how to get through technical inspection by michael royce

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COLLEGIATE ROAD SHOWat IMIS

December 10th 2011

HOW TO GET THROUGHTECHNICAL INSPECTION

by

Michael Royce

Albion Associates LLC

1



Outline

A. General

B. Before the Competition

C. Preparations at the Competition

D. In Tech Inspection

E. After “Tech Inspection”

2



Tech Inspection - General

• Tech Inspection is:

– Is a “no points” activity, but

– Stressful

3



Tech Inspection - General

• The tech inspectors/scrutineers’ job is to:

—Get the car out onto the track in a not unsafe condition

as quickly as possible.

• He/she does this by:

—Checking that the car meets the FSAE Rules.

4



Instructions to the Tech Inspectors

• FSAE is an educational program

• Students have put many hours into their cars.

• Our job is to get the cars out onto the track in a safe condition.

• Know the Rules.

• 95% of Rules are safety rules.

• When in doubt, discuss with your partner.

• Still in doubt, consult the Rules, read the rule exactly.

• Still in doubt, go to the intent of the Rule.

• Still in doubt, talk to the Chief Tech Inspector.

5



Instructions to the Tech Inspectors -Cont’d

• Teach but don’t preach

• Keep moving, don’t gossip, there are many cars.

• Don’t loose your “cool”.

• Don’t get into an argument with the Faculty Advisor – call the Chief

over.

• Be gentle with the Restrictor Guage – don’t ram it down hard!

• Be courteous.

6



Before the Competition• Tech Inspection preparation starts NOW!!

• Ask questions well in advance

– For USA, Kathleen McDonald at [email protected]

• Get your SEF in early• Stay on schedule!

• Have the car inspected by a qualified non-team member

– An SCCA tech inspector

– A team alum

– Use a Tech Form

• Run Noise Tests

– Aim for 107 dBA maximum!

• Do Brake Tests

7



At the Competition

• Timetable

– 1st “statics” day, and often

– The day or 1/2 day preceding that.

• Tech Inspection order:

– Read the “Supplementary Regulations”

• “Take-a-Number”

• FSG - quiz

• FS - send in completed Tech Form with photos

• Process

– Officially Tech Inspection has 3 parts

• Scrutineering• Tilt Test

• Noise, Master Switch and Brake Test

– FH and FS exceptions, MSA Safety Scrutineers

8



At the Competition – Cont’d

• Going into Tech Inspection you will need:

– Your (blank) Tech Form (normally in Registration packet)

– Your Structural Equivalency Form (SEF) or Structural

Requirements Certification Form (SCRF)

– Copy of Impact Attenuator Report

– Copies of any rules questions sent in and the answers

– The actual IA that was tested (unless using the Standard Attenuator)

9





– The car (mounted on its “dry” tires)

– Rain tires (if you have them)

– ALL the drivers’ equipment

• Helmets,

• Suits,

• Shoes, socks

• Gloves,

• Balaclavas,

• Arm restraints

– Fire extinguishers (both) – Push bar

– All the drivers

– Tools to remove the bodywork

10



At the Competition – Cont’d• First impressions


– A polite attitude

– A neat and clean car • Wiring

– Keep the Faculty Advisor away!

– Don’t argue with the inspector(s)

• Move argumentative team members out of the area.

• If you disagree intensely, get Team Captain to ask to speak tothe Chief Tech Inspector.

11



The Tech Inspection Process

• Usually 2 person teams

• Pages 1 through page 4 of Tech Form – Although FS a little different

• Structural, Percy and template checks done first.

• Then a separate MSA “safety” scrutineering check

– Formula Hybrid adds Electrical Tech Inspection and Rain Test

• Bodywork off after page 1 checks.

12




• Fill out the top portion of the Tech Form with

– Engine information (for Noise Test volunteer)

– SEF Deviation (Yes/No)

– Tire information, Dry and Rain

– Transponder number (if applicable)

• Bodywork on

13



Things to Trip You Up

14



B.16.1 Car NumbersCar numbers must appear on the vehicle as follows:

(a) Locations: In three (3) locations: the front and both sides;

(b) Height: At least 15.24 cm (6 inch) high;

(c) Font: Block numbers (i.e. sans-serif characters). Italic, outline, serif,shadow, or cursive numbers are prohibited.

(d) Stroke width and Spacing between Numbers: At least 2.0 cm (3/4 inch).

(e) Color: Either white numbers on a black background or black numberson a white background. No other color combinations will be approved.

