2 The front hoop bracing structure must be attached no lower than 50 mm below the top-most surface of the front hoop, see figure 6. T 3.11.3 If the front hoop is inclined more than 10◦ to the rear, additional braces extending rearwards are required. T 3.11.4 Composite front hoop bracing structures and their attachments cannot be counted towards the front bulkhead support structures and vice-versa for the structural equivalency documentation. 160 mm max. Steering Wheel must 50 mm max. be below this Line 30° min. 30° min. Figure 6: Front hoop bracing, main hoop bracing and steering wheel requirements T 3.12 Mechanically Attached Roll Hoop Bracing T 3.12.1 Any non-welded joint at either end of a bracing must be either a double-lug joint, see figure 7, or a sleeved joint, see figure 8. Spherical rod ends are prohibited. T 3.12.2 If threaded fasteners are used, they are considered critical fasteners and must meet T 10.1. T 3.12.3 Double lug-joints must include a capping arrangement, see figure 7. Formula Student Rules 2024 Version: 1.1 35 of 136 T 3 General Chassis Design T 3.12.4 In a double-lug joint each lug must be at least 4.5 mm thick and the pin or bolt must be 10 mm metric grade 8.8 minimum. The attachment holes in the lugs and in the attached bracing must be a close fit with the pin or bolt. T 3.12.5 For sleeved joints the sleeve must have a minimum length of 38 mm either side of the joint and be a close-fit around the base tubes. The wall thickness of the sleeve must be at least that of the bracing tubes. The bolts must be 6 mm metric grade 8.8 minimum. The holes in the sleeves and tubes must be a close-fit with the bolts. Capping Plate Figure 7: Double lug joint mm 38 in. m Figure 8: Sleeved joint T 3.13 Front Bulkhead T 3.13.1 Any alternative material used for the front bulkhead must have a perimeter shear strength equivalent to a 1.5 mm thick steel plate. T 3.13.2 If the front bulkhead is part of a composite structure and is modeled as an “L” shape, the EI of the front bulkhead about the vertical and lateral axes must be equivalent to a steel tube meeting the requirements for the front bulkhead. The length of the section perpendicular to the bulkhead may be a maximum of 25 mm measured from the rearmost face of the bulkhead. Formula Student Rules 2024 Version: 1.1 36 of 136 T 3 General Chassis Design T 3.14 Front Bulkhead Support T 3.14.1 The front bulkhead must be supported back to the front hoop by a minimum of three tubes on each side; an upper member, a lower member and diagonal bracing to provide triangulation. The upper support member must be attached to the front bulkhead a maximum of 50 mm below the top-most surface of the front bulkhead, and attached to the front hoop a maximum of 50 mm below the upper side impact member. If the attachment point of the upper member is greater than 100 mm above the upper side impact member, node-to-node triangulated bracing is required to transfer load to the main hoop. The lower support member must be attached to the base of the front bulkhead and the base of the front hoop. The diagonal bracing must triangulate the upper and lower support members node-to- node. T 3.14.2 If the front bulkhead support is part of a composite structure, it must have equivalent EI to the sum of the EI of the six baseline steel tubes that it replaces and it must not be counted towards the composite front hoop bracing structures for the structural equivalency documentation (i.e. T 3.11.4). T 3.14.3 The EI of the vertical side of the front bulkhead support structure must be equivalent to at least the EI of one baseline steel tube that it replaces. T 3.14.4 The perimeter shear strength of the monocoque laminate in the front bulkhead support structure must be at least 4 kN. T 3.15 Impact Structures T 3.15.1 The side impact structure must consist of at least three steel tubes, see T 3.2, on each side of the cockpit, see figure 9. The upper member must connect the main hoop and the front hoop. The upper member must be at a height between 240 mm and 320 mm above the lowest inside chassis point between the front and main hoop. The lower member must connect the bottom of the main hoop and the bottom of the front hoop. The diagonal member must triangulate the upper and lower member between the roll hoops node-to-node. T 3.15.2 Other impact structures, see CV 1.3.2, EV 4.4.2 and EV 5.5.2, must be fully triangulated structures and consist of at least three steel tubes, see T 3.2, on each side and rearward of the component that needs to be protected. If the component projects outwards from the roll hoops to the side, the front of the component must also be protected. The upper member must not be higher than 320 mm above the lowest inside chassis point between the front and main hoop. T 3.15.3 If the impact structure is part of a composite structure, the following is required: Formula Student Rules 2024 Version: 1.1 37 of 136 T 3 General Chassis Design The region of the structure up to a height of 320 mm above the lowest inside chassis point between the front and main hoop must have an EI equal to the three baseline steel tubes that it replaces. An example for side impact structure is given in figure 10. The vertical impact structure must have an EI equivalent to two baseline steel tubes and half the horizontal floor must have an EI equivalent to one baseline steel tube. The vertical impact structure must have an absorbed energy equivalent to two baseline steel tubes, exceeding 65 J. The perimeter shear strength must be at least 7.5 kN. Diagonal Side Impact Member Upper Side Impact Member (completely in zone) 320 mm 240 mm Lowest Point in Cockpit Lower Side Impact Member Figure 9: Side impact structure Side Impact Structure 320 mm Lowest Point inside Chassis Figure 10: Side impact structure monocoque T 3.16 Bolted Primary Structure Attachments T 3.16.1 If