How to run the F1 in Schools Challenge - REA Foundationrea.org.au/wp-content/uploads/2014-Teachers-Guide-to-Getting... · 2014 Australia F1 in Schools™ Teachers Guide© Version

How to run the F1 in Schools™ Challenge

at your School.

Tips, hints & secrets for success.

Become World Champions in 2015!

2012 World Champions ‘Cold Fusion’, with teachers and mentors

Brighton Secondary School, SA

2014 Australia F1 in Schools™ Teacher’s Guide©

Version 1.0 – May 2014 2 | P a g e

COPYRIGHT NOTICE This document, all its contents (including images, text, procedures) are copyright 2014, Re-

Engineering Australia Foundation Ltd. All rights reserved.

Re-Engineering Australia Foundation Ltd. PO Box 136 Castle Hill NSW 1765 Australia. Phone: +61 2 9634 2144. Email: [email protected]

REA, Re-Engineering Australia, the Re-Engineering Australia Foundation Logo, and other associated logos are trademarks of Re-Engineering Australia Foundation Ltd. All rights reserved

F1 in Schools: F1 in Schools, F1iS, Formula 1® in Schools, the F1 in Schools challenge, and the associated logos are trademarks of F1 in Schools.

Formula 1: F1, Formula 1® and the associated logos are trademarks of Formula 1® Licensing BV.

REPRODUCTION This document may only be reproduced by schools registered in the F1 in Schools program in

Australia. Non-participating schools in Australia and overseas must first seek permission from Re-Engineering Australia Foundation Ltd. prior to reproducing.

ALTERATIONS Re-Engineering Australia Foundation Ltd. reserves the right to alter any specifications and

documentation associated with the ‘Challenge’ without prior notice.

mailto:[email protected]



Contents Overview Of Project Stages ..................................................................................................................... 4

Essential Resources Checklist .................................................................................................................. 5

Classes of competition ............................................................................................................................ 5

Stage 1 – School & TEAM Registration .................................................................................................... 6

Stage 2 – Into The Classroom- Curriculum Fit ......................................................................................... 6

Stage 3 – CAD Software ........................................................................................................................... 7

Stage 4 – Design ...................................................................................................................................... 8

Stage 5 – Analyse ................................................................................................................................... 10

Stage 6 – Portfolio & Pit Display ............................................................................................................ 11

Stage 7 – Collaborate > Industry Links .................................................................................................. 12

Stage 8 – Make > CAM (Computer Aided Manufacturing) .................................................................... 14

Stage 9 – Make > CNC (Computer Numerical Controlled) Machining .................................................. 14

Stage 10 – Make > Finishing & Assembly .............................................................................................. 15

stage 11 – Verbal Presentations ............................................................................................................ 16

Stage 12 - Test ....................................................................................................................................... 17

Stage 13 – Race ..................................................................................................................................... 18

Stage 14 - Competitions ........................................................................................................................ 19

So, What About the Secrets For Success? ............................................................................................. 23

Need Software, Hardware or Consumables? ........................................................................................ 23

Enquiries ................................................................................................................................................ 23

National Sponsor



INTRODUCTION

Thank you for your interest in F1 in Schools™ Technology Challenge – the largest and most successful primary/secondary school Engineering competition in the world having now more than 42 countries currently involved and 9 million students who have participated since its inception in 2003.

Australia has enjoyed overwhelming success with F1 in Schools™ at the international level with teams being crowned World Champions four times over the nine years it has been staged.

The F1 in Schools™ Technology Challenge in Australia is an initiative of Re-Engineering Australia Foundation Ltd. (REA). REA is a not-for-profit organisation with committed partners providing exciting yet challenging educational programs in engineering and design through the action-learning of science, maths and technology.

REA provides a range of consumables, software and hardware technologies to assist schools in getting started. REA also provides on-going support, training and advice to schools wishing to be involved in F1 in Schools and those who purchase our technologies.

REA coordinate and run all State Finals and the National Final of the F1 in Schools™ Technology Challenge in Australia. Staff also support and accompany teams who travel overseas to represent Australia at the annual World Finals.

We would like to think our support of teams and teachers undertaking the F1 in Schools™ Technology Challenge in Australia has been integral to our teams’ world success on the international stage but we also very much believe we have the most committed teachers and smartest students in the world!

To get you ‘on track’ and into ‘pole position’, we have developed this Teacher’s Guide to Getting Started. Whilst it is not designed to be the ultimate ‘go to’ guide, we hope it supports you and your students through the embryonic stages of your F1 in Schools journey.

This guide is designed to be read in conjunction with the Challenge’s current Rules and Regulations and General Information Booklet. These documents, as well as the information that can be found on the REA website, will provide you with all you need to successfully establish the F1 in Schools Technology Challenge in your school.

To access these documents, go to: http://rea.org.au/f1-in-schools/for-teams/competition-documents/.

A list of REA contacts can be found in the ‘Enquiries’ section of this document.

OVERVIEW OF PROJECT STAGES

This teacher’s guide is presented as a breakdown of the main stages and related learning activities to consider when implementing the F1 in Schools™ Technology Challenge with your students. The guide will also help you gather and organise the resources needed.

The main stages are defined as follows:

1. School & Team Registration 8. Make > CAM

2. Into the Classroom 9. Make > CNC

3. CAD Software 10. Make > Finishing & Assembly

4. Design 11. Verbal Presentations

5. Analyse 12. Test

6. Portfolio 13. Race

7. Collaborate – Industry Links 14. Competitions

http://rea.org.au/f1-in-schools/for-teams/competition-documents/



ESSENTIAL RESOURCES CHECKLIST

The basic and essential resources required to participate include:

3D CAD Software: All cars must be designed using 3D Computer Aided Design software – any with the ability to export an stl file will do. Some 3D CAD is freely available to students, teachers and schools who deliver the F1 in Schools™ Technology Challenge. For more information on 3D CAD refer to Stage 2.

