Ferrari Scrambles as Questionable Diffuser Design Ruled Legal

Formula 1 Diffuser

The complaints over the double-decker rear diffuser designs have been rejected as the diffusers were ruled legal by the FIA’s International Court of Appeal. Brawn, Toyota and Williams were all using the different diffusers which are believed to give the cars at least a half second advantage per lap.

Following the recent ruling, Ferrari stated that they have no choice but to modify the Ferrari F60 in 2009 in order to be able to compete.

Ferrari have gotten off to a horrible 2009 campaign as team drivers Felipe Massa and Kimi Raikkonen haven’t secured even one point in the first two races.

Source: Formula1.com

Auto Parts Suppliers – Bailout Needed

The ripple effect from the decline in GM, Ford and Chrysler has been spreading. Auto parts suppliers have seen their business cut significantly and many of these auto parts companies don’t think they will be able to stay afloat without help from Uncle Sam. Two major auto parts supplier groups will soon make a formal request for a loan from the government. They are expected to ask for $25 billion in order to stay in business. The Original Equipment Suppliers Association states that auto parts suppliers employ about 600,000 people in the U.S. A collapse of this industry would be a major blow to the already difficult U.S. economy.

Companies such as FormTech Industries employs 44o people in Royal Oak, Michigan. They make shafts, gears and other components from raw steel. FormTech’s parts end up in about ninety percent of GM, Ford and Chrysler vehicles. Michael Ryan, President and CEO of FormTech, is almost out of cash and may soon be unable to purchase the raw materials the company uses to create their products.

Auto parts suppliers are normally paid 45 days after delivery of the products. This further adds to their current cash crunch.  The request for government assistance will include a $7 billion lump sum to be used specifically to help speed up the payments to suppliers.

All threats to the auto industry are also threats to motor sports. We have already seen racing teams such as Honda pull out of Formula 1 due to cost concerns. Formula 1 has started to significantly change regulations with cost cutting in mind knowing that auto manufacturers are hurting. Let’s hope the economy and auto industry turns around as soon as possible and this whole problem soon becomes a distant memory.

Source: The AP

Oil Pump and Wet / Dry Sump Systems – Racing Auto Parts

The majority of production cars use a wet sump oil system. In this system, the oil that lubricates the engine is stored underneath the crankshaft in the oil pan. The pan must be large enough to hold four to six quarts of oil. The oil pump sucks up oil from the bottom of the oil pan and then pumps it to the rest of the engine.

In a dry sump system, extra oil is stored in a tank outside the engine and a large oil pan isn’t necessary. A dry sump system uses at least two oil pumps. One pulls oil from the sump and sends it to the tank. The other pump takes oil from the tank and pushes it to lubricate the engine. The dry sump system allows for the minimum amount of oil possible to be in the engine.

Major racing series such as Formula One and Indy Car utilize the dry sump system. A dry sump system is designed to provide lubrication for the engine’s internal parts and also increase performance. A wet sump system is not practical for racing as lateral G-forces would pull the oil to one side, which would momentarily leave the engine without oil. Because the oil is stored in a separate tank, a large oil pan is not necessary. This allows for the engine to sit lower to the ground, which lowers the center of gravity.

Source: f1technical.net, auto.howstuffworks.com

Flywheel and KERS – Racing Auto Parts

In a traditional vehicle, the flywheel is the large wheel connected to the crankshaft that provides the momentum to keep the crankshaft turning while power is not being applied. The momentum is created by the energy generated during the power stroke. This energy is also used to drive the crankshaft, connecting rods and pistons during the three idle strokes of the 4-stroke cycle. This makes for a smooth engine speed. The flywheel forms one surface of the clutch and is the base for the ring gear.

Flywheel and KERS

The upcoming season of Formula 1 will allow teams to incorporate the new Kinetic Energy Recovery System (KERS) system into their cars. This addition will essentially turn the cars into hybrids. KERS is not a battery electric hybrid technology that most people are familiar with. The recovered energy is stored in a rotating flywheel instead of being converted into electricity and then applied through an electric motor. The flywheel is approximately 5 kilograms and contained inside the car’s transmission. This stored energy in the flywheel can be used by pressing a boost button during certain times of the race.

Source: auto.indiamart.com, gas2.org

Camshaft – Racing Auto Parts

The camshaft is an engine component used in piston engines to open and close valves. It is a cylindrical rod that runs the length of the cylinder bank. The rod contains many cams or lobes, each which operate a valve. The lobes open the valves by pressing down on the valve as they spin.

The relationship between the rotation of the camshaft and the rotation of the crankshaft is extremely important. The valves control the flow of the air/fuel mixture intake and exhaust.  The valves must be opened and closed at the exact time during the stroke of the piston in order to operate properly. The camshaft is either connected to the crankshaft directly. It can also be connected by a gear mechanism or with a timing belt (also called a timing chain).

In Formula 1, FIA regulations mandate that camshafts must be manufactured from an iron based alloy and that each camshaft and lobe must be machined from one single piece. No welding between the front and rear bearing journals is permitted.

