F1 Schools 2013-14 Teachers Guide

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    TEACHER’S GUIDE  

    Race Season 2011 -2012

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    TEACHERS GUIDE Race Season 2013/2014 

    F1 in Schools Challenge Teachers Guide 2

    WHAT IS THE F1 IN SCHOOLS CHALLENGE?

    The F1 in Schools Challenge is a global multi-disciplinary competition, open to all secondary schools inthe Republic of Ireland. It challenges secondary school students to design, build and race miniaturecompressed air-powered balsa wood Formula 1™ cars of the future. Student teams will compete against

    each other in a National championship to determine the best engineered and fastest car in Ireland. Thechallenge inspires students to use IT to learn about physics, aerodynamics, design, manufacture,branding, graphics, leadership/teamwork, media skills, sponsorship, marketing and financial strategy,and apply them in a practical, imaginative, competitive and exciting way.

    Design will play a critical role in the success of your teams - both in the design of the car itself and thepeople involved in bringing that design from the initial idea right through to the starting grid. Teammembers must be carefully chosen and trained to work together, using cutting edge design softwareand the latest in manufacturing technology.

    Students are encouraged to use software tools to manage their projects and to develop a projectwebsite to communicate how their designs evolved.

    The competition runs each year from September to April. Regional Finals are held in February and Marchwith the National Final following in April. Winners of the National Final are eligible to compete at theWorld Finals in Autumn 2014.

    WHO RUNS IT?

    The F1 in Schools Challenge is managed by the Irish Computer Society in Partnership with DiscoverScience and Engineering.

    ICS SKILLS is the skills and certification division of the Irish Computer Society and it is ICS SKILLS whichmanages F1 in Schools. ICS SKILLS is a registered charity and runs F1 in Schools on a not for profit basis.

    “F1 in Schools encourages students to take responsibility for their learning and makes

    them independent learners’’ Aidan Keane, Teacher, Coachford College

    “F1 in Schools prepared students for their school work and gave them experience in areas

    of ICT and engineering which they would not have got if they did not enter this

    competition.” Declan Mullins, Teacher, Castleblayney College 

    Pic 1: Competing teachers at the 2012 F1 in Schools National Finals  

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    TEACHERS GUIDE Race Season 2013/2014 

    F1 in Schools Challenge Teachers Guide 3

    WHY HAS THE CHALLENGE BEEN INTRODUCED?

    The F1 in Schools Challenge project aims to help change inaccurate perceptions of engineering, scienceand technology by creating an exciting learning environment for young people to develop informedviews about careers in these disciplines. For junior cycle students the competition offers a fun and

    exciting introduction to many of the skills they could choose to develop at Leaving Cert level, whilesenior cycle students will have an opportunity to practice those skills in an integrated and challengingmanner.

    CAD/CAM, CNC and VR systems are now common place in the manufacturing industry, which is why it isso important for the engineers and designers of the future to get to grips with such software packagesearly on. Students using CAD/CAM, CNC and VR software are able to design, test and manufacture theirown creations using a computer.

    Primarily, the F1 in Schools Challenge provides students with an ideal opportunity to experience the verylatest developments in manufacturing technology:

    CAD (Computer Aided Design) encourages students to think, explore and visualise their ideasin three-dimensions, using features such as complex curve modelling and surface rendering,alongside more traditional orthographic presentations.

    CAM (Computer Aided Manufacturing) packages, such as QuickCAM and UGSCAM, create anenvironment where CAD designs can be developed and prepared for automatedmanufacturing processes. Most CAM packages include a wizard based interface that allowstoolpaths to easily be plotted over complex 3D shapes.

    CFD (Computational Fluid Dynamics) packages, such as SolidWork’s COSMOSFloWorkssoftware allow computer models of car designs to be analysed, with regard to aerodynamicefficiency, then modified to further increase performance before anything is physicallymanufactured..

    CNC (Computer Numerically Controlled) Machines, such as the Denford MicroRouter, allowprocessed CAD drawings to be manufactured to high degrees of accuracy, fit and finish.

    Through direct experience of the technology and processes required to complete this project, it ishoped that more students will be encouraged to explore and/or pursue a career in our design,engineering, manufacturing and technology sectors.