(f) Background shape: The number background must be one of the following:round, oval, square or rectangular . There must be at least 2.5 cm (1

inch) between the edge of the numbers and the edge of the background.(g) Clear: The numbers must not be obscured by parts of the car , e.g.

wheels, side pods, exhaust system, etc.

15



B.16.1 Car Numbers - OK

16



B.16.1 Car Numbers - Not OK

17



B.16.4 Tech Sticker Space & Location

Technical inspection stickers will be placed on the upper nose of the vehicle. Carsmust have a clear and unobstructed area at least 25.4cm wide x 20.3cm high(10” x 8”) on the upper front surface of the nose along the vehicle centerline.

Vehicles that are being entered into multiple competitions in the FSAE seriesmust allow sufficient space along the nose centerline for all inspection stickers.

18



B.3.23 Front Bodywork

Sharp edges on the forward

facing bodywork or other

protruding components are

prohibited.

All forward facing edges on the

bodywork that could impactpeople, e.g. the nose, must have

forward facing radii of at least 38

mm (1.5 inches).

This minimum radius must extend

to at least 45 degrees relative tothe forward direction, along the

top, sides and bottom of all

affected edges.

19



B.3.23 Front Bodywork - Cont’d

All forward facing edges on the bodywork that could impact people, e.g. the nose,must have forward facing radii of at least 38 mm (1.5 inches).

This minimum radius must extend to at least 45 degrees relative to the forwarddirection, along the top, sides and bottom of all affected edges.

20



B.12.3 Edge Radii of Aerodynamic Devices

All wing edges including wings, end plates, Gurney flaps, wicker bills, splitters,

undertrays that could contact a pedestrian must have minimum edge radii of at

least 1.5 mm (0.060 inch).

Note: This means at least a 3 mm (1/8 inch) thick edge.

21



B.3.25.1 - Inspection Holes

B.3.25.1 Inspection Holes

• The Technical Inspectors may check the compliance of all

tubes. This may be done by the use of ultra sonic testing or by the drilling of inspection holes at the inspector’s request.

Presenter’s comment:

Teams have been recommended that they drill inspection holes

in the Main and Front Hoops to the requirements of the 2010

Rules in case the ultra sonic equipment is not available or is

malfunctioning.

22



B.5.4.2 Shoulder Harness Bar

• If the harness is mounted to a tube that is not straight, the joints between this

tube and the structure to which it is mounted must be reinforced in side view by

gussets or triangulation tubes to prevent torsional rotation of the harness

mounting tube.

23



B.4.3.1 Seat - Not OK

B.4.3.1 Seat

The lowest point of the driver’s

seat must be no lower than the

bottom surface of the lower framerails or by having a longitudinal

tube (or tubes) that meets the

requirements for Side Impact

tubing, passing underneath the

lowest point of the seat.

Note: The smallest tube would be

1.00” OD X 0.049” wall)

24



Things to Trip You UpB.14.2 Securing Fasteners

• Loose jam nuts

• Positive locking

– Per the FAQ, the securing system must be:

• 1. Be visible to team members AND tech inspectors

• 2. Does not rely on clamping force

25



Securing Fasteners

FAQ # 83

•B.14.2.1 Securing Fasteners

•Based on a couple of recent questions, the Rules Committee has decided that in order to be

consistent, we need a clearer definition of what constitutes a “positive locking mechanism” as

required by Rule B.14.2.1.

•The definition we will apply is as follows:

•1. The Tech Inspectors (and the team members) must be able to see that the device/system isin place, i.e. it is visible.

•2. The “positive locking mechanism” does not rely on the clamping force to apply the “locking”

or anti-vibration feature. In other words, if it loosens a bit, it still prevents the nut or bolt coming

completely loose.

•Also, “prevailing torque lock nuts” fabricated by a team will not be acceptable. We have no

certainty that they will have the quality control to work all the time.

http://forums.sae.org/access/dispatch.cgi/fsae_pf/docProfile/100176/d20081029212535/No/B.14

.2.1%20Securing%20Fasteners

26



B.14.2 Securing Fasteners - Safety Wire

27



B.14.2 Securing Fasteners - Safety Wire

Good examples

28



B.14.2.3 Securing Fasteners - Spherical Rod Ends

All spherical rod ends on the steering or suspension must be in double shear or

captured by having a screw/bolt head or washer with an O.D. that is larger than

spherical bearing housing I.D.