CAM Software: Computer Aided Manufacturing software is required to convert 3D CAD models to NC code recognised by CNC Routers. Eg. DENFORD QuickCAM Pro. Some 3D CAD packages will do this for you.

CNC Router: All cars must be manufactured in a Computer Numeric Controlled Mill or Router eg. DENFORD Router 2600. If your school does not have a CNC Router, that’s not a problem. You can access this service from within local industry or REA can put you in touch with a school who would be willing to mill your cars for a very reasonable price. Contact REA for further advice. Remember there are machining restrictions for the Cadet and Development Classes.

Balsa & Wheel Kits: All cars must be milled using REA supplied Balsa blanks. These blanks have been designed to meet the car dimensions as outlined in the Rules and Regulations. They also come with a pre-drilled canister hole and tether line slot. The REA Wheel Kits (or parts thereof) are a requirement for teams entering the Development and Cadet Classes of competition. Balsa and REA Wheel Kits can be purchased on-line via the REA E-Store or by emailing or faxing a school Purchase Order to REA.

CLASSES OF COMPETITION

Decisions about what class or classes of competition you will register teams for will need to made early in the year so that students are fully aware of the eligibility requirements and rules and regulations that govern the individual classes as well as the level of work they will need to commit to the project.

Note that some classes of competition have no pathway to either the Australian National or World Final Competitions.

For detailed information on the Classes of Competition, refer to the current General Information Booklet and Rules and Regulations documents.

There are three competition classes:

1. Cadet Class (Yrs 5 – 12) A simplified project with a restricted pathway to state level competitions and no pathway to the World Finals. This class of competition is designed as a stepping stone to the Development and/or Professional Classes.

2. Development Class (Yrs 5-9) For first time entering students or those who have participated previously in the Cadet Class only. Students may only participate in this class once. This class provides an international collaboration team pathway to the World Finals.

3. Professional Class (Yrs 5-12) This is a non-restricted class of competition open to all students across two divisions – Junior and Senior. The overall Professional Class champion team from the Australian National Final will represent Team Australia at the World Finals.

http://rea.org.au/shop/quickcam-pro/

http://rea.org.au/shop/router-2600-2600-pro/

http://rea.org.au/product-category/consumables/



STAGE 1 – SCHOOL & TEAM REGISTRATION

Overview:

Check the REA website for detailed information on registering your School and Teams

Ensure you meet advertised deadlines

Detail: All schools delivering the F1 in Schools project, regardless of whether they intend entering teams into the competition or not, must complete a School Registration. Registering Schools is free of charge. Teachers (not students) must register their schools by the advertised cut-off date.

REA collects statistical data on the numbers of students undertaking the project and these results are not only important for planning Regional and State Finals but also provide a clear picture of growth from year to year.

Teachers should encourage and facilitate the formation of teams and individual team member roles as early as possible. This will assist teams in building cohesive teams based on individual strengths and to focus on their planning their project.

Teams registering for the competition will not be charged a fee unless they are successful in progressing to a State Final. An additional fee will apply to teams progressing from a State Final to the National Final. Go to: http://rea.org.au/f1-in-schools/competition-registration-and-fees/ for more information.

STAGE 2 – INTO THE CLASSROOM- CURRICULUM FIT

Overview:

Choose your curriculum fit

Plan your F1 in Schools™ unit of work & implementation

Detail:

There are a many ways that the Challenge may be integrated into the curriculum. The Challenge has been successfully delivered into the Key Learning Areas of Technology, Design, Science and Maths in Australian Schools. It is particularly suited to school subjects dealing with Engineering, CAD/CAM and design. The Challenge can also be run as extra-curricular or a combination of both.

The Challenge provides for student learning outcomes linked and not limited to:

Design Engineering Manufacturing

Industry Links Collaboration Communication Skills

Career Awareness Financial Management ‘Soft’ Employability Skills

Innovation Research & Testing Presentation

Graphics Multimedia Science

Forestry Team Work Math

Sustainability Project Management Materials and Properties

Literacy CAD/CAM/CNC Resource Management

Enterprise Clarity of Information Initiative & Perseverance

Marketing Self, team & Project Evaluation ICT

Self-Esteem Safety Technical Interpretation

Teacher

Resources

Checklist:

Check REA

website

Register School

and Team/s on-

line by the

deadline

Pay any

associated fee

http://rea.org.au/f1-in-schools/competition-registration-and-fees/



One of the great things about the F1 in School™ program is its portability across key learning areas. Teachers can easily implement the program with a preferred focus. For example the focus could be as a CAD unit of work, an Engineering unit of work or even as an applied physics unit.

Teachers should consider including their whole class, forming multiple teams who each work on designs and project components. Each school may enter as many teams as they wish. We suggest teachers select only their best team/s for progression to the next level of Competition. You can do this by staging an internal school competition.

Use videos and sample project Portfolios that can be found through www.rea.org.au/f1-in-schools.org.au/resources to introduce the initiative. Research of the science behind the project should be the major motivating factor that inspires an aerodynamic F1 car design.

From the beginning attention should be drawn to the Rules and Regulations - this is the project design brief with parameters. Refer students to http://rea.org.au/f1-in-schools/for-teams/competition-documents/.

Teachers may wish to work through the REA supplied DMO (Defence Materiel Organisation) developed Project Management Guide for students.

To be put in touch with teachers in your state who have integrated it successfully in approved curriculum, please contact REA.

