JAYEM AUTOMOTIVES COIMBATORE

DATE: 06.03.2012

1. JAYEM PROFILE
Jayem Automotives Limited can look back on 60 years of Indigenous Research and Development of the Engineering Products. It all started when Mr.D. Balasundaram developed Indias first indigenous electric motor in 1939. Jayem is Indias only independent knowledge-based automobile R&D Company and has over four decades of experience in Automotive Product Development.

1.1 JAYEM MOTORSPORT

Jayem motorsport is one of the leading motorsport businesses. For more than 10 years, they have been running race and rallying programmes for some of the biggest names in the sports.
They are incorporated with MRF. They are mainly doing re-engineering and building new racing and rally cars.

1.2 JAYEM PRODUCTS

Product Portfolio for Cars, UVs/MUVs/SUVs, Trucks & Buses:

BIW Structure Interior trim / Seats Exterior Trim / Bumpers Chassis systems (Suspension / Brakes / Steering / Fuel / Exhaust) HVAC Safety Systems & Occupant Protection Engine - Design / Development / Validation / Calibration / OBD / EMS Transmission - manual / automatic / CVT Electrical / Electronics

2. RACING CARS
Racing cars are cars specially designed for fast racing competitions in specially designed racing circuits. Jayam motor sport`s one of the indigenous product in this section is MRF Formula ford 1600. It is a single-seat, open cockpit, open-wheel racing car.

2.1 FORMULA FORD 1600

The MRF Formula 1600 is a single seater formula car having Van Diemen design chassis with a 1.6 L Ford Duratec Engine. The chassis is a multi- tubular chromely space frame which is bronze braced and Tig welded in the cockpit and foot well areas. The car has been designed by Elan Motorsports, USA. 2.1.1 MRF FORMULA 1600-SPECIFICATIONS DRIVE TRAIN 1.6L Ford Duratec Engine Power 130 bhp approximately Twin cam 16 valve Electronic engine controls Hewland 5 speed sequential shift gearbox

SUSPENSION Advanced push rod activated system opening on wide based oval section wishbones with the latest anti-intrusion bar requirements Alloy casting, heat treated uprights with large diameter angular contact bearings
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Anti sway bars adjustable front and rear Bilstein shocks, height adjustable

CHASSIS Multi- tubular chromoly space frame with bronze brazed and Tig welded in the cockpit and footwell areas. BODYWORK Formula One design features of a high nose, deep side pods and an engine cover with an air intake encompassing the roll hoop. BRAKES Light- weight, double- acting callipers with large diameter discs all around Cockpit adjustable bias

WHEELS Front Rear 8 x 13 10 x 13

One piece aluminum OZ centre lock rims

TYRES Front MRF 200/540 R13 Rear MRF 240/570 R13

DIMENSIONS (Approximately) Wheel Base Front track Rear track Weight 450 kg 2532 mm 1382 mm 1450 mm

AERODYNAMICS Front Wing Rear Wing Full width, with adjustable flaps Two upper elements, lower element mounted on gearbox, with end plates Bottom Flat (no ground effects)
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OTHERS Detachable steering wheel with inbuilt display Rack & pinion steering On-board 2.5 kg fire system Six point safety harness Fuel tank mounted behind the drivers seat Pi data logger

3. RALLY CARS
Rallying also known as rally racing is a form of auto racing that takes place on public or private roads with modified production or specially built road-legal cars. This motorsport is distinguished by running not on a circuit, but instead in a point-to-point format in which participants and their co-drivers drive between set control points (special stages), leaving at regular intervals from one or more start points. Rallies may be won by pure speed within the stages or alternatively by driving to a predetermined ideal journey time within the stages.

Jayem motorsports are also focus on Indian Rally Championship. Recently they won 2011 rally championship by driver Gaurav gill and co-driver Musa Sherif. The main cars used for rally are 1. Baleno 2. Lancer Cedia 3. Esteem 4. Indica 5. Ford Escort

3.1 FORD ESCORT RALLY CAR SPECIFICATION

ENGINE No. cylinder CC (x1.7 if turbocharged) Bore / Stroke (mm) Comp. Ratio Max.Power (bhp) Revs. Max.Torque (kg/m) Revs. Induction Turbo No. Valves No. + Position Cams Location

4 in line 1993 (3390) 90.8 / 76.9 9,6:1 300 5500 60 4000 Ford F8 IHI 16 2 Overhead Camshaft Front-Longitudinal

TRANSMISSION Location Differential (FrontCentral-Rear) Clutch (Manufacturer) Gearbox (Manufacturer)

4WD Active-Active-Mechanical Carbon (AP) 3 plate 6 speed sequential (Ford)

BRAKES Front / gravel Front / asphalt Rear / gravel Rear / asphalt

DV315 DV378 DV315 DV315

SUSPENSION (SHOCK ABSORBERS) Front Rear McPherson (HT/Dynamics) McPherson (HT/Dynamics)

DIMENSIONS Length (mm) Widht (mm) Height (mm) Wheelbase (mm) Front track (mm) Rear track (mm) Weight (kg)

4211 1770 1425 2550 1530 1530 1230

4. AERODYNAMICS DESIGN
In aerodynamic design, the designer has to take care of two things mainly. 1. Creation of down force to help push the car's tyres onto the track and improve cornering forces 2. Minimising the drag that gets due to turbulence that acts to slow the car down

4.1 AERODYNAMIC DEVICES Scoops

Scoops, or positive pressure intakes, are useful when high volume air flow is desirable and almost every type of race car makes use of these devices. They work on the principle that the air flow compresses inside an "air box", when subjected to a constant flow of air. The air box has an opening that permits an adequate volume of air to enter, and the expanding air box itself slows the air flow to increase the pressure inside the box.

