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Bertrandt Composite Car 2 |
BCC2 – The vehicle developed by Bertrandt UK came 6th
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The event which the Times called the »Garden Party of the Gods« is one of the most impressive in the world. At the Goodwood Festival of Speed, which is held once a year near Chichester in the South of England, you will see the best cars, motorcycles and drivers from all the leading countries.
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Bertrandt was at the tenth festival from 11th to 13th July 2003 with its own vehicle and did well in the Soapbox Challenge.
The vehicle which Bertrandt UK decided to race was completed in just nine weeks, from design through development to production. The team working with Dave Roche, CAE (Computer Aided Engineering) Team Leader, worked very hard with the sponsors. The result was a soapbox which could stand alongside the best. |
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The short development time - other teams had had 52 weeks to do this - was met because this soapbox was developed exclusively in a virtual environment. Particular attention was paid to the aerodynamics, because the BCC2 had to be able to move as quickly as possible without power. The conditions set by the Goodwood race organiser also had to be observed. One good example is the size of the soapbox length 1950 mm, width 1100 mm and a maximum weight of 135 kilograms. The eye level of the driver sitting in the cockpit has to be at least 770 mm. Also the maximum wheelbase and track are specified exactly. The dimensions were checked via an ultimate test, »The Absolute Device« where a wooden crate without a floor with the corresponding dimensions is placed over each soapbox. If it is too big, it is not allowed to race.
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The virtual creation process
Virtual design starts with optimisation. When using composite materials, the calculation work is many times greater, which was the case with the BCC2. Taking into account all the specifications, and with the aid of a CAD model of the driver, Barry Lee, Dave Roche and his team designed the outer form of the vehicle. These vehicles were then used for the optimisation process, when an algorithm was used to determine the load paths through the vehicle.
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The composite layer was specified with the “Patrans Laminate Modelling” software. The sponsor, MSC, provided the licences for using the Patran program, Nastran and ADAMS – a new algorithm, which optimises the fibre direction and lamination. Using this technology, the partner succeeded in building a monocoque structure weighing 14 kg, but with a torsion strength of 40 KNm/degree. The chassis was made in a similar way. The ADAMS program was used to determine the optimum curvature, the best wheel after-running and also the track adjustment. A digital model of the slope was then simulated and the ADAMS Soapbox was driven down it virtually to test the settings.
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Vehicle Build
Hope Technology supplied high strength aluminium hubs and adaptable hydraulic brake discs for making the BCC2. SKF Advanced Composites Group provided the racing wheel bearings made in ceramic. These were made specially for the vehicle and had 40 percent less rolling resistance than comparable steel bearings. The Advanced Composites Group supplied various types of carbon fibres and other key materials for the monocoque construction; SPA Composites made the pre-calculated monocoque construction from these. To do this, the carbon fibres were laid in special moulds and cured in an autoclave for more than 200 hours - a process that requires considerable know-how.
The moulds were made on a five-axis milling machine from H. Eccles Patternmakers Ltd. The material consisted of special temperature-resistant high-density foam. The leather seat for the Bertrandt Composite Car was made by Protrim. All the components were assembled at Bertrandt UK in just two days – just in time for the qualification test for the race. On 3rd June, Bertrandt UK qualified for the Festival of Speed with its soapbox. The driver, Barry Lee, achieved some very impressive times, when the car reached a maximum speed of 108 km/h. The race was on... |
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