STAGE 3 – CAD SOFTWARE

Overview:

Check you have 3D CAD software at school

Locate any relevant F1 in Schools™ CAD tutorials

Detail: Schools or students wanting to undertake the F1 in Schools™ program must have access to 3D CAD software to design their models.

There are a large number of 3D CAD solutions on the market developed by AutoDesk®, PTC, Dassault Systemes and Siemens to name a few, and all are suitable to use for the F1 in Schools™ program but must have the ability to export an stl file. Many vary in price, training and support and the options which are included in the Academic licencing arrangements for schools and students. Teachers will need to do their own homework by visiting the various websites.

Whilst REA do not recommend any particular software, there are four providers that have developed an F1 in Schools™ tutorial which would make it easy for schools to get up and running quickly.

AutoDesk® – Inventor

PTC – CREO Parametrics 2.0

Dassault Sytemés – CATIA

Dassault Sytemés - Solid Works

For more information about 3D CAD and the new F1 in Schools™/Autodesk partnership providing free 3D CAD software for schools participating in the project, go to: http://rea.org.au/3d-cad/.

Teacher Resources

Checklist:

Select Learning

Area / Syllabus

Teachers Unit

Outline

Form Teams

Sample car

parts, balsa /

wheels

Motivational

videos

Teacher Resources

Checklist:

3D CAD Software

CAD Tutorials

Check out free

Autodesk software

http://www.rea.org.au/f1-in-schools.org.au




http://rea.org.au/3d-cad/

http://rea.org.au/3d-cad/



Curriculum Fit

QLD Essential Learnings: Technology, investigating and designing, producing evaluating and reflecting. Technology Practice, Materials, Information and Systems. Science

NSW Industrial Technology Engineering, Design and Technology, Graphics Technology, Technology Mandatory, Engineering Studies, Science.

ACT Technology KLA Essential Learning (EL) 25. Interdisciplinary EL1, EL2, EL3, EL5, EL6. English EL8, EL9, EL10. Maths EL16, EL17, EL18. Science EL19, EL20.

VIC Essential Learning Standards, Year 9 -10 (Developing Pathways). Interdisciplinary Learning, Communication domains of: Design, Creativity and Technology. Information and Communications Technology. Thinking Processes. Science.

TAS Vocational and Applied Learning: Digital Media, Powered Technology, Resistant Materials, Business Enterprise and Combinations. Four strands of Innovation and Design, Systems and Processes, Applications and Solutions and Futures Planning. Science

SA Cross Disciplinary Studies –Stage 1. Integrated Learning. Business Enterprise and Technology – Design and Technology, Information Processing and Publishing, Information Technology, Workplace Practices.

WA WACE Endorsed Program – F1 in Schools™ Technology Challenge. Technology and Enterprise – Technology Process, Materials, Information, Systems, Enterprise, Technology Skills, Technology in Society.

NT EsseNTial Learnings - domains of Inner Learner, Creative Learner, Collaborative Learner and Constructive Learner. Learning Technology: [LT-R], [LT-P], [LT-O], [LT-S]. Learning Area: Technology and Design - Designing, Producing and Critiquing.

STAGE 4 – DESIGN

Overview:

Read and understand the Rules and Regulations

Research the principles of aerodynamics & sketch initial ideas

Use 3D CAD to model chosen design

Test drag virtually using CFD software

Understand design for CNC manufacture limitations including machining restrictions for Cadet and Development Classes

Keep it simple!

Detail: All cars must be designed using 3D CAD software. Students will need to be familiar with using your school’s 3D CAD package, but before letting them loose on designing F1 racers, there are some things to consider!

As with any design project, students need to be familiar with the Design Brief, in this case the Design Brief is the Challenge Rules and Regulations.

Be sure to carefully consider and understand the special restrictions for the Cadet and Development Classes!

Teacher Resources

Checklist:

CAD Software

CAD Tutorials

CAD template files

of wheels etc.

Rules & Regulations

Design

considerations for

3-Axis Machining

Research pointers



Another good starting point is for students to carry out research and investigation related to aerodynamics, motion, F1 car design, CAD/CAM/CNC and manufacturing in Industry. Based on initial research findings, students can start proposing car designs, usually hand sketches to begin with. Be sure to have students record and keep all initial ideas and research for Portfolio inclusion!

Teams can begin their research by watching a series of Julius Sumner Miller videos the links for which can be found on the REA website at http://rea.org.au/f1-in-schools/for-teams/resources/professor-julius-sumner-miller/.

Initial ideas need only be presented as hand sketches. You may choose to move students onto CAD to model and further develop their preferred car body design/s.

Students will need to create a CAD Assembly of their complete F1 in Schools™ product. A complete assembly would comprise the following minimum separate parts:

Car Body with aerofoils

4 x Wheels

4 x Axle Bearing Grommets

2 x Axles

2 x Tether line guides

REA supplies CAD template files for the mandated wheel and axle system in STL and IGES format to save students modelling these from scratch. These can be found for download at http://rea.org.au/f1-in-schools/for-teams/resources/.

When CAD Designs are complete, students should create a photo-realistic render of their final design. This will mean applying materials, texture and colour to different components, or even digital copies of any relevant sponsor decals. You are allowed and may wish to export your complete CAD assembly into other specialist 3D Rendering software packages for this.

K.I.S.S – remember Keep It Super Simple. The best F1 in Schools™ car designs are not necessarily the most complex ones. Designs need to be justified in terms of engineering and performance. Unjustified extravagant creations are not rewarded with marks. Students will sometimes be inclined to spend too much time trying to model intricate features, but are these necessary and will this time be rewarded in the Engineering assessment components?

