VXmodel key to success in creating Formula SAE race car for engineering student competition

Creaform Engine Model In Progress

Jayhawk Motorsports, a team of 40 engineering students from the University of Kansas, is using the Creaform HandySCAN 3D scanner to create two racecars, including creating a powerful 3D model of the engines. The team was one of the 10 selected as part of the 2015 Student Project Sponsorship for the SAE Collegiate Design Series.

The team is competing in the Formula SAE series, a worldwide student design and engineering competition for developing (and racing!) small Formula-style cars. Jayhawk Motorsport (JMS) is designing and manufacturing vehicles belonging in two categories: combustion and electric engine.

In order to help them carry out this yearlong project, Creaform loaned a HandySCAN 3D scanner as well as a high-performance laptop to JMS equipped with VXmodel. The team also benefited from training and support from Creaform, for both the scanner and the software.

Multiple uses for the 3D scanner

The JMS team was able to put the 3D scanner HandySCAN 3D to good use throughout the manufacturing process. One of the largest project was to develop an accurate engine model using the VXmodel Scan-to-CAD software module. Intuitive functionalities such as alignment, geometrical entities and cross-sections and mesh editing in VXmodel really help to achieve reverse engineering projects efficiently and all that in a seamless integration with VXelements.

Creaform Engine Scan

JMS also used the HandySCAN 3D for numerous, very diverse systems such as the intake, exhaust, oil, cooling, gear train, chassis, and suspension. Collected data was then applied to many different separate projects.

The 3D design and engineering equipment loaned by Creaform was especially useful when it comes to the oil system. With the help the HandySCAN 3D and using the finite element method (FEA), the team was able to optimize its oil pan, making it both lighter and stiffer. Furthermore, the accurate model obtained with the handheld 3D scanner enabled them to design a tight tolerance swivel oil pickup that efficiently redistributes the oil in high G-force corners.

On top of that achievement, the team planned to use the HandySCAN 3D to design their own internal dry sump pump, thus replacing the less effective stock part.

Additionally, the team was able to use the 3D scanner during the quality control phase of the project, both to ensure conformity of different parts after manufacturing and to test the assembled chassis.

Jayhawk Motorsport Check

The better the model, the more accurate the assembly

Taylor Lawson, manufacturing lead for the Jayhawk Motorsports Formula SAE team, explained that “in years past having an inaccurate model for mounting caused assembly and performance issues affecting suspension geometry. With the help of the scanner as well as the VXelements 3D software platform and application suite [which VXmodel is a part of], we have successfully created a reliable model to ensure accurate assembly. Now the intake, exhaust, and cooling components can all be fully designed before the assembly of the chassis and suspension”.

Even from the perspective of our experts, the engine model brought forward by the University of Kansas team is very elaborate; probably one of the most impressive projects done with VXmodel to date! Jayhawk Motorsports is unveiling both its vehicles on April 12, with competitions to follow in late spring. Good luck to the team.

You can follow Jayhawk Motorsports on Facebook and Twitter.

Article written by Creaform

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