Source: wikipedia.org, formula1.com

Spark Plugs – Racing Auto Parts

From Left to Right, F1, GP bike, Production Car

A Formula 1 engine is an amazing technological achievement. The engines are rev-limited at 19,000 rpm, which is over twice what most production sports cars are capable of. To ensure that the high-reving engines don’t rip themselves apart, the Formula 1 engine piston only travels about 1.6 inches. Compare this with the 4 inch stroke of a V8 Corvette engine. The bore is approximately 3.8 inches which is more comparable to the 4.13 inch bore of the Corvette.

Spark Plug Anatomy

Spark plugs for production cars are generally about 3.5 inches long, with a diameter of about three quarters of an inch. The lower third of the spark plug is covered by a steel thread sleeve. On the top of the spark plug is a metal stud. The white part is ceramic and called the insulator. On the bottom of the threads is a small hook that bends down close to another electrode. This is the gap where the spark occurs and ignites the fuel and air mixture in the cylinder.

In an effort to conserve weight, Formula 1 spark plugs have been designed to be much smaller than spark plugs for road cars. Formula 1 spark plugs are about 1.50 inches long and the diameter of the threads is around .3 inches. The plug also has no small hook for an electrode like you would find on conventional spark plugs. They are designed this way to save space inside the cylinder and the design is called a surface-gap spark plug. If the spark plug were to have a protruding electrode, it would be shaken loose or crushed by the piston. The spark occurs on the bottom of the threads.

There is almost no room for error when it comes to manufacturing Formula 1 engine components. If the spark plug is just a fraction too long, the piston may hit. To error on the side of caution, the bottom of the piston has a divot to avoid any possible contact.

Source: caranddriver.com

Brake Pads – Racing Auto Parts

Formula 1 cars use “carbon/carbon” brake pads. Carbon/carbon is a composite material that consists of carbon fiber in a matrix of graphite. It was originally created for the nose cones of intercontinental ballistic missiles and is also the material used for nose cone and leading edges on the Space Shuttles. Carbon/carbon was brought to Formula 1 by the Brabham team in 1976 and the material is now standard in Formula 1 brake systems.

The carbon/carbon brake pads are actuated by a 6-piston opposed caliper. The calipers must be made of aluminum alloy. The calipers also utilize titanium pistons. The titanium pistons help save weight, but they have a low thermal conductivity, which reduces the flow of heat into the brake fluid. No more than two brake pads are allowed per rotor.

Full carbon pads with full carbon rotors allow for normal operation up to 3000 degrees Fahrenheit!

Source: wikipedia.org

Shocks and Suspension – Racing Auto Parts

The suspension of a Formula 1 car creates the essential interface between different elements that work together to produce its performance. The suspension harnesses the engine’s power, the down-force created by the aerodynamics and the tires grip. It allows these forces to combine effectively and create a performance machine.

In Formula 1 cars, the driver’s comfort is not considered, performance is the only thing that matters. Spring and damper rates are extremely firm to make sure the impact from driving over bumps is defused as quickly as possible. The spring absorbs the energy of the impact and the shock absorber releases the energy on the return stroke.

Active electronic-controlled suspension is no longer allowed in Formula 1. The cars now utilize multi-link suspension which is similar to double wishbone suspensions present on some road cars. The multi-link suspension features suspension arms that are unequal in length on the top and bottom to allow better control of the camber angle taken by the wheel during fast cornering. The longer effective radius of the lower suspension arm causes the bottom of the tire to slant out farther than the top during cornering and helps maximize the grip of the tire.

Formula 1 springs are not mounted to the suspension arms directly. They are operated remotely with push-rods and bell cranks. This allows for variable rate springing. The spring is initially soft when pushed slightly, but becomes stiffer as the spring is pushed harder. Carbon Fiber is now used for suspension links in order to reduce weight and add strength.

Formula 1 car suspensions can be adjusted specifically for different track types and conditions. The cars are tuned to the driver’s preferences to suit their style of driving. Other track set-up decisions such as aerodynamics and tire choices must be considered when tuning the suspension.

Air Filter – Racing Auto Parts

An engine is essentially an air pump.  More air entering the engine increases the efficiency of the combustion process. This results in more engine power. Maintaining optimal, unrestricted air flow does not happen since it must pass through a filtering medium. The amount of air resistance varies depending the attributes of the filter such as the size and surface area.

Air filters are essential for internal combustion engines. They are required to remove solid particulates such as dirt and any other debris in the air. The air filter should let in as much air as possible to give the engine maximum power while still filtering out any particles which may cause damage.

Source: wikipedia.org, knfilters.com

Clutch and Gearbox – Racing Auto Parts

Clutch Control and Electro-Hydraulics

Formula 1 cars use a semi-automatic sequential gearbox with seven forward gears and one reverse gear. The driver changes gears using paddles on the back of the steering wheel. Electro-hydraulics perform the gear change as well as the throttle control. Clutch control is also handled by electro-hydraulics. From and a standstill, the driver must operate the clutch using a lever mounted on the back of the steering wheel. The modern Formula 1 clutch is a multi-plate carbon design with a diameter of less than four inches and weighing about 2.2 pounds. This small part can handle the 900 hp these cars put out.

The Dual Clutch Transmission

The current Formula 1 cars use a seamless shift gearbox called a dual clutch transmission. These gearboxes and clutches almost entirely eliminates the short power interruption during a gear change. The time savings from the shifting time being reduced is estimated to be about five to ten seconds over a course of a race. The shorter shift times are a significant gain considering how close these races can be.

Source: wikipedia.org