SHELL ECO-MARATHON ASIA 2011

Colin Chin Shell Global Solutions Sdn. Bhd. Shell Eco-marathon ASIA 2011

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 1

1.0 THE TRACK

Sepang International Circuit

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 2 THE SEM EVENT WILL BE HELD ON THE NORTH TRACK

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 3 TRAFFIC FLOW FOR SEM ASIA

Technical garages: 16-21

Pit lane Main track Team garages Technical

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 4 HOW ITS RUN

Competition format: Teams are allowed 5 runs (attempts) Each run consists of 4 laps for both vehicle categories UrbanConcept cars must stop 3 times for a 10 second pit stop Time limits are 28 and 23 minutes for the UrbanConcept and Prototype cars respectively

5432 8 UrbanConcept

Prototype

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 5 PROGRAM

Day/date > Fri Activity ul 5-Jul

Sun Sat

Mon

Tue

Wed

Thu

3-Jul 6-Jul 7-Jul 8-Jul 9-Jul

4-J

Student registration x x Initial briefing 1a Daily briefing 2 Scrutineering x Track tours x Free practice x Competition x Opening ceremony x Closing ceremony x x x x x x x x o 3 o 4 1b 1c

o On Request only Practice & Competition start 1/3 of a day earlier

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 6 Briefings/Familiarization

Mandatory: The following briefings are mandatory for the team manager and driv er: Initial Team briefing (6th or 7th July) attend one of 3 Daily briefing 2 (7th July) Daily briefing 3 (8th July) Daily briefing 4 (9th July) Teams that do not attend these briefings will not be allowed to compete Optional: Track tour on 6th July SCHEDULE FOR TRACK ACCESS

Day

Time

Activity

Wednesday 6th July 10 h 15 h 15 h 19 h Track tour and discovery by walking Practice Thursday 7th July Friday 8th 7 h30 15 h 15 h 19 h 8 h 13 h 16 h 19 h Practice Competition Competition Last start at 18h30 Last queue number 18h00 Saturday 9th July 7 h30

16 h

Competition

Last start at 15h30 Last queue number 15h00

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 8

2.0 TECHNICAL INSPECTION AREAS

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 9 OVERALL VIEW OF TECHNICAL INSPECTION AREAS

Hotel shuttle bus stop

Hotel shuttl e bus Official parking Inspection area 3

H2

Test drive area Inspection areas 1 & 2

Team garages Team garages Technical Team garages gate Team garages Public access gate 2 Starting arch Finish arch (same place as timing loop) Dynamic brake test required as downhill speed at Sepang can be as high as 55 km /h Timing loop (20 m away)

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 10 TECHNICAL AREAS (6TH & 7TH)

Pit lane 8.0

16.0 Inspection area 1 16 21 Inspection 17 18 19 20

24 m

8.0 3.9 4.2

3.7

Results area

Timing area 2 4.0

6.5

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 11 TECHNICAL AREA Pit lane 8.0

Measurement Fuelling

16.0 Inspection area 1 16 21 Inspection 17 18 19 20

24 m

8.0 3.9 4.2

3.7

Results area

Timing area 2 4.0

6.5

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 12 INSPECTION AREA 3

H2 storage area Clutch & Emergency Shut Down Test

Official parking Inspection area 3 H2 Test drive area

Brake ramp for self test

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 13 ACTIVITIES IN TECHNICAL AREAS

Inspection area 1 Weighing drivers Weighing cars Dimension checking 1 Inspection area 3 Slalom (steering) test Brake testing Noise level testing Activity Area 3 Driver

Weigh car Dimensions Brakes Brake checking Safety belt checking Visibility checking Vehicle design & components ICE Fuel system inspection Electrical inspections (e-mobiilty +hybrid) Kill switch/Clutch Records Recording inspection details Checking validity of runs R

Input of measurement results Fueling Fueling /initial measurements Safety belt 1 Visibility Design ICE E-mobility Hydrogen Slalom Brake 3 Inspection area 2 H2 calibration H2 inspections Copyright of Shell Global Solutions Sdn. Bhd. 2 Final check of cars Measurements Volume/weight /energy used 2 F

6/22/2011 Noise Records R Fueling F Fueling 14 M

3.0 TECHNICAL INSPECTION

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 15 INSPECTION PROCESSES

Team Register

Cars Safety briefing S Team Track tour

Get queue number P S D W

H2 flowmeters H2?

