VEHICLE AND TEAM EQUIPMENT SPECIFICATIONS National High School evgrandprix 2016

Transcription

1 VEHICLE AND TEAM EQUIPMENT SPECIFICATIONS National High School evgrandprix 2016 This document presents the vehicle specifications to be followed for the building of a racing Go Kart, and the team equipment needed to compete in the 2016 High School evgrand Prix event. The specifications contained herein will be strictly enforced at all times including, but not limited to, practices, qualifications, races, efficiency runs, technical competition, and outreach activities. Every person or group of persons who undertake, organize or participate in these events shall sign an affidavit deeming that person is acquainted with the rules and his/her participation shall constitute his acceptance of them. In addition, honorable conduct and good sportsmanship of all participants will be demanded. The specification and requirements are to be interpreted and enforced by the United States Auto Club (USAC). A team will be disqualified if failing to conform to these specifications. The High School evgrand Prix is an educational event that has an Motorsports theme. The Rules Committee has reviewed and used numerous regulatory documents and standards in the development these rules. The prime objective is to assure we have put an effective rule set in place to give our students the challenge of innovation and development while making sure the risks are minimized and student safety remains the top priority. The educational aspect of the rule set incorporates some of the same safety evaluations and abatement procedures that students may have to perform in their careers as they go forward as graduates. The High School evgrand Prix has a ZERO tolerance policy regarding safety compliance both on and off the track. We want to maintain a safe, educational and exciting event to further the learning experience of all students involved. The primary focus of this document is safety. Definitions of roles, within the High School evgrand Prix, student teams and classes will be explained in supplemental documents as well as on-line offerings thru Purdue University e-learning. Please check the High School evgrand Prix web site for the other rules and procedures including but not limited to: A. Race Procedures B. Outreach procedures C. Design procedure D. Energy Efficiency information E. Others United States Auto Club 4910 W. 16 th Street Speedway, IN evgrandprix@usacracing.com

2 1. Jurisdiction 1. Interpretation 2. Inspection Stickers 3. Deviation Requests 4. Workmanship TABLE OF CONTENTS 2. Race Vehicle Specifications and Requirements 3. Type 4. Weight 5. Material Specifications 6. Chassis 1. Frame 2. Bumper and Side Bars 3. Side Bars / Impact Bumpers 4. Wheelbase 5. Tread Width 6. Tires 7. Wheels 8. Mirrors 7. Bumpers and Bodywork 1. Front Bumper 2. Rear Bumper 3. Side Pods 4. Driver Fairing 5. Dislodged Or Missing Bumpers 6. Propulsion System 1. Batteries 2. Battery (Voltage) 3. Battery Capacity 4. Exchangeable Battery Packs 5. Battery Enclosure 6. Wiring 7. Fusing 8. Emergency Switches 9. Power Limit 10. Power and Energy Limit Enforcement 1 1. Motor Specifications 1 2. Kart Speed 7. Control Systems 1. Throttle 2. Controllers 3. Data Acquisition 4. Remote Control 8. Battery Charging 1. Chargers

3 9. General Vehicle Safety 1. Brakes 2. Mechanical Driveline Guards 3. Steering Control 4. Steering Wheel 5. Front Spindle and Rear Axle 6. Seat and Floor Pan 10. Vehicle Identification 1. Numbers 2. School Affiliation 3. Series Sponsors 4. Race Sponsor 5. Team Sponsor 1.0 Jurisdiction 1.1 Interpretation All subsequent rules and specification in this document will be interpreted by the technical inspection team who will determine the acceptability of the vehicle and the safety equipment for the competition. 1.2 Inspection Stickers An inspection sticker, indicating a race vehicle has been accepted for competition shall be positioned at a conspicuous place on the race vehicle chosen at the time of the technical inspection Spec Stickers All spec parts including motor, controller, and all battery cells will be marked with a tamper proof decal. Removal of decal or transfer to another part will result in a DQ from the event. 1.3 Deviation Requests Any deviation request must be submitted by April 1 with USAC action reported back by May Workmanship The Technical Director has the right to question poor workmanship and the resulting safety hazard it presents and require the team to repair the deficiency. 2.0 Race Vehicle Specification & Requirements 2.1 Vehicle Type The race vehicle selected and accepted for the 2016 competition will be a commercially available Sprint Kart chassis. For reference, Margay has designed and built a special kart for electric racing use for Purdue University. This one is highly recommended as it was specifically designed to hold the battery weight but all competitors are free to choose their kart chassis.