Front Aerofoil Design:

Development & Professional Class teams are permitted to design and manufacture the front aerofoil from a separate non-metallic material. It’s very common for these parts to be rapid prototyped using either SLS (Selective Laser Sintering) or other 3D printing technologies. Teams can establish links with industry who have these technologies, or locate a school who has 3D Printing technology.

Teams intending to get aerofoils rapid prototyped should design the aerofoil as a separate part body using 3D CAD. This part can then be used to complete the car design as part of the 3D CAD assembly.

Rapid Prototyped front aerofoil designed by ‘Brisk in Pink’ for the 2006 World Final

http://rea.org.au/f1-in-schools/for-teams/resources/professor-julius-sumner-miller/

http://rea.org.au/f1-in-schools/for-teams/resources/professor-julius-sumner-miller/

http://rea.org.au/f1-in-schools/for-teams/resources/

http://rea.org.au/f1-in-schools/for-teams/resources/



Design for Manufacture:

An important learning outcome and design consideration is for students to understand the constraints and limitations for car body designs that exist due to the need to manufacture their design using a 3-axis CNC machine.

The balsa blank is placed in a fixture mounted in the CNC machine and car machining occurs from both sides and/or top and bottom.

Remember, the special machining regulations for the Cadet and Development Classes only that can be found in Section 1 of the current Rules and Regulations document.

VERY IMPORTANT - All F1 in Schools™ cars must be designed to fit within and be milled from one REA supplied balsa wood block. Block dimensions can be found in the Rules and Regulations.

STAGE 5 – ANALYSE

Overview:

Optional

Obtain CFD software

Analyse the aerodynamics of 3D CAD models

Detail:

Teams may wish to evaluate a variety of car designs, or car parts, using computational fluid dynamics (CFD) software, such as the REA supplied Virtual Reality Wind Tunnel software or other packages such as COSMOS Flow Xpress, supplied with Solid Works or Autodesk® Flow Design supplied free with the new partnership arrangements with F1 in Schools.

Computational Fluid Dynamics (CFD) is the prediction of processes involving fluid flow, heat & mass transfer, chemical reaction and/or combustion. Anything that involves fluid flow can be simulated using these techniques; with varying degrees of accuracy.

CFD is based upon the laws of physics, of conservation of mass, momentum and energy. The equations are embodied within a mathematical model and solved using a grid superimposed on the region of interest of a 3D model.

CFD software allows you to import your F1 in Schools™ 3D CAD assembly model and then calculate how air flows around a part or assembly model. Results such as velocities, pressures, areas of turbulence, lift and drag, using vector plots, contour plots, streamlines and iso-surfaces can be analysed. Forces on the car body can be calculated and plotted.

‘White Lightning’ Pioneer State High School, QLD Development Class Best Engineered Design

2011 Australian Grand Prix

An example of mirrored side machining

Teacher Resources

Checklist:

CFD Software

CFD Tutorials

3D Car models

designs ready

for testing



Based on the calculated results, you can analyse problem areas (excessive drag) in your design and improve on these by tweaking your model using your CAD software again. All these refinements can be made before you manufacture any physical parts.

CFD calculations are intensive, but the software does the complex math for you!

STAGE 6 – PORTFOLIO & PIT DISPLAY

Overview:

Check out portfolios on the REA website

Consider the supplied Development Class Portfolio template for suggested content and structure

Understand competition marking criteria for Portfolios & Pit Display

Develop team identity & graphics

Detail:

Clearly organised, concise and professionally presented project portfolios and/or reports are common requirements in Senior School studies and the workplace.

F1 in Schools™ provides for an excellent foundation of learning related to Design Portfolios and has been shown to provide students with exceptional portfolio presentation skills which are of benefit to them in later project work.

Teams should start developing their Project Design Portfolios early. Development Class teams can use the Development Class Portfolio Template supplied at http://rea.org.au/f1-in-schools/for-teams/competition-documents/. This Microsoft PowerPoint file provides an example Portfolio structure and content overview for the 12 pages permitted.

Examples of exemplar Australian team’s World Final portfolios can be found at the following link: http://rea.org.au/flip/. Remember, these examples are only to provide teams with an idea of suggested content and layout. They must NOT be plagiarised.

Teams should develop their own logos and team identity early on which then feature throughout, individualising the look and feel of their F1 in Schools™ Design Portfolio and Pit Display.

F1 in Schools is a lesson in Project Management and this should be clearly addressed in the team Portfolio. The Defence Materiel Organisation has developed a Project Management Guide that may assist teams in understanding and implementing the key elements of Project Management. To access this guide, go to http://rea.org.au/f1-in-schools/for-teams/competition-documents/

Teacher Resources Checklist:

Sample Portfolios on website

Folio Template File for Development Class teams

F1 in Schools marking criteria

Logo design teaching aids

MS Powerpoint Lab

‘Basilisk Performance’ 2010 World Final car

CFD streamline results using Caedium by Symscape


http://rea.org.au/flip/




Suggested Design Portfolio Content:

Cover Page including photo realistic render of final car

Team Structure & Identity

Project Management

Marketing & Sponsorship

Research & Initial Design Concepts

Design Development

Design Testing & Innovation

Use of CAD/CAM

Orthographic Drawing

Manufacturing

Collaboration & Industry Links Overall project evaluation

Be sure your students are familiar with the marking criteria and assessment score cards. This will help them determine what needs to be communicated and presented within the Design Portfolio and Pit Display to get the highest possible score.

Remember to read and understand the restrictions governing Development Class Portfolios and Pit Displays. More information on this can be found in the Rules and Regulations booklet. The F1 in Schools™ Australia Marking Criteria (including the score

cards used by judges at State and National Finals), and the Rules and Regulations are downloadable from the REA website at: http://rea.org.au/f1-in-schools/for-teams/competition-documents/.