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    TEACHERS GUIDE Race Season 2013/2014 

    F1 in Schools Challenge Teachers Guide 4

    KEY STEPS 

    The key steps of the Challenge are below. Later in the document there is further detail on the stages.

    01 / PLANStudents form an F1 team of 3-6 students. Register and brainstorm. Put your best ideas together in afive-page plan, proving why their team should be selected to have their car manufactured. If the teamsbid is accepted, proceed to step 2.

    02 / DESIGNUsing 3D CAD (Computer Aided Design) software, design an F1 car of the future to the set specifications,just like in Formula One™.

    03 / ANALYSEAerodynamics are analysed for drag coefficiency in a virtual wind tunnel using Computational FluidDynamics (CFD).

    04 / MAKE

    Using 3D CAM (Computer Aided Manufacture) software a CNC router converts the car design into aphysical car. If your school does not have a CNC router we will team you with a participating 3rd level.

    05 / FINISHEach team kits their car out with your team colours, logo and high-quality finish.

    06 / RACERace your car!! Teams should provide supporting evidence of their design, a verbal presentation anddisplay stand.

    HOW ARE THE TEAMS ORGANISED?

    Each team must have between three and six students.Each school can enter as many teams as they wish for the Qualifying Stage (five page plan), butonly a maximum of two from each category (Junior or Senior Cycle) will progress through to theRegional Final stage.

    Each team member should be assigned one or more of the following roles: team manager,resources manager, manufacturing engineer, design engineer, graphic designer or marketingand communications manager.

    Each team should have one teacher coordinator.

    There are two levels of entry, Junior and Senior Cycle.

    HOW ARE TEAMS JUDGED?

    Qualifying Stage

    Team’s five page plans are judged to select approximately 100 teams to progress to

    Manufacturing and Regional Final. Marking scheme contained in Rules and Regulations

    Document.

    At Regional and National Final Stage teams are judged in five (5) main judging categories:

     Specification Judging

     Portfolio and Display Judging

     Engineering Judging

     Verbal Presentation Judging

     Racing

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    TEACHERS GUIDE Race Season 2013/2014 

    F1 in Schools Challenge Teachers Guide 5

    Judging score cards

    The F1 in Schools™ judging score cards provide detailed information in relation to what the Judges

    will be looking for. The key performance indicators are used by the judges in awarding points during

    the judging activities. These score cards are used by the judges during the competition.

    The 2013/14 judging score cards can be found at the back of the Rules and Regulations document.

    KEY DATES | RACE SEASON 2013/2014 

    Sep - Nov Team registration and preparation of 5-page plan

    Nov 22nd  Deadline for Qualifying round submissions

    Nov - Jan Design and analysis stage

    Jan Manufacture of cars

    Jan - Feb Finishing of cars and portfolios

    March Teams on the grid for Regional Finals

    April Race for chequered flag at National Finals

    TEAM PRIZES 

    There will be separate awards for:

    The Overall Winner of the Challenge

    The 1st, 2nd and 3rd Winners in each Category

    The Fastest Car

    Best Engineered CarBest Newcomer

    Best Use of ICT

    Best Team Website

    Best Digital Marketing

    Best Team Marketing and Sponsorship

    The Grand Prize winners receive:

    Opportunity to represent Ireland at the F1 in Schools World Finals€2000 for the winning school…and much more! 

    The International TripThe overall winning team from the 2013/2014 season are eligible to represent Ireland at the F1 inSchools Technology Challenge™ World Finals in Autumn 2014, at a location yet to be decided. There,they will compete against teams from over 34 countries across the globe for the prestigious BernieEcclestone Trophy.

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    TEACHERS GUIDE Race Season 2013/2014 

    F1 in Schools Challenge Teachers Guide 6

    STAGE ONE –  SCHOOL REGISTRATION 

    Register your school for the F1 in Schools Challenge on our website (www.f1inschools.ie). Youcan keep updated by visiting our website regularly or viewing our Facebook page on for all thedetails and deadlines you need to know about the Challenge.

    To complete the school registration you must complete the Challenge Agreement, whichcommits you to entering at least one team to the competition. In the registration process youwill be asked for your personal email address, this is so we can forward you updated informationon the competition. You will also be asked to enter the team managers email address, this is sowe can also forward them information on the competition and that they can have their ownlogin to the website to register the remaining team members.