Adjustable tie-rod ends must be constrained with a jam nut to prevent loosening.

29



Positive Locking - Examples

30



B.6.3 - Wheel Mounting

• B.6.3.2 Any wheel mounting system that uses a single retaining nut

must incorporate a device to retain the nut and the wheel in the event

that the nut loosens. A second nut (“jam nut”) does not meet these

requirements.

• B.6.3.3 Standard wheel lug bolts are considered engineered fasteners

and any modification will be subject to extra scrutiny during technical

inspection. Teams using modified lug bolts or custom designs will be

required to provide proof that good engineering practices have been

followed in their design.

• B.6.3.4 Aluminum wheel nuts may be used, but they must be hard

anodized and in pristine condition.

31



B.2.5 & C.2.2.1 Visible Access

B.2.5 Visible Access

All items on the Inspection Form

must be clearly visible to the

technical inspectors without using

instruments such as endoscopesor mirrors. Visible access can be

provided by removing body

panels or by providing removable

access panels.

Note: This same wording is

repeated in C.2.2.1 Technical

Inspection

32



B.5.1 Belts - General

• B.5.1.2 Harness Requirements

All drivers must use a 5, 6 or 7 point restraint harness meeting thefollowing specifications:

a. All driver restraint systems must meet either SFI Specification 16.1,SFI Specification 16.5, or FIA specification 8853/98.

b. The belts must bear the appropriate dated labels.

c. The material of all straps must be in perfect condition.

d. There must be a single release common to the lap belt and shoulder harness using a metal-to-metal quick release type latch.

e. To accommodate drivers of differing builds, all lap belts must have a“quick adjuster” feature.

Lap belts with “pull-up” adjusters are recommended over “pull-down”adjusters.

33



B.5.1 Belts - General

• B.5.1.2 Harness Requirements

All drivers must use a 5, 6 or 7 point restraint harness

34



Belts - “Quick Adjusters”, Tilt-Lock Adjusters

or “Zip Adjusters”

35



B.5.3.4 Lap Belt Mounting - cont’d

OK Not OK

“To fit drivers of differing statures correctly, in side view, the lap belt must be capable of pivotingfreely by using either a shouldered bolt or an eye bolt attachment , i.e. mounting lap belts bywrapping them around a frame tube is no longer acceptable.”

36



B.4.5 Firewall

• A firewall must separate the driver

compartment from all components of the fuel

supply, the engine oil and the liquid cooling

systems.

• It must protect the neck of the tallest driver. It

must extend sufficiently far upwards and/or rearwards such that any point less than 100 mm

(4 ins.) above the bottom of the helmet of the

tallest driver shall not be in direct line of sight with

any part of the fuel system, the cooling system or

the engine oil system.

• The firewall must be a non-permeable surface

made from a fire resistant material.

• Pass-throughs for wiring, cables, etc. are

allowable if grommets are used to seal the pass-

throughs. Also, multiple panels may be used to

form the firewall but must be sealed at the joints.

37



B.5.6 Head Restraint

B.5.6.2 The restraint must:

• Be vertical or near vertical in side view.

• Be padded with an energy absorbing material suchas Ethafoam or Ensolite with a minimum thickness of 38 mm (1.5 inches).

• Be located so that:

- It is no more than 25 mm (1 inch) away from theback of the driver’s helmet in the uncompressedstate, with the driver in his/her normal driving position.

- The contact point of the back of the driver’shelmet on the head restraint is no less than 50mm (2 inch) from any edge of the head restraint.

Notes:

(1) The head restraint must meet the above

requirements for all drivers.(2) Head restraints may be changed to

accommodate different drivers

(See B.1.2.2.d)

Note: Head restraint on the right is NOT OK.

38



B.4.6 Vehicle Controls

OK “Fixed”

All vehicle controls, including the shifter, must be operated from inside the cockpit

without any part of the driver, e.g. hands, arms or elbows, being outside the planes

of the Side Impact Structure defined in B.3.24 and B.3.31.

39



B.4.6 Vehicle Controls - cont’d

OK OK

All vehicle controls, including the shifter, must be operated from inside the cockpit

without any part of the driver, e.g. hands, arms or elbows, being outside the planes

of the Side Impact Structure defined in B.3.24 and B.3.31.

40



B.3.17.1 Foot & Toe Protection

B.3.17.1 Front Impact Structure

The driver’s feet must be completely contained within the Major Structure of theFrame. While the driver’s feet are touching the pedals, in side and front views

no part of the driver’s feet can extend above or outside of the Major Structure

of the Frame.