STAGE 7 – COLLABORATE > INDUSTRY LINKS

Overview:

Locate potential Industry partners / mentors

Find industry with help of industry associations

Make links and set-up collaboration meetings for teams

Investigate links becoming potential team / school sponsors

Detail:

F1 in Schools™ mission is to link exciting classroom activity with careers in the Engineering, Design, Manufacturing and related Science and Technology domains. There are also links to careers in Graphic Design, IT, Marketing and Business and Enterprise.

All F1 in Schools™ teams are mandated, through the assessment criteria, to explore links between their F1 in Schools™ project and Industry.

Teams through teacher guidance should establish links with Industry Mentors. These mentors can provide advice and

Teacher Resources Checklist:

Industry Research resources

Contact your local Partnership Broker to help with link ideas or,

Chambers of Commerce or Regional Development Australia Boards

Local Engineers Aust. / AiGroup / APESMA or ACEA




guidance on a wide range of aspects of the F1 in Schools™ project, from Engineering, Manufacture, Science, Design to Project Management, Graphic Design and Marketing, to name just a few!

Research conducted by REA through the University of South Australia, demonstrates strong links between student career choice decision making and ‘heroes’. There are plenty of hero figures in the world of Formula One, but you don’t need to look that far abroad to connect your students to heroes. Local industry can help and be heroes for your students too!

These mentors and Industry Professionals assist students with guidance, understanding and project improvements. Because these professionals are helping students make a better project, they soon become heroes, the role models capable of influencing student learning and career pathways.

Choose links carefully. Teams are required to document these collaborations in their Portfolio, describe activities, discuss career awareness and justify the links in terms of project development and needs.

Teams can outsource some project work to industry mentors. This could be in the form of decal make and application, team uniform manufacture or even graphic design. If you do outsource – be ready to justify and explain your understanding of the processes and technologies accessed through outsourcing. Document in your Portfolio or be penalised!

REA recommends that schools and teachers be considerate of their relevant child protection policies, student well-being and duty of care when facilitating Industry links, mentors and/or visitations.

Professional bodies such as Australian Industry Group (AiGroup), Engineers Australia, Association of Professional Engineers, Scientists, Managers Australia (APESMA) and Association of Consulting Engineers Australia all endorse the F1 in Schools™ program. Contact your local chapter / office for help with Industry Links. You might need to give them a quick heads-up!

Other Business & Education Network groups such as Business Chambers, Regional Development Australia along with Partnership Brokers have a good knowledge of local industry and are keen to connect with schools. See your school’s careers adviser for more information here.

Many tertiary institutions such as Universities and TAFE are actively involved and can be a great source for Mentors and project assistance. Often these institutions can help with access to specialised technologies if needed. These links also serve to show students the next steps in their Engineering, Design and Manufacturing learning and career pathways

Sponsorship

Financial sponsorship should not be necessary for teams at School and Regional levels of the Challenge. Teams progressing to State / Territory or National Championships are permitted and may need to engage additional project partners as financial sponsors. Extra financial resources may be necessary for production of team uniforms, display assets, team travel and accommodation where necessary.

All sponsorships should be accounted for in the Project Management section of the design Portfolio.

Remember that Collaboration is linked with ‘Mentoring’ and Marketing is linked with ‘Sponsorship’ and are two entirely different key assessment criteria. One organisation could provide both services but they need to be clearly differentiated in the Portfolio.



STAGE 8 – MAKE > CAM (COMPUTER AIDED MANUFACTURING)

Overview:

Determine CNC machine and CAM software to be used

Understand the machining restrictions applied to the Development and Cadet Class

Use CAM software to generate CNC machining code

Consider using the REA developed QuickCAM tutorial if you already have QuickCAM software

Detail:

All Challenge car bodies must be manufactured on a 3 axis CNC machine from a single balsa wood blank.

Before transferring completed designs to CAM – Computer Aided Manufacture Software, you need to determine the type of CNC machine you will be using. Different CAM processes and software are required for different machines.

Once a car body design is finalised in CAD, export your 3D model to CAM software such as the wizard based DENFORD QuickCAM Pro, available through REA.

CAM software turns your 3D design into CNC G&M Code (Preparatory and Miscellaneous Codes). This is the 3-dimensional X, Y and Z mathematical co-ordinates and other manufacturing instructions such as feed rates and spindle speed that control the 3-axis milling or routing machine. We

recommend that car bodies be manufactured using a long series 6mm diameter slot machining cutter.

STAGE 9 – MAKE > CNC (COMPUTER NUMERICAL CONTROLLED) MACHINING

Overview:

Use a CNC machine to make car bodies from balsa wood

Contact REA to find a manufacturing centre who will make it for you if you don’t have your own machine!

Detail:

If your school doesn’t have 3-axis CNC manufacturing capability, no problem!

There are many schools around Australia set-up as REA Certified Advanced Educational Manufacturing Centres.

Simply send one of them your design, usually be email, and for a small fee your machined design comes back in the post, ready for assembly! Contact REA for the contact details of centres close to you.

Teacher Resources

Checklist:

QuickCAM Pro or

other suitable

CAM software

CAM Tutorials

Aids to teach 3

axis machining

principles

Teacher Resources

Checklist:

3-Axis CNC

machine

CNC machine

code created

using CAM

software

Machining fixture

Balsa blanks

Milling cutter



If your school has a 3-axis CNC machine that you intend to use for car body manufacture, you will need to do some planning and testing to check your CAM requirements and CNC process and balsa billet mounting.