4 2.2 Weight Battery packs alone cannot exceed 50% of the total vehicle weight as weighed without the driver or battery packs. Each race vehicle will be weighed at technical inspection to determine conformity to weight requirements. Per J2880 Standards. 2.3 MATERIAL SPECIFICATION For any additional revisions or other modifications to the Kart the following are material specifications: A. 1 OD by.083 wall thickness seam for the kart components: welded or seamless round steel tubing, or B. Unbent 1 by.083 wall thickness radius corner square seamed welded or seamless steel tubing, or C. 1 OD by.125 wall thickness seam welded or seamless drawn round 6061-T6 aluminum tubing, or D OD by.083 wall thickness welded or seamless drawn round 6061-T6 aluminum tubing. E. 18 gauge or heavier sheet steel or sheet aluminum. F. Aluminum (16-24 gauges) material allowed for use as fairings, cowlings, and shields and must not present a hazard Fasteners Class five (5) fasteners, at a minimum, are required for all non-metric screw / bolt type fasteners of.250 inch diameter and larger. A class 8.8 is required for metric fasteners of 6mm and larger. A class five (5) fastener is indicated by three-lines on the head of the cap screw where the lines will be at a 120- degree angle. A class 8.8 is clearly marked as Kingpins, pedal attachment points, steering wheel bolts, and all parts of the brake throttle, and steering linkages shall be cotter pinned. All cotter pins shall fit snugly in the holes and pass through the nuts or through a serrated section of a castellated nut A distorted thread or expansion type steel lock nut may be used instead of cotter pins where the nut or bolt is not subjected to rotation. These nuts may not be reused more than five (5) times as recorded in the team s safety log Safety wire is to be used on bolts installed in threaded components. The safety wire must pass through the bolt head Nylon-fiber locknuts are required to secure seat mounting bolts, chain guards, motor and controller mounts and floor pans. They may also be utilized on fasteners that are #10 or smaller in size. Nylon nuts must be snug and unable to be loosened by hand during inspection The front axle nuts must be castle type and cotter pinned or nylon and clipped Plastics and composites - The only plastic or composite

5 materials allowed on the vehicle are the seat, number panels, mirrors, nylon ties, data information display monitor, casing for the batteries, front impact crushable, rear crushable, side impact bumpers, and fairings. A. All polycarbonate plastic sheets must be at least.0625 inch (1/16 ) thick or greater. B. Composite Fiberglass reinforced resin can only be used for molded seats. C. Polyethylene may be used to make crushable body components Acrylic based plastics are not allowed on the racing vehicle Welds Only TIG welds of high quality, as determined by the technical inspectors, shall be acceptable for any welds other than the original factory welds. Butt welds must be reinforced by an inner sleeve at least twice the tubing diameter in length. One 1/8 hole per weld must be drilled into the sleeve area to indicate the presence of the sleeve. ANY NON-FACTORY WELDS MUST BE CLEAN AND UNPAINTED FOR INSPECTION. No plastic body filler or load will be allowed in seams. Any broken or poor quality welds observed on a race vehicle by the inspectors shall disqualify the race vehicle from further participation until the welds can be made to pass inspection. 2.4 Chassis Frame We recommend that you strongly consider the Margay Electric Kart for Purdue, However, any spring Kart Frame will be acceptable. No endure, lay down style frame, or off set frames will be allowed. Nerf bars are a required part of the race vehicle frame. NO aluminum base frames will be allowed in the 2016 competition. All parts of the race vehicle must clear the ground by one (1) inch at all times. The clearance rule will be enforced if parts of the race vehicle are seen by a USAC official to be dragging or as a hazard during technical inspection, practice, qualifications, or race. Penalties will consist of lap penalties, banning from practice sessions, restricting the race vehicle from participating in event or session Bumper and Side Bars Bumpers and sidebars must have a minimum effective width as measured from the top of the bumper to the bottom of the bumper of six (6) inches, and they must be in a vertical line with each other. Bottom bars must be seven (7) inches or less above the ground and top bars must be six (6) inches or more above the bottom bar. Distances shall be measured from the centerlines of the bars. The Margay Chassis already meets the specifications as reference. While bumpers and nerf bars may need modified to accommodate battery mounting, the system must remain as strong as or stronger than the original factory equipment regarding driver protection Side Bars / Impact Bumpers Side impact bumpers, commonly referred to as nerf bars, must be of a C type as viewed from above and surround the main frame in such a manner that any side impact will be transferred to the main frame directly. Side impact bars that are

6 attached to each other from side to side with a bar that goes across the width of the frame must be attached to the frame or at a reaction point on the frame. Impact bumpers must be installed so that the bumper of another race vehicle will not pass over or under them. Bumpers should extend to the center of the wheels. Bumpers and side bars must not extend beyond a line from the center of front tire tread to the center of the rear tire tread, and must extend to less than four (4) inches from the tire. The bumpers and sidebars must be connected with metal material to prevent bumper hooking. Side bars / nerf bars may be used to mount batteries on the vehicle Wheelbase The Standard IKA for Sprint type chassis will be the standard for wheel base Tread Width The total width of the race vehicle shall be between thirty (30 minimum front) inches and fifty-five (55 maximum rear) inches measured from the outside-to-outside edge of the tires Tires Tires shall be between nine (9) inches and inches outer diameter and of the pneumatic type only. No tire softener will be allowed in the pits or used in any fashion. Tires must be mounted for the proper rotation as prescribed by the manufacturer arrows on the tires. One set of tires will be included in the entry fee, and will be provided by Hoosier Racing Tires. This set of tires must be used for the entire duration of the event. Penalty will result in loss of practice session, loss of qualifying time, or disqualification from the race. Replacements for a puncture will be handled on a case by case basis by the Director of Competition Wheels All wheels shall be of racing quality and void of any defects. Wheel bearings shall be of ground ball or roller type only. Axle nuts shall be castellated and secured with cotter pins of at least 1/8 in diameter or nylon nuts with clips. Safety wire or bolts through the axle are not acceptable Mirrors Mirrors will not be allowed on karts. 2.5 Bumpers and Bodywork Front Bumper All karts must be equipped with a commercially available front crushable, which is attached to the front bumper to minimize shock in the event of a front impact. The front crushable must be a CIK nose Rear Bumper All karts must have rear protection by a CIK style plastic rear bumper. The rear protection shall extend to the outside of the rear tire/wheel assembly Side Pods All karts must have two CIK-style side pods attached to the nerf bars which may be modified for battery mounting options. However, they must maintain their original integrity.