41



B.5.7 Driver’s Leg Protection

• To keep the driver’s legs away from moving

or sharp components, all moving suspension

and steering components, and other sharp

edges inside the cockpit between the front

roll hoop and a vertical plane 100 mm (4

inches) rearward of the pedals, must beshielded with a shield made of a solid

material.

• Moving components include, but are not

limited to springs, shock absorbers, rocker

arms, anti-roll/sway bars, steering racks and

steering column CV joints.

• Covers over suspension and steering

components must be removable to allow

inspection of the mounting points.

42



Driver Checks

43



B.8.4.1 Air Intake System Rollover Protection

All parts of the engine air and fuel control systems (including the throttle or carburetor,

and the complete air intake system, including the air cleaner and any air boxes) must

lie within the surface defined by the top of the roll bar and the outside edge of the four

tires (see figure 13).

44



B.8.4.1 & B.9.5.1 Air Intake & Fuel System Rollover

Protection - cont’d

Not Correct Envelope Correct Envelope

All parts of the fuel storage and supply system, and all parts of the engine air andfuel control systems (including the throttle or carburetor, and the complete air intakesystem, including the air cleaner and any air boxes) must lie within the surfacedefined by the top of the roll bar and the outside edge of the four tires (see figure13).

45



B.8.4.1 & B.9.5.1 Air Intake & Fuel System Rollover

Protection - cont’d

Not OK OK

All parts of the fuel storage and supply system, and all parts of the engine air and fuel controlsystems (including the throttle or carburetor, and the complete air intake system, including theair cleaner and any air boxes) must lie within the surface defined by the top of the roll bar andthe outside edge of the four tires (see figure 13).

46



B.8.9.3 Intake Manifold Attachment

Not OK OKIntake Manifold – The intake manifold must be securely attached to the engine block or

cylinder head with brackets and mechanical fasteners. This precludes the use of hose

clamps, plastic ties, or safety wires. The use of rubber bushings or hose is acceptable for

creating and sealing air passages, but is not considered a structural attachment.

47



B.8.9.2 Fuel Rail Attachment

Fuel Rail – The fuel rail must be securely attached to the engine cylinder block,

cylinder head, or intake manifold with brackets and mechanical fasteners. This

precludes the use of hose clamps, plastic ties, or safety wire.

48



B.8.13 - Drivetrain Shields & Guards

• B.8.13.1 Exposed high-speed final drivetrain

equipment such as Continuously Variable

Transmissions (CVTs), sprockets, gears,

pulleys, torque converters, clutches, belt drives

and clutch drives, must be fitted with scatter

shields in case of failure.

•

The final drivetrain shield must cover the chainor belt from the drive sprocket to the driven

sprocket/chain wheel/belt or pulley.

• The final drivetrain shield must end parallel to

the lowest point of the chain

wheel/belt/pulley. (See figure). Body panels or

other existing covers are not acceptable unless

constructed from approved materials per

B.8.13.3 or B.8.13.4.

Comment: Scatter shields are intended to

contain drivetrain parts which might separate

from the car.

49



B.8.11 System Sealing

B.8.11 System Sealing• B.8.11.1 The engine and transmission must be sealed to prevent leakage.

• B.8.11.2 Separate catch cans must be employed to retain fluids from any ventsfor the coolant system or the crankcase or engine lubrication system. Eachcatch-can must have a minimum volume of ten (10) percent of the fluid beingcontained or 0.9 liter (one U.S. quart) whichever is greater.

• B.8.11.3 Catch cans must be capable of containing boiling water withoutdeformation, and be located rearwards of the firewall below driver’s shoulder level, and be positively retained, i.e. no tie-wraps or tape.

• B.8.11.4 Any catch can on the cooling system must vent through a hose with aminimum internal diameter of 3 mm (1/8 inch) down to the bottom levels of theFrame.

• B.8.11.5 Any crankcase or engine lubrication vent lines routed to the intakesystem must be connected upstream of the intake system restrictor.

• B.8.11.6 Crankcase breathers that pass through the oil catch tank(s) toexhaust systems, or vacuum devices that connect directly to the exhaust system, are prohibited.

50



B.8.9.1 Fuel Lines for LPI Systems

Fuel Lines – On low pressure fuel injected systems, any flexible fuel lines must be either

(i) Metal braided hose with either crimped-on or reusable, threaded fittings, or

(ii) Reinforced rubber hose with some form of abrasion resistant protection with fuelline clamps per B.8.8.2.