Whilst you can use any 3 axis CNC machine available, REA fully supports and recommends schools make their models on a DENFORD 3-axis CNC Router. Using a DENFORD CNC Router along with DENFORDS’s QuickCAM Pro CAM software is the fastest, simplest, most highly developed and best supported process for F1 in Schools™ car body manufacture. Most F1 in Schools™ Cadet & Development Class car designs can be completely manufactured in under 20 minutes using a DENFORD CNC Router.

During manufacture, the Balsa wood blank needs to be held securely in the CNC machine. Systems used to hold billets of material in place for manufacture are called fixtures. REA has developed and can supply a specially designed F1 in Schools™ car manufacturing fixture which can be mounted in most 3-axis CNC machines.

STAGE 10 – MAKE > FINISHING & ASSEMBLY

Overview:

Finish preparations and car body painting

Assemble wheels to your models

Add decals / team identity livery

Choose and fit tether line guides

Detail:

F1 in Schools™ Challenge entries are assessed on quality of manufacture. As with all project manufacturing, a reasonable amount of time needs to be dedicated to ensuring a high quality of final finish and assembly. Finishing should involve the following steps:

Smoothing down machine scalloping from the car body with a light grade abrasive paper.

Finish using a fine abrasive paper.

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

Apply thin coats of paint as necessary (you may want to undercoat it first).

Decorate the car body with decals as required.

Only a limited amount of hand finishing of the body is allowed. Any major hand finishing will result in marks being deducted. All F1 in Schools™ racers need to be completed with a high quality paint finish, including the application of any graphics and sponsorship liveries where appropriate.

Cadet and Development Class Challenge teams must use the REA supplied wheel system. These inexpensive wheel kits can be purchased through REA.

The system is designed to be assembled to car bodies having axle location holes drilled through at a diameter of 6mm. Cars machined using QuickCAM Pro following the REA Tutorial will have these holes automatically and accurately drilled by the CNC machine.

Teacher Resources

Checklist:

Paint finishes

Safety

Abrasive paper

Decals / Livery

REA Wheel kits

Tether guides



The REA supplied Wheel and Axle System kit includes:

2 x Front Wheels

2 x Rear Wheels

4 x Axle Bearing Grommets (to suit 6mm hole)

2 x Brass axles

2 x Plastic Insert Tether line guides.

Read the Rules and Regulations carefully as some minor modifications are allowed to the standard wheel system for the Development Class only. Development Class teams can use alternative tether line guides and axles but must ensure that the chosen system complies.

Use these simple steps as a guide for assembly of Wheel and axle systems for the Cadet and Development Classes

1. Remove parts from injection moulding sprue carefully.

2. Assemble Axle Bearing Grommets into 6mm drilled axle location holes.

3. Assemble one front (narrower) wheel to one axle.

4. Place in car body and mark desired axle length at other end, remove and cut to length.

5. Re-assemble to body and connect the other front wheel

6. Repeat steps 3 – 5 for rear (wider) wheels

7. Mark location for tether line guides on underside of body.

8. Add your own tether line guides or insert the standard ones supplied. For standard guides, insert sideways into balsa slot, push locating pin into model surface. Use a pair of fine long nose pliers, rotate the guide so that the locating ‘wings’ cut into the sides of the balsa slot.

9. Your model should be then ready to run! Remember, Professional Class teams can use alternative wheel systems so long as they comply with the Rules and Regulations.

STAGE 11 – VERBAL PRESENTATIONS

Overview:

8 Minute presentations

Check marking criteria for required content

Get some presentation skills coaching assistance

Detail:

Team Verbal Presentations are an important pioneering aspect of the Challenge. Teachers are encouraged to get their school based teams to develop and deliver presentations as part of the class project.

Teacher Resources

Checklist:

Data Projector

MS PowerPoint

Presentation

Skills Resources



Delivery of an 8 minute Verbal Presentation by each team is a mandatory competition component at the State / Territory and National Championship levels.

Learning effective presentation skills is a very valuable and important attribute for young people to develop. Effective communication of ideas and concepts is a critical employability skill, no matter what industry a student may enter. Effective presenters also develop higher levels of confidence and performance.

REA encourages teachers to seek mentoring or support from other

teachers or industry in helping your students with tips and essential verbal presentation skills. Turn your students into ‘gun’ presenters!

The inclusion of a MS PowerPoint as part of the presentation is popular but not mandatory. Many teams have developed unique styles in delivering their presentation.

STAGE 12 - TEST

Overview:

Optional - use physical wind and smoke tunnels to conduct scientific aerodynamic tests

Hands on validation of engineering design

Detail:

If you have access to Wind or Smoke Tunnels, students can conduct physical tests and scientific experiments to validate their designs and further examine aerodynamic properties.

Many schools in Australia have REA supplied desktop sized Smoke Visualisation and Drag Co-Efficient measuring Wind Tunnels. These technologies are ideal for examining the science behind car performance in a hands-on environment.

The Flo Smoke Visualisation Tunnel allows constant streams of smoke to be passed over the surface of the car, very effectively highlighting areas of turbulence and drag.

The Scout Wind Tunnel blasts designs with high speeds of air, emulating race conditions, whilst recording the amount of drag. The Wind Tunnel can be connected to a PC for capturing and graphing of scientific data.

Teacher Resources

Checklist:

Smoke and/or

Wind Tunnel

access

Aerodynamics

theory

Research use of

wind tunnels in

real F1 car

design

The “Stingers” – Delivering their Verbal Presentation



Schools who are members of Regional Design and Technology Hubs can often gain free access to this equipment. Schools wishing to purchase their own should contact REA or see more information on the www.rea.org.au website.

Some teams have been able to access similar technologies through links to Universities and industry.

STAGE 13 – RACE

Overview:

Use specially designed computerised system to race and time cars over 20m distance

Time Trials - Auto Racing

Reaction Races – Driver controlled launching cars by reacting to start lights.