7 2.5.4 Driver Fairing A CIK style driver fairing must be attached to all karts. The driver fairing must have a 3 clearance to any part of the steering wheel Dislodged Or Missing Bumpers If a bumper, side pod, or driver fairing falls off the kart or is dragging, the kart will be flagged into the pits and required to replace or repair the dragging part. 2.6 Propulsion System Batteries All race vehicles must be powered from electricity supplied by a battery. For the High School series only Lead Acid based battery chemistries may be used. All batteries and/or batteries packs made of individual cells must be encased in an acceptable enclosure that will not leak if punctured. Only batteries meeting these requirements will be allowed to participate in events, in practice, or in competition. Batteries must display all original manufacturers labels. Batteries must be securely attached to the vehicle in such a manner to protect them from direct impact and withstand the forces of impact or roll-over. Final judgment of mounting integrity is reserved for technical inspection. For LEAD ACID BATTERIES Gel or AGM type batteries are allowed, but liquid electrolyte type batteries are Not Acceptable for the event. Only batteries available either for purchase or donation to any competitor may be used. Batteries that are not commercially available must be approved by USAC Battery and Storage Battery packs and all other electrical components are limited to a nominal 48 volts (maximum of 60 volts) during race vehicle operation Safety / Hazard Analysis It is required that all teams perform a Hazard Analysis. The analysis shall comply with OSHA 29 CFR (NFPA 70E). The individual team will be responsible for compliance, and that the race vehicle meets those requirements in the technical inspection review. Each team is responsible for safe operation of their race vehicle Battery Capacity The total energy available will be limited to 3,000 Watt-Hours for the entire race regardless of battery chemistry. All batteries must be wired so all electrical power from the batteri e s is directed through the Energy Power Monitor device. Team is responsible to provide manufacturers specifications to document amp hour and cell voltage and show total Watt-Hour calculations if asked by a technical inspector or race official Battery Pack Fastening Batteries must be enclosed and adhere to battery specifications. Batteries will be safely removable, with proper terminal connections and covers. Elasticized fasteners will not be allowed to secure the batteries to the vehicle. Proper quick disconnects are required and must be properly rated for the expected amperage draw of the race vehicle. An acceptable quick disconnect is one of the Anderson Multipole family. Race officials

8 will inspect all battery attachment systems to determine that the batteries will remain securely attached to the kart during the race and during any foreseeable accident scenario Removal Process Removal systems must be designed to be safely operated and take into consideration ergonomically acceptable standards for weight and size. Individual removable battery pack sections should weigh no more than 50 pounds for a one- person removal. Mechanical systems may be employed but must be approved by the technical inspector prior to use Battery Enclosure Batteries must be enclosed in a solid, shatterproof enclosure, which must meet the approval of the race safety officials. Battery cells inside the enclosure must be isolated by an insulating material and mounted to maintain electrical isolation. The side of a battery pack containing connections with live voltage must be covered by a nonconductive material. Polycarbonate is an encouraged, material for this purpose. The enclosure will contain holes for running cables, and/or for heat dissipation. The purpose of the enclosure is not to create an airtight package, but to protect the batteries from damage in collisions, and to prevent objects and personnel from contacting the battery terminals. Acrylic is strictly prohibited for use in the battery enclosure Wiring All wires must be rated to handle the voltage and amperage load that can be applied through the circuit. For clarification please consult the wire size chart located in the National Electrical Code Article 400 Table 400.5(B). In all cases, manufacturer data will supersede the general information from the NEC. Wiring must be well insulated and securely attached to the vehicle. All wiring must be kept free from moving parts and protected from chafing. Wires that pass through a hole with sharp edges or through sheet metal must be protected by an insulating grommet or other suitable device. Terminals must be secured and protected so they will not come loose or short out during competition. No electrical terminals may be exposed. No part of the electrical system may use the vehicle frame as a conductor and the frame must remain ungrounded. The vehicle will be checked for maximum frame to electrical leakage during Technical Inspection. Maximum voltage allowed is 5 volts measured from the most positive and the most negative of battery pack to frame with vehicle in run position. Voltage must dissipate to net zero upon application of a 10,000 ohm resistance Fusing A fuse or circuit breaker is required for the electrical circuit between the battery and any electrical load. All fuses or circuit breakers will be mounted in electrically rated enclosures as close as practically possible to the source of power. All fuses or circuit breakers will be sized to protect the wiring to which they are connected. Fuses will be sized to carry no more than 85% of the maximum allowable current for the wiring. This means the peak amperage of the fuse has to be less than the peak amperage of the wire being used at all times. The main traction drive fuse will be inspected for appropriate type, voltage, and amperage rating. If the fuse must be replaced, the kart will need to be re-inspected prior to allowing the vehicle to operate in the event.