    Teams must be registered by 22nd November 2013. Registration is online at www.F1inSchools.ie  

    STAGE TWO  –  CAD SOFTWARE 

    Check your school has access to a suitable 3D CAD software package. Note that the software

    must be able to meet the design and presentation criteria outlined in the Rules and Regulations.

    Many schools have received Solid Works software through the T4 subjects (Design &Communications Graphics, Architectural Technology, Engineering Technology and Technology),this software is suitable for the competition.

    If your schools does not have access to 3D CAD software for the Challenge, through F1 in SchoolsGlobal Premier Software Partner, Autodesk, your school can receive a free copy of theirAutodesk CAD software for all schools who participate in the challenge. Details on how toobtain your free copy of Autodesk CAD software from F1 in Schools is available on the website(www.f1inschools.ie).

    If you are unsure if your software is suitable for the Challenge contact [email protected]

    STAGE THREE  –  INTRODUCING THE CHALLENGE 

    There are a number of ways that the Challenge may be implemented in schools. Our new videoon www.f1inschools.ie is a good starting point to give everyone a taste of what’s involved. Insome schools groups of students get together and ask the teacher to allow them to register forthe competition in other cases the teacher picks the students most interested. Organise anyinterested students into teams of 3-6, positively encouraging mixed gender groups.

    If the teacher wishes to include the whole class we would recommend that multiple teams of 3-6are formed in class and work on designs in their own teams. Each school may enter as manyteams as they wish for the Qualifying Stage, but a maximum of two teams from each category

    (Junior / Senior Cycle) will be allowed to progress through to the Regional Finals.

    Teachers can use the videos and presentation supplied on the www.F1inSchools.ie website tointroduce the initiative and stimulate interest amongst students. Attention should be brought tothe relevant Rules and Regulations document.

    http://www.f1inschools.ie/http://www.f1inschools.ie/http://www.f1inschools.ie/http://www.autodesk.co.uk/mailto:[email protected]://www.f1inschools.ie/http://www.f1inschools.ie/http://www.f1inschools.ie/http://www.f1inschools.ie/mailto:[email protected]://www.autodesk.co.uk/http://www.f1inschools.ie/

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    F1 in Schools Challenge Teachers Guide 7

    D-Type Car

    STAGE FOUR: DESIGNING THE CAR USING CAD SOFTWARE 

    What kind of car do we design?

    There will be two categories of car in this year’s F1 in Schools Challenge: 

    D-Type Car: The body of the standard D-Typecar is made from a single block of balsawood. Junior Cycle teams must produce theD-Type car.

    Formula One™ Car: The more complex FormulaOne™ car body must also be made froma single block of balsa wood, although the

    wings can be made froma separate piece of material. Senior Cycleteams must produce the Formula One™ car. 

    If you have any doubts about which car you should produce, please don’t hesitate to ask the F1 in  

    Schools team by emailing: [email protected]

    Your team must use 3D CAD (Computer Aided Design) software to produce your ideas and modelthem in 3D. Hand drawn sketches are allowed at Qualifying Stage.

    CAD software templates and dimensions for the balsa wood blocks are downloadable from the F1in Schools website (www.f1inschools.ie). When designing your F1 racing car, bear in mind that the

    extreme ends of the block must be left clear for attachment of the manufacturing jig fixtures.

    STAGE 5 - QUALIFYING STAGE 

    Due to the increasing numbers entering the competition and a limited number of manufacturingslots that are available it has been necessary to introduce a Qualifying Stage.

    Teams develop a 5 page plan which is judged to select approximately 100 teams to progress toManufacturing and Regional Final stage. Entry to this Qualifying Stage will be open to all schoolsand entry is free.

    The Qualifying Stage will be judged on the submission of a 5 page plan, by 22nd November 2013.Further details for this stage can be found in the Qualifying Stage section of the Rules andRegulations documents.

    The teams that score highest in the Qualifying Stage will proceed through to the Regional Finals.All schools will be notified by email if they have/have not succeeded in progressing through tothe Regional Final stage. There is a fee of €80 per team for those who qualify for the RegionalFinal stage.