Detail: When car design and manufacture is complete, the race is on!

At State and National Final events, F1 in Schools™ CO2 powered cars are raced over an official distance of 20m. A specially designed computerised car launch and racing timing system accurately records results to 1/1000th of a second! The F1 Impulse Race System emulates a real Formula One Race Start.

Cars are raced in Time Trials, launched automatically and also through Reaction Time races where a team driver reacts to pushing the manual firing button which replicates a real Formula 1® starting grid. Several races are conducted on purpose built two lane elevated race tracks. Lane changes occur as part of the racing procedure and program. At many Finals events, racing is webcast including a live timing scoreboard.

Can you beat the elusive 1 second barrier and join the exclusive REA Sub-One Club?

Schools who are members of Regional Design and Technology Hubs can often gain free access to this equipment for testing of cars prior to events.

REA can supply interested schools with F1 in Schools™ Race Systems and Tracks. REA also stocks quality 8 gram CO2 canisters.

Be mindful of student safety when using gas canisters. Eye protection is recommended. Only teachers or trained students should operate the race system. Be sure all cars are safely secured to the tether line guide! Keep and dispose of all spent canisters.

Teacher Resources

Checklist:

Race timing

system

Track

8 gram CO2

cylinders

Safety

Race score sheet

‘Redline Racing’, Trinity Christian School, ACT achieving a sub one second result at the 2008 National Final in Canberra

http://www.rea.org.au/



STAGE 14 - COMPETITIONS

Overview:

Run your own exciting school based competition to find best teams

Enter your best school teams in your regional final

Understand competition requirements and judging criteria to be used at Regional level

Best Regional teams can progress to State and National Finals

National Champion Development and Professional Class winners go to the World Final.

Detail:

F1 in Schools™ is a Global Challenge with over 42 countries participating from around the world. Australia is one of the Program Founding Partners and has enjoyed great success at the international level. Australian Teams have been World Champions in 2006, 2011, 2012 and 2013, placing regularly in podium positions and winning category awards including the prestigious Best Engineered Design Award multiple times.

Becoming F1 in Schools™ champions at any level is about more than just having the fastest car. To succeed you must address all assessment and marking criteria as outlined in a separate document. Appropriate levels of attention and time must be dedicated to each of the criteria, considering the mark values shown for each key performance indicator. Becoming champions is about gaining the maximum TOTAL score possible.

Challenge Marking Criteria Overview

The total maximum number of marks available is 900 and will be distributed as per the following judging criteria.

Engineering: 235 marks in total consisting of:

1. Specifications: 60 marks 2. Form & Finish: 15 marks 3. CAD & Analysis: 85 marks 4. Manufacturing: 45 marks 5. Technical Merit: 30 marks

Portfolio & Pit Display: 220 marks in total consisting of:

6. Portfolio: 60 marks 7. Marketing: 40 marks 8. Pit Display: 40 marks 9. F1 Design Process: 80 marks

A1 Racing: 2013 World Champions Phoenix P-12 Community College VIC & Pine Rivers State High School QLD

collaboration.



Verbal Presentation: 220 marks in total consisting of:

10. Technique: 40 marks 11. Composition: 30 marks 12. Subject Matter: 150 marks

Race: 225 marks in total consisting of:

13. Grand Prix Race: 175 marks 14. Fastest Reaction Time: 20 marks 15. Knockout Race: 30 marks

The official score cards used by the Judges can be found within the Marking Criteria which can be downloaded from the REA website.

The Australian Competition occurs through several levels. Teams progressing from one level to the next are permitted and encouraged to further develop and refine their designs and associated entry assets.

Check www.f1inschools.org.au for event dates and locations.

The Competition process can be at five levels:

1. School Competitions

2. Regional Finals

3. State / Territory Finals

4. National Finals

5. World Finals 1. School Competitions:

(May – July)

Recommended Minimum School Competition Project Inclusions

o 1 or 2 completed cars per team (1 for Cadet Class)

o Portfolio sections or poster as defined by teacher

o Industry links or related study

o Verbal presentation

Teachers choose some or all of the Challenge Marking Criteria and set these as the school based assessment criteria for determining their best school teams. Racing is the highlight and we encourage teachers to run their own school based race-off. This is a great opportunity to showcase the project to other students and the rest of the school community. Schools may also choose to invite existing or potential industry partners to visit or even participate as a judge.

Teachers are encouraged to award outright and category awards. Industry partners often agree to sponsor prizes. Why not create a school perpetual trophy? REA has a template certificates available for school competitions.

Generally speaking the best 2 to 3 top scoring teams will represent their school at a Regional Final. However this can vary from region to region and you should liaise with your Regional Coordinator to confirm this.

http://www.f1inschools.org.au/



2. Regional Finals

(July – September)

Recommended Minimum Project Entry Inclusions o 1 to 2 completed cars per team (1 for Cadet

Class)

o Poster (Cadet Class) or 12 page portfolio (Development Class) or 20 page portfolio (Professional Class)

o Basic rule and regulation compliance

o Team wear school uniform but proposed future team uniform design in Portfolio.

o Pit display design proposed. (n/a Cadet Class)

o Verbal presentation – optional (n/a for Cadet Class) At many regional events, teams are only required to present project work to satisfy a reduced number of assessment criteria. Your Regional Final Coordinator can provide further information regarding this.

Teams competing at Regional Finals must be registered with REA. You will need to check our website www.rea.org.au or email [email protected] to locate details related to your nearest regional final and make contact with the coordinating teacher.

Whilst it’s ideal for students to attend regional finals, we recognise this is not always possible. Cadet teams can send their cars for racing and poster for assessment to the Regional Final coordinating school ahead of the event. Arrangement will need to be made with the Regional Coordinator for return of project elements. The best Cadet,

Development and Professional Class teams from each region progress to the State Finals. 3. State Final

(September – November).