9 2.6.9 Emergency Switches An emergency stop circuit must be employed on the vehicle. The circuit will consist of a kill switch located on the steering wheel and a mushroom style emergency stop switch located on the rear of the vehicle in a location which is easily recognizable, labeled, and accessible to emergency personnel. The kill switch and the emergency stop switch will be wired in series with a main contactor coil circuit. The contactor and power circuit must have a short circuit current rating that exceeds the maximum peak current draw of the vehicle. The circuit will consist of an appropriately sized contactor (also known as solenoid relay) that will be connected in the main positive power cable between the battery and any motor controller. An indicator light must be included to signal when the main contractor is closed. The light must be placed near the emergency stop switch and must be visible to track personnel. See Appendix G for an example Power Limit The traction drive power system must not exceed 10kW peak at any time during the race. Power shall be defined as the instantaneous voltage multiplied by the instantaneous current delivered by the battery. The system may use any combination of battery instantaneous voltage and instantaneous current, as long as this value does not exceed 10kW. The voltage used for this calculation is not the battery pack nominal voltage but the actual voltage, so teams must be aware of any overvoltage present in their packs when setting control limits Power and Energy Limit Enforcement The power and energy limits (10kW and 3,000 watt-hour respectively) will be enforced by the race officials using an Energy Power Monitor (EPM) installed by the teams with the supervision of the race officials before the race. The race vehicles must pass technical inspection prior to installation of the EPM. Teams will prewire and prepare a mount on their vehicle as specified and must make wiring schematics available to the race officials before the measurement system can be installed. If a team is found to exceed the maximum power usage during the race, they may be removed from the event, or other penalties may be applied. The vehicle is subject to reinspection at any time Motor Specifications Motors will be rated by the manufacturer to handle the expected power load over the duration of the race. The peak power available to the motor drive system will not exceed 10kW. There is no limit on motor RPM, but teams must be aware of the manufacturer s limitations for their motor. No water-cooled motors will be allowed Kart Speed Kart shall not exceed a maximum speed of 50 mph and karts will be checked during practice and races to ensure compliance.

10 2.7 Control Systems Throttle Race vehicles shall be equipped with a foot-operated throttle potentiometer with two return springs, which will return the potentiometer to produce zero speed signals when the pedal is released. One spring must be located between the throttle pedal and the vehicle frame. A throttle return spring must also be located on the potentiometer throttle box to assure the potentiometer returns to zero signal when the pedal is released or in case a throttle cable is broken to prevent undesired actions Controllers Any type of power controller is allowed. Controller must be appropriately matched to the motor in order to stay within the power limit and teams must follow all manufacturer requirements related to the operation of the controller. The forward power command to the motor must return to zero when the driver releases the accelerator pedal. There are no restrictions to energy management throttle control. Computers on or off the vehicle are permitted, however; remote control of a vehicle is not permitted. Karts with the ability for reverse will not be allowed Data Acquisition Computers on or off the vehicle are legal for data acquisition purposes Remote Control Remote control of a vehicle is prohibited. No control signal can be transmitted back to the race vehicle for on the fly adjustments. 2.8 Battery Charging Chargers Battery charging and equipment is the responsibility of the race teams. Chargers with open components and circuits or damage will not be allowed. Charging of batteries either on or off the vehicle will not be permitted in the pit or on or near the track area. A specific battery charging area may be provided where charging equipment can be set up and operated. Back-up type generators are not permitted to be operated during race events. Rules standards and procedures for the use of charging equipment and procedures will be provided in a separate charging equipment specifications document issued by USAC officials. 2.9 General Vehicle Safety Brakes All race vehicles shall be equipped with pedal operated hydraulic brakes operating in such a manner as to stop both rear wheels equally. Brake linkages must have at least two (2) inches clearance off the ground. A cotter pin must be placed through the pivot pin, which connects the brake linkage lever to the master cylinder. Brake discs must be at least 1/8 thick. Brakes must be able to lock both rear wheels at maximum speed Mechanical Driveline Guards (Chain Guard) Open mechanical drivelines including chain, belt, or gears must be

11 guarded to reduce the possibility of personal injury and contact with the racing surface. Totally encased drives are exempt from this section Sprockets and sheaves mounted on the rear axle drive components must include a blank sprocket guard. The blank sprocket guard must be at least 1/4 larger in diameter than that of the axle sprocket or sheave being used. The bottom of the blank sprocket must maintain at least a one inch clearance above the racing surface at all times (measured with the race vehicle fully loaded). If tire wear or other circumstance create a condition where the guard, sprocket or sheave contacts the racing surface the race vehicle will be black flagged to the pits for corrections All open mechanical components will be guarded by a metal guard to prevent whipping if chain or belt breaks, prevent incidental contact with moving parts, and to prevent injury from rotating parts and pinch points. The guard will be securely mounted Steering Control The steering control shall be a direct acting mechanical system of suitable design for the maximum safety and prevention of over center lock. The steering shaft shall be either a minimum diameter of 5/8 solid rod or 19mm tubular steel. The steering wheel hub may be attached to solid shaft by a taper and key. Solid or tubular shaft hub connections may be made using a quality TIG weld made to the non-stressed side (upper or steering wheel side) of the hub. A through bolt of at least.3125 inch diameter may be used on tubular shaft provided that there will is no play evident between the hub and shaft during inspection. All steering assembly fasteners shall be castellated and cotter pinned. All steering assembly fasteners shall be of class 5 or better and a minimum of 3/8 inch in diameter. All rod ends shall be protected from collision. Nylon lock nuts are not permitted in the steering assembly. No plastic steering components allowed Steering Wheel The steering wheel shall be of a circular or enclosed wing design. No post or handlebar steering wheels are allowed. The steering wheel shall be attached to the hub by at least three cotter pin bolts with cotter pinned nuts or by bolts with safety wired heads where a threaded hub is used. Any sharp protrusions shall be covered. All nuts and bolts must be available for inspection Front Spindle and Rear Axle The front spindle and rear axle shall not extend beyond the wheel widths. The rear axle shall be solid steel in diameter for cadet karts; all others must use a 40 mm or 50 mm tubular axle. Rear axles may be made of steel or aluminum or documented equivalent construction and strength Seat and Floor Pan The floor pan must fill the space inside of frame extending from the front frame member to the seat and