Pass flow meters (for calibration) & Inspection area 1 - W general ICE No Inspection area 3 steering, brake, noise, kill switch, clutch own H2 cylinders (for storage) Flow meters Own H2 cylinders H2 Yes Inspection area 2 EM

Results Desk - record, issue sticker P

Free practice

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 16 PASSPORT

You will be given a Passport on registration P S P W S D

This is to follow your car throughout the event and given to the results desk d

uring competition Attendance at Initial and Daily briefings will be marked with a colored chop It will act as your passport to compete Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 17 REMINDER BEFORE GOING FOR INSPECTION

Bring the following for the inspection process a printed copy of your fuel system drawing a printed copy of your electrical system drawing Any other documentation pertaining to your vehicle design (a folder with everyt hing would be good) For lithium polymer batteries bring any documentation /proof of what the BMS do es Driver gear (helmet, gloves, ballast) Preparation before: Ensure that your fuel system is completely drained You may do a self test of your brake system on the brake ramp outside For e-mobility install your joulemeter and wires in advance (refer to guideline s) Ensure you have a chain guard Ensure that your bulkhead is good Ensure that electrical systems have a fuse as close to the battery (source) as p ossible Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 18 TEST DRIVING

At all times the car should be pushed No driving of cars is allowed except in the designated test area. Even in this area, please avoid speeding

Official parking Inspection area 3 H2 Test drive area

Brake ramp for self test

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 19 WEIGHING & CHECKING DRIVERS

Inspection checklist will be given All drivers will be weighed (with suit, helmet, shoes, gloves) Driver attire will be checked Activity Area Driver Weigh car Dimensions Brakes This will be recorded in the in Run checklist Extra weight may be required if the driver is underweight

P W Safety belt

Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise Records Fueling Measure M R F 3 2

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 WEIGHING CARS 20

Car weight will be determined with portable scales Team to lift car onto the scales Limits Prototype 140 kg Urban 205 kg Activity Area

Driver Weigh car Dimensions Brakes Safety belt 1 Visibility Design ICR E-mobility Hydrogen Slalom Brake Noise Records Fueling Measure M R F 3 2

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 DIMENSION CHECKING 21

Vehicle dimensions will be checked Done using template and measuring tape Activity Area Driver Weigh car Dimensions Brakes Safety belt Visibility Design ICE E-mobility Hydrogen 2 1

Slalom Brake Noise Records Fueling Measure M R F 3

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 BRAKE TESTING 22

Check that front and back brakes work independently Car with driver will be placed onto brake ramp Car should not slide down brake ramp Slope is 20% (20:100) Note: An extra brake ramp will be located outside in the test drive area for yo u to test brakes on your own before going in for inspection. Do make use of it. Inspection area 3 Activity Area Driver Weigh car Dimensions Brakes Safety belt 1 Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise H2 3 2

Brake ramp for self test Official parking

Test drive area Records Fueling Measure M R F

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 SAFETY BELT CHECKING 23

Strength of safety belt will be checked For prototype cars, lift bar upward till 70kg registered on weighing scale Check that 5 point safety belts are present Activity Area Driver Weigh car Dimensions Brakes Safety belt 1 Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise Records Fueling Measure M R F 3 2

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 24

VISIBILITY CHECK

Check that mirrors are OK Check that 180 visibility is OK Activity Area Driver Weigh car Dimensions

5m radius

30 Brakes Safety belt Visibility Design ICE E-mobility 4 1

Hydrogen Slalom Brake 5 Records 6 7 3

Noise R Fueling F

Measure

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 DESIGN CHECK 25

Check design Bulkheads Start light Horn Fire extinguisher Lights Clutch Check stickers/logos Chain guard Fuel system Activity Area Driver Weigh car Dimensions Brakes Safety belt 1 Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise Records Fueling Measure M R F 3 2

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 26 ICE FUEL SYSTEM INSPECTION

Determination of the volume of fuel in the fuel system By determining the volume of fuel required to fill it up to the mark. Teams should have drained out their fuel system earlier, otherwise you will hav e to exit and do it later Activity Area Driver Weigh car Dimensions Brakes Safety belt 1 Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise Records Fueling Mesure M R F 3 2

