Testing
Initial data could be collected in tests with the racing car on the track. They provided information on both the behaviour over time and the amount of torque applied to the drive shafts. The data log showed, for instance, the torque to a drive shaft, the speed, the engine speed, and the accelerator pedal position over time. This enabled the engine torque to be determined at any time during operation in the racing car. On the one hand, the power values of the engine on the test bench could be compared directly with those in the vehicle, thus enabling the transmission losses in the racing car to be calculated. On the other hand, this allowed changes in engine torque during the tests to be objectively detected. This enabled the quantification of the impact of changes in the internal combustion engine's application on the engine torque at certain rotational speeds and perfectly complemented the driver's feedback by ascertaining their assessment by numerical values.
Unexpected variations in engine performance could also be detected at an early stage and responded to accordingly. For instance, an incorrect chain tension could be detected. Furthermore, the drive shaft design could also be validated by torsion measurements; in particular, the stress peaks occurring in the drive train could be quantified. The collected data allowed for further optimization and, thus, reductions in weight. The collected data could also help adjust the differential gear. During cornering, the maximum transferable torque differed between the two powered rear wheels. The difference in torsion between the left and right drive shafts allowed the drive torque transferred to the respective wheel to be extrapolated and, thus, the optimum degree of locking of the differential to be determined and adjusted. The data obtained also helped optimize the self-developed lap-time simulation. This significantly supported design decisions and consequently the development of the racing car. The three performance values determined in the test run could be used to validate and further optimize the simulation model and to obtain even more precise simulation results.
The impact of various dynamic parameters on the achievable lap time could be calculated with as precise a simulation as possible. This information enabled future racing cars to be made even faster. The test runs for measuring the torsion using strain gauges on the racing car’s drive shafts during the previous season enabled the team to gain valuable insights which have proved to be very helpful in installing the strain gauges in the racing car under development. Along with the application in the drive train, there were also other areas, such as in the chassis, where stress and strain measurements allowed for optimization in terms of lightweight construction and stiffness. Due to the support of HBK who provided the required components, the young engineers of High-Octane Motorsports e.V. were able to gain valuable experience and insight into HBK’s product portfolio and the potential applications.