12 made of material that meets specification 2.3. Seats may be made of resin impregnated fiberglass fabric. Fiberglass seat must be in good condition with no cracks or holes and be fastened to metallic seat supports using fender type washers and spacer grommets. No holes large enough for any part of the driver's body to inadvertently pass through shall be permitted. The seatback must not exceed a 135-degree angle from the floor pan. Seat bottom must be higher than the lower edge of frame tubing Seat Belts Seat belts or any type of driver restraint system that holds a driver into the seat is prohibited. Drivers must not be held in the seat in any fashion that would pin them underneath the kart should it become inverted or become airborne Vehicle Identification Numbers Kart numbers will be assigned by the Director of Competition on a first come, first served basis with the exception of #1, which is reserved for the previous year s winner Only numbers 2-99 will be assigned to teams Numbers will be assigned upon the completion of technical inspection, in the order in which teams pass inspection It is mandatory that each kart display its racing number on all four sides. One on the top of the driver fairing, two near the rear of each side pod, and one in the center of the rear bumper Only Mylar stick-on numbers will be allowed. No taped numbers are allowed School Affiliation It is recommended that a decal displaying school affiliation be placed on the side pods of the kart Series Sponsor A 4 x 4 area on the front panel of the race vehicle will be reserved for a series sponsor decal. Series sponsor decals must be displayed at all events during the season Race Sponsor(s) A 4 x 4 area on each side panel of the race vehicle will be reserved for race sponsors decals. These must be displayed at all times the event is running Team Sponsor(s) The evgrand Prix encourages the recruitment of commercial sponsors (marketing partners) for individual team entries. Teams must clear their sponsors through USAC and insure compliance with their affiliated school guidelines before entering into any agreement. Any information given to before recruiting a sponsor will be held in confidence. No team may be sponsored by any organization or business associated with alcohol or tobacco, or things of a sexual or denigrating nature. This includes bars, where the bar is not set apart (separate) from a family area. USAC has final say on any discrepancies with the rule. Advertising of sponsors on

13 the racing vehicle shall be limited to signage located on front, rear and side panels and crushable of the race vehicle. The advertising in the front shall be kept at least 3 inches from each side of the front number panel. 3.0 TEAM EQUIPMENT 3.0 Required Safety Equipment All team required safety equipment is the responsibility of the individual race team and shall be brought to technical inspection and shall also be available for re-inspection at any time. 1.1 Appearance It is essential that every effort be made to present the most professional racing appearance possible. To this end, certain minimum requirements shall be imposed on all competitors. 3.2 Helmet The driver s helmets must be full faced, a minimum of Snell 2005 approved and not older than five (5) years from manufacturing date. Long hair must be securely fastened beneath the helmet or driver s suit. Visor must be clean with minimal scuffs and scratches. SA-rated helmets are required. See Appendix M for additional information about helmets. 3.3 Drivers Protective Clothing Drivers suit must be manufactured for racing. Suit must be constructed of heavy weight, abrasion resistant nylon. Driving suits must meet SFI rating The driver s suit must cover the ankles and wrists while seated in the kart. Exposed skin will result in a black flag penalty To prevent or minimize abrasions, all drivers shall wear gloves of Kevlar, leather or vinyl material The driver shall wear approved neck brace, socks covering the ankles, and full coverage sturdy shoes, boots or racing shoes. 3.4 Crew Clothing At all times in the pit and paddock area all crew members must wear shirts, closed toe shoes, full length pants, and safety glasses. No sweat pants, jeans with holes, polyester or plastic clothing, or shorts will be allowed. Sponsor and school logos are allowed. All graphics on clothing must be in good taste. It is encouraged that each team have a uniform look for visual impact and professionalism. 3.5 Fire Extinguishers Each team will provide at least one CO 2 type Underwriters Laboratory approved fire extinguisher with a minimum capacity of 2 1/2 pounds. This must be brought to technical inspection, practice, qualifications, and the race. The fire extinguisher must have been inspected within the last twelve months, tagged, and sealed are required. All fire extinguishers within the pit area must display the inspection sticker provided at the technical inspection. Fire extinguishers must be on hand when the race vehicle is being energized.

14 The Program: The High School Go Karting Series Hosted by Purdue University and the Indianapolis Motor Speedway Sanctioned by USAC This series remains in the development/ pilot mode and should be able to go out to as many as 20 pilot schools for the 2015 / 2016 school year. This event is very similar to the International Collegiate evgrandprix at IMS that the Colleges and Universities from around the world compete in. The only real difference is the High School Series will utilize Gel Cell Lead Acid Batteries for energy storage, a very similar electric motor, a very cost effective controller and a sprint kart chassis. This makes the competition much more affordable then the lithium ion big brother series. It also presents much less risk and also presents no safety risks being inside a building (would not have to drain fuel every time). The first three pilot karts ran at IMS in They performed very well and all were impressed with the performance. This National Final race will be held at IMS with the other three races. We encourage the College / University students to work with and mentor the High School Students both at the track and at school. Guidelines: Restricted to 11 th and 12 th grade students as a preparation for post high school education with some real world experiences. A student team would consist of students in many different disciplines: (i) Engineering and Technology bound students. (ii) Liberal Arts Students (iii) Marketing and promotions group (iv) Community outreach team (v) Mechanically inclined students As an example, the Marketing and promotions group would be charged with development of a sponsorship plan, complete with activation, to begin the marketing campaign for this team and the necessary equipment that will be required. The Kart will have to have a paint scheme and graphics displayed as part of activation in marketing. The Liberal Arts students can take this charge.