two parts of the primary structure are bolted together, each attachment point between the two parts must be able to carry a load of 30 kN in any direction. T 3.16.2 Data obtained from the laminate perimeter shear strength test must be used to prove that adequate shear area is provided. Formula Student Rules 2024 Version: 1.1 38 of 136 T 3 General Chassis Design T 3.16.3 Each attachment point requires a minimum of two 8 mm metric grade 8.8 bolts and steel backing plates with a minimum thickness of 2 mm. T 3.16.4 For the attachment of front hoop bracing, main hoop bracing and main hoop bracing support to the primary structure the use of one 10 mm metric grade 8.8 bolt is sufficient, if the bolt is on the centerline of the tube, see figure 11. Figure 11: Bolted roll hoop bracing support T 3.16.5 When using bolted joints within the primary structure, no crushing of the laminate core material is permitted. T 3.16.6 For the AIP to front bulkhead attachment, and if two panels or plates of the primary structure are bolted together, for each 200 mm of reference perimeter a minimum of one 8 mm metric grade 8.8 bolt(s) must be used, rounded up to the next integer. Smaller, but more, bolts may be used, if equivalency is shown. The bolts must be evenly distributed over the circumference using good engineering practices. The reference perimeter is the outside perimeter of the attached part at the connection. The bolts are considered critical fasteners and must comply with T 10. T 3.17 Impact Attenuator T 3.17.1 Each vehicle must be equipped with an IA assembly consisting of an IA and AIP. T 3.17.2 The IA must: Be installed forward of the front bulkhead. Be at least 100 mm high and 200 mm wide for a minimum distance of 200 mm forward of the front bulkhead. Not be positioned more than 350 mm above the ground, for any portion of the required 100 ×200 ×200 mm3 volume. Not be able to penetrate the front bulkhead in the event of an impact. Be attached securely and directly to the AIP. Not be part of the non-structural bodywork. Formula Student Rules 2024 Version: 1.1 39 of 136 T 3 General Chassis Design Be designed with a closed front section. Not be wider or higher than the AIP. T 3.17.3 The baseline design for the AIP is a 1.5 mm solid steel or 4.0 mm solid aluminium plate. If the IA and AIP (IA assembly) are bolted to the front bulkhead, it must be the same size as the outside dimensions of the front bulkhead. If it is welded to the front bulkhead, it must extend at least to the centerline of the front bulkhead tubing in all directions. The AIP must not extend past the outside edges of the front bulkhead. T 3.17.4 Alternative AIP designs are permissible if equivalency to T 3.17.3 is proven by physical testing as in T 3.19.2. T 3.17.5 The IA may be attached to the AIP by a minimum of four 8 mm metric grade 8.8 bolts that are considered critical fasteners and must comply with T 10. Attachment(s) using adhesive must be able to carry a load of 60 kN in any direction. T 3.17.6 The attachment of the IA assembly must be designed to provide an adequate load path for transverse and vertical loads in the event of off-center and off-axis impacts. Segmented foam attenuators must have the segments bonded together to prevent sliding or parallelogramming. T 3.17.7 A team may use one of the “standard” FSAE IAs, in order to avoid testing, provided that: if the front bulkhead width is larger than 400 mm and/or its height is larger than 350 mm a diagonal or X-bracing that is a front bulkhead support tube or an approved equivalent per T 3.2, must be included in the front bulkhead. Or equivalent for mono- coque bulkheads. must use a 1.5 mm solid steel AIP that is welded along its full perimeter to a steel bulkhead or use a 4 mm solid aluminium AIP that is bolted to any bulkhead with a minimum of eight 8 mm metric grade 8.8 bolts if the “standard” honeycomb IA is used, the IA must be of pre-crushed type adhesive used to mount the “standard” honeycomb IA to the AIP must have a shear strength of at least 24 MPa T 3.17.8 If the standard IA is used, but does not comply with the requirements of T 3.17.7 physical testing must be carried out to prove that the AIP does not permanently deflect more than 25 mm. T 3.18 Impact Attenuator Data Requirement T 3.18.1 All teams must submit an IA data report using the Impact Attenuator Data (IAD) template provided at the competition website. T 3.19 Impact Attenuator Test Requirements T 3.19.1 The IA assembly, when mounted on the front of a vehicle with a total mass of 300 kg and impacting a solid, non-yielding impact barrier with a velocity of impact of 7 m/s, must meet the following requirements: Formula Student Rules 2024 Version: 1.1 40 of 136 T 3 General Chassis Design Decelerate the vehicle at a rate not exceeding 20 g average and 40 g peak. The energy absorbed in this event must meet or exceed 7350 J. Teams using the standard IA are not required to submit test data with their IAD report, but all other requirements must be included. Equivalent (higher) test velocities are only allowed to accommodate for a lower total testing mass, as long as the energy absorbed is 7350 J or more. If these requirements cannot be met, a team must use the standard IA. T 3.19.2 During the IA test: The IA must be attached to the AIP using the intended vehicle attachment method. The IA assembly must be attached to a test fixture that has geometry representative of the intended primary structure and equal or higher stiffness and strength. When alternative materials are used for the AIP, the test fixture must be a copy of the intended primary structure (i.e. materials, lay-up, joining methods). There must be at least 50 mm clearance rearwards of the AIP to the test fixture. No part of the AIP may permanently deflect more than 25 mm beyond the position of the AIP before the test. T 3.19.3 Teams usin