    Each plan should give details of team members, show some areas of teams research, displayteams initial design ideas and show some elements of their portfolio e.g. timeline, brandingetc…

    Team’s ideas and plan should be original; however there are exemplar plans downloadable fromwww.F1inSchools.ie

    Formula One™ Car 

    mailto:[email protected]:[email protected]:[email protected]://www.f1inschools.ie/http://www.f1inschools.ie/mailto:[email protected]

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    Plan –maximum 5 pages (A4)

    All team plans must be submitted by 5pm 22nd November 2013 

    Plans should be submitted by email to [email protected] or by post to:ICS, 87-89 Pembroke Road, Dublin 4.

    The plan should consist of the following:

    Introduction (1 page)

    Research (1 page)o  A look at the different ideas behind making your car the Fastest.

    Design (1-2 pages)o  Pencil sketch will suffice, but 3D CAD more advantageous (so long as it links with

    the ideas of your design through your research!)

    Resources planning (1-2 pages)o  Outline plan to include, for example: timeline, budget, marketing etc..

    Winning teams innovate!!

    Formula One™ is constantly innovating in all areas of the Formula One™ business i.e. design,

    research, marketing. Each team has the option of an additional 10% of their overall marks for theplan, for an innovative idea. For further breakdown of marks for the plan view the QualifyingStage section of Rules and Regulations document.

    STAGE 6 - ANALYSE / TEST 

    Teams may also wish to evaluate a variety of car designs, or car parts, using computational fluiddynamics (CFD) software.

    If your school has a copy of Autodesk you should have a copy of Autodesk SIM CFD , fluid flowsimulation. If you have Solid Works you should also have included a copy of COSMOS. COSMOS

    FloWorks can be used to quickly analyze the Race Car Block part which is used in the Race CarAssembly.

    CFD or Computational Fluid Dynamics software calculates how fluid, (air or water) flows througha part or assembly model. Based on the calculated velocity field, you can find problem areas inyour design and improve them before you manufacture any parts.

    Details of how to obtain your **free** copy of Autodesk CAD software is available onwww.F1inSchools.ie. 

    STAGE SEVEN -  COMPUTER AIDED MANUFACTURE  JAN 

    **This step is completed by Make Centres (3rd level), if your school does not have access to a CNC

    router.When your students have completed their F1 racing car designs, the CAD drawings must beconverted into a CNC program. The CNC program is formatted using standard G and M codelanguage, used by CNC machines for plotting all their movement and cutting operations. CAMsoftware packages can be used to help automate this process.

    Many schools do not have the machinery to manufacture their own cars and for this purpose wehave teamed up with ‘Make Centres’, these are third level institutions who have agreed toparticipate and convert your teams designs to a CNC (Computer Numerical Control) program andmanufacture them using CAM (Computer Aided Manufacture).

    CAM software turns 3D designs into X, Y and Z coordinates, the tool path that controls the

    movements of the 3-Dimensional routing machines cutting tool. You may wish to contact thecollege whom we team you with if you wish to know more about the process. For example, will

    mailto:[email protected]:[email protected]:[email protected]://www.f1inschools.ie/http://www.f1inschools.ie/mailto:[email protected]

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    two separate CNC programmes need to be created – one for cutting the right side elevation ofthe F1 racing car, the second for cutting the left side elevation or will a ‘mirror’ command suffice.

    Manufacture will occur in an F1 in Schools approved Make Centre. You will receive notice from F1in Schools as to the location of your local Make Centre. If your school has a CNC machinery toproduce the car body, you can create your own car, but please let F1 in Schools know ([email protected]).

    The 3D design files should be sent to a Make Centre electronically. F1 in Schools will send you ondetails of the person to contact in your relevant Make Centre, a deadline for submission on filesto the Make Centre and the file type for your teams design to be submitted to Make Centre e.g..stl, .step etc. The CNC programmes produced by your Make Centre will then be manufactured atthe Make Centre. You may wish to arrange a visit to the college to see your designs beingmanufactured.

    If you intend to manufacture at your school, ensure your CNC machine meets the specificationrequired for construction. Check against items such as your machine working envelope,maximum spindle speeds, available router bits etc. by referring to both your original CADdrawings and the parameters defined in your CNC program.

    You will also need to purchase or construct a jig fixture, to hold the balsa wood block during

    machining. This will also make it much easier to configure any offsets, since the block can beaccurately replaced in the machine working area. Remember, you will probably have to load andrun a CNC program that machines one side of the car, then remove, revolve and replace theblock, before loading and running the second CNC program that machines the opposite side.Offset configuration is the MOST important time to be accurate, since any mistakes at this pointcould easily damage your material or equipment.

