Racing is a great way to test students' creative thinking and implementation skills from elementary school to university in various forms. Many schools and universities around the world have begun to implement programs that challenge students to design and build their own car races. Other students and schools compete in the international soapbox derby SAE equation, and college students design competitive style cars.
The first SAE Formula game took place in 1979; since then, it has expanded to multinational organizations around the world. A team of engineering students from the University of Connecticut has been participating in this competition since 2009. When they started planning their designs for this year's competition, the students decided that they could design their vehicles more efficiently if they had a 3D model of their engine.
To get help, the team turned to Bolton Works, a company specializing in 3D scanning, metrology and reverse engineering, for help, and asked if they could scan and create a detailed 3D model engine. Bolton Works agreed to help and began researching other engines that have been scanned and modeled in 3D.
"We didn't think so far when we looked at other universities," said Mark Bliek of Bolton Works. “What we noticed is that whether the models are very detailed, or they are built in a way that individual components cannot be closed.â€
The company wants to do better, so they start scanning the entire installation and converting the data into STL files. They then disassembled the engine and scanned each individual component, using 3D System's Geomagic software package. Using the scanned installer as a template, they reassembled the individual components into a new model with Geomagic Design X software. The final CAD part will be transferred to SolidWorks MCAD software.
“Before we had only this fuzzy model, there were only some engine reference points...but not very accurate,†said Jon Sobanski, chief engineer of UConn's SAE equation. “So when we got this new model, we were finally able to create a more complex connection to the engine. Not only that, but we were able to actually design the frame of our engine for the first time.â€
According to bliek, it takes at least six months for such a project to take the old software program. With the 3DSystem software, the company only took a month from start to finish.
“Bolton Works provided us with CAD data that allowed us to put all the parts together, they needed the perfect interval and the intake is perfect,†said team mechanic engineer Mikaela Worthington. “No one is possible if we try to simulate all of its hands.â€
The multiracial SAE competition took place on May 11-14 in Michigan. Despite some weather-related setbacks, the University of Connecticut team won the twenty-sixth place in 100 teams.
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