Project Entry Requirements Elements and quantities will be defined in supplementary information provided leading up to State Finals.

o 2 - 3 completed cars per team (1 for Cadet Class)

o Poster (Cadet Class) or 12 page portfolio (Development Class) or 20 page portfolio (Professional Class)

o Team uniforms (school uniform for Cadet Class)

o Pit display –an expo style booth supplied by REA with nominal external dimensions of 2m (w) x 1m (D) x 2.4m (H) (n/a for Cadet Class)

o 8 minute verbal presentation (n/a for Cadet Class)

o Address all the applicable marking criteria!

The Stingers had modest, yet effective beginnings. 2005 Victoria University Regional Final.

The Stingers – Year 8 2006 F1 in Schools World Champions

Teams are judged by Professional Engineers!





REA hosts and manages all State / Territory Competitions. These are usually conducted at interesting venues and can include industry visits as part of the programmed activities.

At this level of the competition, the full range of marking criteria will be assessed. The top scoring Development Class Team, Professional Junior Class Team and Professional Senior Class Team are invited to represent their State / Territory at the National Finals. Champion Cadet Class teams from each state final will be invited to provide their projects for display at the National Final.

Teams progressing to this level of the competition will need to consider budget and logistics for travel, team uniforms and display assets. To participate, team attendance at this level is essential for all teams other than the Cadet Class. Teams may need to engage financial sponsors to help with the required budget. 4. National Final:

(February - March)

The Australian National Final is a most prestigious event, normally conducted over 3-4 days including the Gala Awards Presentation, attended by the media and VIP’s from Industry and Government. The 2008 National Finals Gala Awards Presentation was held in the Great Hall of Parliament House with 25 Members of Parliament in attendance!

Project entry requirements are the same for the teams as for State Finals. Elements and quantities will be defined in supplementary information provided leading up to the National Final. Expect the bar to rise significantly and the need for further project refinement in order to be competitive.

Teams progressing to this level of the competition will need to consider budget and logistics for travel, team uniforms and display assets. To participate, team attendance at this level is essential for all teams other than the Cadet Class. Teams may need to engage financial sponsors to help with the required budget. 5. World Final

(September - November)

World Finals are generally staged over one week (including organised team activities) between September and November of each year and where possible are held in conjunction with a Formula 1® Grand Prix.

In the past, World Finals have been hosted by England, Australia, Malaysia, Singapore, Abu Dhabi and the USA. In 2014, the World Finals will be held in Abu Dhabi, UAE.

Australia has an enviable track record at World Final events with teams being crowned World Champions in 2006, 2011, 2012 & 2013. Australia is currently ranked the Number 1 country in the world for the F1 in Schools™ Technology Challenge.

For a full breakdown of World Final results for Australian Teams go to: http://rea.org.au/f1-in-schools/for-teams/competition-results/world-finals/.

2008 National Final – Parliament House Canberra

2013 World Final Teams Texas Capitol Building, Austin, Texas USA

http://rea.org.au/f1-in-schools/for-teams/competition-results/world-finals/

http://rea.org.au/f1-in-schools/for-teams/competition-results/world-finals/



SO, WHAT ABOUT THE SECRETS FOR SUCCESS?

Other than all of the information and resources presented here, there are no secrets really… but when it comes to project design, many teachers will hold the cards close to their chests! There are however teachers who are happy to help others get started. We can put you in touch with one in your region if you require extra assistance.

As a teacher, one of the most valuable things you should consider is becoming a ‘manager’ of the technology learning environment. Technology Educators can no longer afford or strive to be an expert in all technologies available to students. Understanding the basics and capabilities of the technologies, then steering students on their learning journey, is an approach that’s proving highly successful with F1 in Schools™. REA has completed and remains engaged in doctoral research and other R&D activities, developing resources and support tools that allow you, the teacher to let your students fly!

Don’t forget, tell your Principal what you do… you will have many amazing student success stories to share. The school Principal will be eager to have these stories and your classroom as a school showpiece. This will, importantly, lift the status Technology Teaching - Applied and relevant learning!

NEED SOFTWARE, HARDWARE OR CONSUMABLES?

REA stocks and supplies Software, Hardware and Consumables required by schools to facilitate Design, Analyse, Collaborate, Make, Test and Race learning activities for the Challenge. REA is a not-for-profit company and all revenues from product sales is directed back into program management, support and development.

It is not a requirement of schools to utilise all REA supplied products. Schools can source other suitable solutions or use any of their own existing technologies.

REA has partnered with several local and overseas suppliers to manufacture and source a wide range of products related to the F1 in Schools™ Challenge. All technologies have been assessed by qualified Technology Education Teachers for their suitability and application in the classroom environment. Most of the technologies are built on Industry platforms providing for skill transfer and also provide for wider school curriculum application beyond the F1 in Schools™ Program.

To review the available products, visit the www.rea.org.au website or email [email protected] for more information.

ENQUIRIES

All enquiries regarding the Australian F1 in Schools™ Technology Challenge should be directed to:

Re-Engineering Australia Foundation Ltd.

Mailing Address: PO Box 136

Castle Hill NSW 1765

In Australia call: 1300 204 478 International: +61 2 9634 2144

Facsimile: +61 2 8079 0622 Email: [email protected] Website: www.f1inschools.org.au

http://www.rea.org.au/




Documents

How to run the F1 in Schools Challenge - REA Foundationrea.org.au/wp-content/uploads/2014-Teachers-Guide-to-Getting... · 2014 Australia F1 in Schools™ Teachers Guide© Version