15 Community outreach is a very big part of the program. A team of students would have to develop a plan, and implement this plan (taking pictures and documenting their activities) for the Outreach Competition. The Engineering and Technology based students would need to begin to plan for the Design Review Competition for the event as well as design necessary components for the Teams Mechanical / Electrical Crew Chiefs. The more mechanically inclined students would be the actual kart team that supports the Kart and Driver at practices and race events. They will do much of the hands on work to the Kart and need to be specifically trained in Race Safety (NFPA 610). Objective: The objective of this initiative is to get the High School Students involved in more STEM related hands on activity. To make sure as the program progresses that they have to take some courses that will help them make sure they are prepared in the STEM disciplines to enter postsecondary education well prepared. To bring all disciplines together as a team to represent their school in an academic competition that cannot be achieved with Football or Basketball. We want to make sure each student understands the strengths of the others in their school. Not all mechanically inclined students are any less valuable than one that is math strong and headed to Purdue for an Engineering Degree. To understand everyone has their strengths and weaknesses but that it takes all of our skills to work together in the real world after High School. Next Steps: Review all the materials. Make a decision regarding competition in the program. Establish your team. Begin to work on a funding / sponsorship plan. Select a Kart and Electrical Power Train package. Begin to develop your plan of action. Find a Champion to Coach your team. Someone who is very familiar with racing and better yet, Karting. Go to the USAC Web Site and register your team. Training Events and Opportunities: Purdue will be developing on-line courses that will be rolling out thru the school year for the construction of the kart, safety training, driver training and how to market your team and secure sponsorship.

16 Purdue will be coordinating regional workshops that will be available on Saturdays at select locations. Andretti Autosports could be one as well as Fisher, Hartman, Carpenter Racing on Main Street in Speedway. Cost of Competition: 1) You can order the entire package from EVC Racing which includes the Kart, Wiring Package and Drive Train with Batteries. 2) You can order the Drive Train Package from EVC Racing and purchase a used Sprint Type Kart used from Comet Kart or from an individual. (Usually around $1,500 for a year or two old kart) 3) USAC Entry Fee which includes insurance and the race day set of tires (Hoosiers) 4) Logistics to and from testing and to and from the event. 5) Decal kit for your kart. 6) Look at the rules book before choosing a Kart Chassis (body work is required). The Race and Academic Competition: Energy Efficiency This will be calculated by a similar method that is utilized in the International prototype series. More to come as we move forward with continue development on the rule set. Community Outreach Identical to the International competition. Design Review Identical to the International Competition. Race Placement It is just that. Clinics and Workshops: We will be holding clinics and workshops around the state to support this academic series. The University will develop on line coursed to teach teachers, coaches and students how to understand chassis dynamics, driving training, electric power train and tires. These will all be available on a web based format. Summer Camps This year, 2015, Purdue Polytechnic of South Bend will be putting on a number of summer camps with Electric Go Karting. There are a number of offerings and if you want a jump start on the program check out one of these very cool summer offerings.

17 Event Information Purdue University Motorsports Contact: Danny White Director of Motorsports Purdue University Office of Engagement (317) Cell (317) Office If you have specific question as you make the decision to participate in the event, feel free to reach out to me any time. Feel free to call me with input and ideas regarding the event as well. This is the first inaugural race for the National Gas Series and feedback is very welcome. and click on the drop down races. If you want to register, click on the USAC link and it will take you directly to the event registration page. USAC Racing: usackarting.com this site will provide you with all of the information you will need. as Courtney can assist you with questions, concerns and event registration.

18 djw 5/27/2015

19 MSTEM 3 High School evgrand Prix Teachers Guide

20 1.1 Introduction and Purpose: It was the general idea of this guide to try to put ourselves in the position of a K-12 Teacher who has heard about this new program and wants to know more. Here we will give you the overview that is necessary for you to make a decision about participation and clearly understand what is required for success. You will find that the academic competitions are interesting and required at all level of competition (thru University and Collegiate). Kart building on the other hand is a bit more of a lesson for all the first time thru. This should be helpful as you charge ahead with a true hands on STEM experience that they will cherish for a lifetime. Racing at the Indy 500! The culminating event, which is held at the Indianapolis Motor Speedway, is a day to remember. The University and Collegiate Students are racing on the same track and they will all use the same pit area. This allows for a bit of coaching and mentoring from the University and Collegiate Teams. It clearly demonstrates to the High School student how the Collegiate Teams interact and compete. This program will assist them with engineering and technical skills, project management, sales and marketing, design, fabrication, team work / team building and outreach into your community. Many of the items in the karting program fit well as relevant props for many math and physics problems that many students just cannot seem to get their hands around in the class room. College bound or not, this is one program that will give students a hand up with hands on! 2.1 Budget 2.2 Links to suppliers: Can be found on the USAC web site; usackarting.com Or, try purdue.edu/mstem3 2.3 Hardware Costs Total estimated budget for equipment apr. $5,400 Kart - Apr. $3100 Purpose built Margay Purdue Electric Kart (recommended) Margay Karting (314) Comet Kart Sales (317) Rex (Sprint Type Chassis) Fox Valley Karting (765) John Copeland (Sprint Type Chassis) Motor, controller and wiring harness DC Motor and Alltrack Controller Kit apr. $1,000 plus shipping Electric Motorsports (510)