    STAGE EIGHT –  FINISHING  JAN - MAR 

    Finishing should involve the following steps:

      Smooth down the balsa wood car body with rough / medium grade glass paper.

      Finish using a fine grade glass paper.

      Apply a coat of sanding sealer if available. Sand lightly when dry.

      Apply several coats of paint (you may want to undercoat it first).

      Decorate the car body

    Only a limited amount of hand finishing of the body is allowed. Any major hand finishing mayresult in team disqualification. This will be at the Judge’s discretion. We expect all F1 racing carsto be completed with a high quality paint finish, including the application of any graphics,sponsorship or liveries, where deemed appropriate.

    STAGE NINE –

      PRODUCTION OF MODEL CAR  JAN - MAR 

    Standard wheels and axles will be included in your Car Kit when it is sent to you in December. It isoptional to use these standard components and teams are free to design/manufacture their owncomponents – once they meet the specifications as per Rules and Regulations document.Ball bearings are permitted and wheel material is unrestricted.

    mailto:[email protected]:[email protected]

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    TEACHERS GUIDE Race Season 2013/2014 

    F1 in Schools Challenge Teachers Guide 10

    STAGE TEN – RACING EVENTS  MARCH AND APRIL 

    The top teams will proceed through from the Qualifying Stage to the Regional Final stage. Youwill be informed by email when and where your Regional Final will take place, together with anyspecific requirements and arrangements for the event. Please ensure you confirm your intentionto attend the Final at least 2 weeks before the date of the final.

    Information regarding any race event will also be posted on the F1 in Schools website(www.f1inschools.ie) and emailed to the registered email address.

    REGIONAL AND NATIONAL FINAL STAGE 

    For teams successfully getting through to the Regional final stage the following should becompiled:

    At regional and national final stages each team must produce a design portfolio whichdetails the design, production and evaluation process including, initial ideas, designdevelopment, manufacture and evidence of testing and evaluation. Max 20 pages (A3).

    At regional and national final stages each team must supply a 1st or 3rd angleorthographic projection and a graphic rendering of their final design, both producedusing a 3D CAD package.

    At regional and national final stages teams must prepare a verbal presentation on theirwork about the design and development of their final F1 racing car design. 5 minuteswill be allocated to present to the judges.

    The judges score sheets that will be in use at the Regional and National event arecontained at the back of the Rules and Regulations document. Teams should make surethey are familiar with what the judges are looking for in each of the judged areas toensure maximum score.

    Points Allocation

    Specifications

    CAD CAM Analysis

    Quality of Manufacture

    Portfolio

    Pit Display & Marketing

    F1 Car Design Process

    Technique (VP)

    Composition (VP)

    Subject Matter (VP)

    Time Trials

    Reaction Racing

    Knock-Out Racing*

    http://www.f1inschools.ie/http://www.f1inschools.ie/http://www.f1inschools.ie/http://www.f1inschools.ie/

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    F1 in Schools Challenge Teachers Guide 11

    EDUCATIONAL CONTENT 

    The F1 in Schools Technology Challenge is specifically aimed at secondary level schools.The Challenge offers the perfect opportunity for teachers and students to explore the world ofCAD/CAM/CNC and allows students to experience the entire design process from beginning toend.

    HOW TO OBTAIN SOFTWARE, HARDWARE AND CONSUMABLES 

    If you would like to purchase any equipment for the challenge please contact:Sureweld Educational Division, Fonthill, Lucan, Co. DublinTel: 01 6266 242

    To obtain your free copy of Autodesk CAD software from F1 in Schools visit the website(www.f1inschools.ie).

    MANUFACTURING CENTRES 

    Teams will be paired with a Manufacturing Centre (3rd level institution) by F1 in Schools, if you donot have facilities in your school.

    ENQUIRIES AND QUESTIONS 

    All questions and queries about the F1 in Schools Technology Challenge should be e-mailed to: [email protected]

    For the very latest information, visit the F1 in Schools Technology Challenge Website(www.f1inschools.ie).

    mailto:[email protected]://www.f1inschools.ie/http://www.f1inschools.ie/mailto:[email protected]

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    www.F1inSchools.ie