Note: Hose clamps over metal braided hose will not be accepted.

51



B.8.8.2 Fuel Lines - Non-Aeroquip Type

If rubber fuel line or hose is used, the components over which the hose is clamped must haveannular bulb or barbed fittings to retain the hose.

Also, clamps specifically designed for fuel lines must be used. These clamps have three (3)important features,

(i) a full 360 deg. wrap,

(ii) a nut and bolt system for tightening, and

(iii) rolled edges to prevent the clamp cutting into the hose. Worm-gear type hose clamps arenot approved for use on any fuel line.

52




• Plastic Fuel Fittings

– Plastic fuel lines prohibited per B. 8.8.1.

– Plastic fuel FITTINGS are not specifically (except at FSG)

– But DON’T!

• Plastic Fuel Rails

– Not prohibited, except at FSG(?)

• “Quick Connect” Fuel Line Connectors

– Not specifically prohibited by rule,

– Except maybe by B.8.8.1.

– Not suitable for FSAE usage

– So, Don’t use!

53



B.9.6 Fuel Tank Filler Neck & Sight Tube

All fuel tanks must have a filler neck:

(a) at least 38 mm (1.5 inches) diameter,

(b) at least 125 mm (4.9 inches) vertical heightand

c) angled at no more than 45 degrees from thevertical.

The 125 mm of vertical height must be abovethe top level of the fuel tank, and must beaccompanied by a clear, fuel resistant sight tubefor reading the fuel level (Figure 7).

The sight tube must have at least 75 mm (3inches) of vertical height and a minimuminside diameter of 6 mm (0.25 inches). Thesight tube must not run below the top surface of the fuel tank.

A clear filler tube may be used, subject toapproval by the Rules Committee or technicalinspectors at the event.

54



B.9.6 Fuel Tank Filler Neck & Sight Tube - OK

55



B.9.6 Fuel Tank Filler Neck & Sight Tube - cont’d

?? ??

56



B.9.6 Fuel Tank Filler Neck & Sight Tube - cont’d

Not OK Not OK

57




- Electrical

• Battery Attachment

– Per B.11.4.1, “Must be attached securely to the frame.”

– Normal interpretation – metal hold down, no bungees!

• “Hot” terminal insulated, BN.11.4.3

– FS also requires “ground wire” to be tagged with yellow.

58



B.7.3 Brake Overtravel Switch

Not Activated Activated

59



B.7.4 Brake Light

The car must be equipped with a red brake light of at least 15 watts, or equivalent, clearlyvisible from the rear.

If an LED brake light is used, it must be clearly visible in very bright sunlight.

This light must be mounted between the wheel centerline and driver’s shoulder levelvertically and approximately on vehicle centerline laterally.

60



Percy’s Placement

Formula Hybrid Rule - The bottom 200 mm circle will be placed on the seatbottom with the center of the circle (”Percy’s” hips and buttocks) no less

than 91.5 cms (36 inches) from the rear face of the pedals in their most

forward position.

61



After Scrutineering - Tilt Test

45 degrees for Fluid Leaks 60 degrees for Stability

62



After Scrutineering

• Noise Test

– Simple test

– Test speeds at:• http://www.sae.org/students/fsaenoisetest.pdf

– Properly tuned exhaust does not rob power

– Get inexpensive meter and have it calibrated

– No ambient corrections

– Aim for 107 dBA max.

63



After Scrutineering

• Brake Test

– High stress on car. – Must try it to see.

– Must test (before going to Competition)!!

64



Summary, Do’s and Don’ts

• Do start NOW!

• Do have all team members look at the FSAE Tech Inspectors’

web site at:

– http://web.me.com/smr01/fsae_technical_inspection/Welcome.html

and – http://web.me.com/smr01/fsae_technical_inspection/Technical.html

• Don’t miss your dates.

• Do have your car inspected by a qualified outside party well

before the Competition.

• Do test, test, test!• Do including brake, noise and master switch tests!

• Do think safety ALL the time!

65



Copyright © 2011 Michael J. Royce. All rights reserved.Copyright © 2011

COPYRIGHT OWNERS name. All rights reserved.© 2011 COPYRIGHT

OWNERS name. All rights reserved. © 2011 COPYRIGHT OWNERS name.

All rights reserved.

66

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