21 Thunderstruck Motors (707) Batteries Interstate $49ea (3/4 required) Interstate Battery SLA v 35AH at 49.95ea (317) Andrew Willis Battery Charger Donated by Don Schumacher Racing Call Danny direct on this one. Don Schumacher Racing will be supplying the chargers Drivers Suit, Helmet and other PPE Apr. $1,000 Simpson Racing Products (800) IMPACT Racing (317) Comet Karting (317) Rex Fox Valley (765) John Copeland USAC entry fee - $500 Usackarting.com chandi@usacracing.com 3.1 Funding This is a student activity with most teams and schools. The students have to be of many disciplines. The team will need to prepare a presentation as one of the first and most important tasks. The students will have to develop and present to the businesses and funding sources in your immediate area to sponsor the team. Just like real racing it takes the sales and marketing forces to bring in the fund raising.

22 Most schools have the community partners come to the school for a presentation instead of the students visiting each business in your community. A Pilot School from the 2014 /2015 Season (Decatur Central Marion County) has put their sponsorship document up for the new teams to see an example. This worked for their team and they hope it gives you some guidance. 4.1 Academic Competition We designed the competition for learning not just racing. While the racing may be cool the learning is exceptional. This requires hands on skills sure, but to win, it will take many different students working together as a team. In the same way they would in a real world race team Community Outreach: Community outreach competition is one where the students will go into the community, bring the community in, appear at teacher conferences or different events in your community and reach out and let people know about electric transportation. Promote the High School Karting Program. But most importantly promote that spirit of competition that will give them the advantage. Make sure they document everything they do in this category and their next task will be to put all that information into a cool presentation for judging at the world finals at IMS. This is all about communication, team work, leadership and soft skills. 4.3 Design Review: This is the competition that would require a student to be able to utilize engineering software. Autodesk CAD Software is free to all schools. This will require a presentation of a different nature. This is one where the lead engineering or technology skilled student will present the design concept and what sets their schools kart apart from the rest of the field. You must utilize some type of CAD drawing or renderings in the presentation to be competitive. This competition assures you that the student team will have to be creative but also know how to communicate it to a group. As they would trying to convince the crew on a real team of their latest idea and why it will make the race car go faster. 4.4 Energy Efficiency: This competition is very engineering based and requires a bit of testing on track or on a dynamometer to see if you have it correct. The idea is to be the fastest and finish very well but use the least amount of fuel to do so. Many factors come into play including gear ratios, kart set up, tires size / pressure and the human factor of course. Energy will be measured before and after the race thru a black box system used by timing and scoring. 4.5 School Logo: Develop your school racing logo. While not a competition it is bragging rights.

23 4 5.1 In the Classroom Many will chose the option of using this program in the classroom as a great platform of relevant examples of physics, engineering, technology, math, science, liberal arts, medical, manufacturing and fabrication, communication, team work and soft skills. 5.2 Course Offerings: Many different course offerings complete with classroom curricula is in development and has a firm time line. Purdue University and other members of our MSTEM 3 Team are deconstructing karts and mapping kart platform of many of the functions, parts, pieces and their working relationship into course materials that would be relevant to what they are learning and what they will need to be successful at most careers. 5.3 Teacher Input: We value teacher input and consider this one of the best methods of working pilot programs. Great communications between the teachers, coaches /mentors on the ground and our MSTEM 3 academic team will make things progress at a much higher rate. Share with all of us please. 5.4 Teacher Coaches: We have a couple very valuable High School Teachers that were in the early Pilot of 2014 / 2015 and are willing to lend a hand with some guidance and help you get thru a technical tough spot. They see the value of the program and what it has done for their students. They are great consultants and coaches. 5.5 Workshops: We plan at a minimum of two workshops in the spring of 2016 at an Indy Car Team Headquarters and another location to be announced. These two workshops will give you the chance to get answers to you questions in both electrical and mechanical areas of you kart. Karting experts will be on hand at the second workshop to help you understand how to tune the frame of your kart when testing. We will have a break out session on how to establish a testing log book and how to use the data when setting up the kart. 5.6 After School: The Purdue Extension Offices around the State will be available to assist in most of the urban and extreme rural communities Coaches and Mentors: There are coaches and mentors available in most communities. In some areas our Municipal Firefighters have stepped forward and agreed to coach a few after school teams. It takes a village and these Firefighters are an example role model in the urban school district and serve in that capacity as well. This program is a lot like football or baseball if you sign up for after school. After school has initially been a bit harder as it requires a bit of passion for it. It is hard work and not just all fun and games. With the correct Coach and structure, an after school program can work effectively. However, the academic advantage cannot be fully recognized in the after school application without a skilled high school teacher. In many rural communities it could be the local car dealership mechanic and a farmer who are the coaches for the team. It all works.