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 E-MOBILITY 27

Covers e-mobility vehicles (solar, hydrogen, plug-ins) and hybrid vehicles Checking of electrical systems Batteries Joulemeters Wiring Fuses Electrical circuits External measurement point Joulemeters and wires

Collection at results desk Daily return for charging

Copyright of Shell Global Solutions Sdn. Bhd. Activity Area Driver Weigh car Dimensions Brakes Safety belt 1 Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise Records R Fueling 6/22/2011 28 HYDROGEN VEHICLE INSPECTION F Measure M 3 2

Design compliance of hydrogen vehicles will be checked Leak checks Proper sequence Mandatory components Electrical system Electrical fusing Shut down mechanism

Supply of cylinders Own cylinders must be handed in Returned every day Activity Area Driver Weigh car Dimensions Brakes

Safety belt

Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise Records Fueling Measure M R F 3 2

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 SLALOM 29

Check that driver can control the vehicle properly by navigating a slalom cours e Check that kill button works Check that clutch is present Activity Area Driver Weigh car Dimensions Brakes Safety belt 1 Visibility Design ICE E-mobility Hydrogen Slalom Brake Noise Records Fueling R F 3 2

Measure

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 DYNAMIC BRAKE TEST 30

Check that driver can stop the car while travelling at speed (40 km/h) Activity Area Driver Weigh car Dimensions

0 km/h

40 km/h Brakes Safety belt Visibility Design ICE 1

Car should stop before second cone Apply brakes here E-mobility Hydrogen Slalom Brake Noise Records Fueling R F 3 2

Measure

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 NOISE TEST 31

Check the noise level of the car Must be <90 dB at 4m Activity Area Driver Weigh car Dimensions Brakes Safety belt Visibility Design ICE 90 dB E-mobility Hydrogen Slalom Brake Noise Records Fueling Measure M R F 3 2 1

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 RESULTS DESK 32

Submission of completed technical inspection sheets Pass stickers Transponders Activity Area Driver Weigh car Dimensions Brakes Safety belt Visibility Design ICE 1

Copyright of Shell Global Solutions Sdn. Bhd. E-mobility Hydrogen Slalom Brake Noise Records 6/22/2011 R Fueling 33 F Measure M 3 2

4.0 COMPETITION

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 34 TO GO ON TRACK

Must attend: Mandatory briefing Daily briefing on day of competition

Must pass technical inspection

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 35 COMPETITION PROCESSES

Daily briefing S D

Pass P No

Yes

Get queue number

Wait to be called Team Garages Back to garage

Get queue number for inspection Proceed to Garage 18

Fueling

Measurement

Yes

No Valid Inspection Garage 21

Check whether ballast is needed/added W F M

Technical garage Competition

Results desk

P W Start

D F M

DNF

Finish

Tow truck

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 36

5.0 TIPS BEFORE COMING

Aim to pass inspection the first time around !

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 37 COMMON PROBLEM AREAS

Brake systems not working or not suitable Roll bar

Bulkhead gap Bulkhead to wheels Safety belt (not 5 point, not secured properly) Chain guard Weight (car, driver) No electrical fuses close to batteries Poor electrical connections H2 - leakage

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 38 WHAT TO BRING

For own use Tools Personal protective equipment (gloves, safety glasses) Electrical adaptors for UK plugs

For technical inspection bring printed copies of Fuel system diagram Electrical system diagram For e-mobility, details of what the BMS does Any other documentation from equipment suppliers which might be useful

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 39 WHAT WILL BE PROVIDED

Fire extinguishers Engine oil Translucent fuel hoses

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 40 SPECIAL ARRANGEMENTS

If you need any of the following you may communicate with the organizing commit tee to help supply on your arrival: Battery (specify voltage, ampH) Brake fluids Transmission fluids

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 41 REMEMBER

To work and behave safely Above all, we want you to go home safely to your loved ones after the event

To attend the mandatory Initial briefings and daily briefings

To prevent disappointment

Aim to comply with the rules before coming & pass scrutineering in one go (we want all of you to be able to complete, but safety & compliance comes first) Be aware of all safety rules 3 warnings will result in disqualification

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 42 FINAL RECOMMENDATIONS

1.

Read the rules and check your compliance before coming

2.

See #1

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 43

THANKS AND GOOD LUCK!

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 44

Copyright of Shell Global Solutions Sdn. Bhd. 6/22/2011 45