24 5 6.1 Karting Build Manual Each team will be supplied with a complete kart build manual that was developed by students in the Purdue University EPICS Program. This manual took a number of semesters and different teams to complete. You will see it was worth the effort. All of your question should be easily answered with this great build manual. 6.2 Required Trainings for Electro Mechanical: There are several electro mechanical required trainings that are on-line offerings from Purdue (some remain in development) Safety in the Classroom / Lab: Gives a great breakdown or overview of the safety related trainings necessary for student safety. We recommend that you include some of your own school specific training as well Electrical Systems Overview: This training gives the student the necessary understanding of the electrical circuits necessary and why. This will really test the students and the real technology minded students will emerge. It may be the student that loves to mess with RC Cars or the First Robotics / VEX Robotics electrical student Seat Mounting and Kart Balancing: This one teaches the methods necessary to mount the seat for the driver where the kart is in a neutral balance position of 47% front and 53% rear as the kart is weighed on special scales NFPA 610 Awareness Level Training: Each student that participates and is going to the race venue must take the awareness level course. It is like basic training for the novice racer regarding safety at the race track. Again, something they will take with them forever Finding Your Line: The physics of finding the path of the least resistance around a given race track. How and when to properly utilize your brakes and turning in. How to utilize a good tire management system to get the result you will need at the end. This is only mandatory for the drivers but it is very interesting to others in the team. 7.1 Motorsport Safety Motorsports safety is the most important mission of the sport. An Indy Car can safely run down a straight away at 240mph and a Top Fuel Dragster can exceed 300mph and both do so safely. That is exactly why safety is so important. We would not all be here racing today if it were not for strong safety programs in Indy Car, NHRA and USAC. 7.2 NFPA 610 Compliant: All race and testing activities will be NFPA 610 compliant. Enforcement is USAC responsibility but training and implementing is all of our responsibilities. Keeping our students safe is the highest of priorities. A great safety system assures that.

25 7.3 Practice and Testing: Any operation of the racing kart outside of a sanctioned track is strongly discouraged. It is highly recommended that you utilize a designed race course or one set up with USAC supervision and over sight Regional Tracks: We are currently establishing relationships with Regional Tracks across the State. The series will spread State Wide for the 2016/2017 Season. Regional Events will begin to happen in the fall and late spring before Indy of Indoor Tracks for Practice and possible Winter Months Race: We are currently working with an Indoor Karting Facility to utilize their course during the colder off season winter months. 7.6 Purdue Track: We are currently working on a race at the Purdue Grand Prix Track to add to the mix. 7.7 Rental Tracks: The Whiteland Raceway and the New Castle Motorsports Park are two locations that are lease by the hour tracks. Others may be available and we will keep the USAC Web Site up to date on any new opportunities. 8.1 Winning the Event 8.2 A rubric is in place for combining the following: * Race Placement 40% * Community Outreach 20% * Design Review 20% * Energy Efficiency 20% 9.1 How do I get started? 9.2 Buy-In: Get your schools buy-in first. 9.3 Establish your team / teams: Make sure you have a very talent diverse group as the different categories will require different skill sets. All must be versatile. 9.4 Marketing Plan: Have the Sales and Marketing Team draft a plan immediately to seek sponsorship. 9.5 Community Partners: Do an assessment of possible community partners. 9.6 Presentation and Sales Pitch: Develop your presentation and invite your partners in for the pitch. Don t forget activation. What are they going to get from this experience? 9.7 Purchase 1: Order your Kart and Motor / Controller Package 9.8 Purchase 2: Order your Battery Packs from Interstate See USAC Web Site

26 9.9 Establish who is the Crew Chief: Must be organized and good with people skills Select the Driver: I would recommend that you go to Fast Times or another type indoor karting facility and you will quickly see who is the fastest Set up the Build Space or Lab: Set up and area where your Kart can stay put and not be disturbed and valuable parts and pieces must be secured Tools: Your team will need a great set of hand tools. I would check with the local auto parts store, hardware retailer and just ask for the donation to the program. You do not need as many different tools as you would first think. Most of the bolts are of two / three sizes. As you add items to electrify the thing try to stay with the same sizes and you keep you required tools to a general set. Make a list of what you need and do not over buy Begin: Start the classes with Shop Safety first naturally and then seat mounting and kart balancing Work from the Build Manual and fabricate the necessary parts and pieces to build your kart Liberal Arts Team to Continue moving forward with Community Outreach and Sponsorship activities Continue moving forward with Design Review and Engineering documentation Attend a Work Shop: Attend one of the two workshops to meet some of the other schools and catch up on some teacher breakout sessions Attend a Test Day at one of the Regional Tracks Have fun! Call me with any questions: Danny J. White, Director Purdue University Motorsports K-12 Program Office of Engagement (317) Cell White66@purdue.edu

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28 Purchasing Guide The Purdue University USAC Karting Team has put a great guide together to assist school districts as they move forward with purchasing the necessary hardware and items to compete in the MSTEM3 High School Karting Program. We list numerous options and suppliers for most items. Please feel free to contact us direct with any questions or concerns. Hardware Costs Total estimated budget for equipment apr. $5,300 plus registration. Kart - Apr. $3100 Purpose built Margay Purdue Electric Kart (recommended) Margay Karting (314) Comet Kart Sales (317) Rex (Sprint Type Chassis) Fox Valley Karting (765) John Copeland (Sprint Type Chassis) Motor, controller and wiring harness DC Motor and Alltrack Controler Kit apr. $1,000 plus shipping Electric Motorsports (510) Thunderstruck Motors (707) Batteries Interstate $49ea (4 required)