NACA Ducts
NACA ducts are useful when air needs to be drawn into an area which isn't exposed to the direct air flow the scoop has access to. Quite often you will see NACA ducts along the
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sides of a car. The NACA duct takes advantage of the boundary layer, a layer of slow moving air that "clings" to the bodywork of the car, especially where the bodywork flattens, or does not accellerate or decellerate the air flow. Areas like the roof and side body panels are good examples. The longer the roof or body panels, the thicker the layer becomes (a source of drag that grows as the layer thickens too). Anyway, the NACA duct scavenges this slower moving area by means of a specially shaped intake. The intake shape, shown below, drops in toward the inside of the bodywork, and this draw the slow moving air into the opening at the end of the NACA duct. Vortices are also generated by the "walls" of the duct shape, aiding in the scavenging. The shape and depth change of the duct are critical for proper operation. Typical uses for NACA ducts include engine air intakes and cooling.

Spoilers
Spoilers are used primarily on sedan-type race cars. They act like barriers to air flow, in order to build up higher air pressure in front of the spoiler. This is useful, because as mentioned previously, a sedan car tends to become "Light" in the rear end as the low pressure area above the trunk lifts the rear end of the car. Front air dams are also a form of spoiler, only their purpose is to restrict the air flow from going under the car.

Wings
Probably the most popular form of aerodynamic aid is the wing. Wings perform very efficiently, generating lots of downforce for a small penalty in drag. Spoiler are not nearly as efficient, but because of their practicality and simplicity, spoilers are used a lot on sedans.
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The wing works by differentiating pressure on the top and bottom surface of the wing. As mentioned previously, the higher the speed of a given volume of air, the lower the pressure of that air, and vice-versa. What a wing does is make the air passing under it travel a larger distance than the air passing over it. Because air molecules approaching the leading edge of the wing are forced to separate, some going over the top of the wing, and some going under the bottom, they are forced to travel differing distances in order to "Meet up" again at the trailing edge of the wing. This is part of Bernoulli's theory. What happens is that the lower pressure area under the wing allows the higher pressure area above the wing to "push" down on the wing, and hence the car it's mounted to. Wings, by their design require that there be no obstruction between the bottom of the wing and the road surface, for them to be most effective. So mounting a wing above a trunk lid limits the effectiveness.

4.2AERODYNAMIC DESIGN TIPS

Cover Open wheels. Open wheels create a great deal of drag and air flow turbulence. Full covering bodywork is probably the best solution, if legal by regulations, but if partial bodywork is permitted, placing a converging fairing behind the wheel provides maximum benefit. Minimize Frontal Area. It's no coincidence that Formula cars are very narrow. It is usually much easier to reduce FA (frontal area) than the Cd (Drag coefficient), and top speed and acceleration will be that much better. Converge Bodywork Slowly. Bodywork which quickly converges or is simply truncated, forces the air flow into turbulence, and generates a great deal of drag. As mentioned above, it also can affect aerodynamic devices and bodywork further behind on the car body. Use Spoilers. Spoilers are widely used on sedan type cars such as NASCAR stock cars. These aerodynamic aids produce downforce by creating a "dam" at the rear lip of the trunk.

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This dam works in a similar fashion to the windshield, only it creates higher pressure in the area above the trunk. Use Wings. Wings are the inverted version of what you find on aircraft. They work very efficiently, and in less aggressive forms generate more downforce than drag, so they are loved in many racing circles. Wings are not generally seen in concert with spoilers, as they both occupy similar locations, and defeat each other's purpose. Use Front Air Dams. Air dams at the front of the car restrict the flow of air reaching the underside of the car. This creates a lower pressure area under the car, effectively providing downforce. Use Aerodynamics to Assist Car Operation. Using car bodywork to direct airflow into side pods, for instance, permits more efficient (ie. smaller FA) sidepods. Quite often, with some for-thought, you can gain an advantage over a competitor by these small dual purpose techniques. Another useful technique is to use the natural high and low pressure areas created by the bodywork to perform functions. A useful high pressure area is in front of the car, and to make full use of this area, the nose of the car is often slanted downward. This allows the higher air pressure to push down on the nose of the car, increasing grip. It also has the advantage of permitting greater driver visibility. Keep Protrusions Away From The Bodywork. The smooth airflow achieved by proper bodywork design can be messed up quite easily if a protrusion such as a mirror is too close to it. Many people will design very aerodynamic mounts for the mirror, but will fail to place the mirror itself far enough from the bodywork. Rake the chassis. The chassis, as mentioned in the aerodynamics theory section above, is capable of being slightly lower to the ground in the front than in the rear. The lower "Nose" of the car reduces the volume of air able to pass under the car, and the higher "Tail" of the car creates a vacuum effect which lowers the air pressure. Cover Exposed Wishbones. Exposed wishbones (on open wheel cars) are usually made from circular steel tube, to save cost. However, these circular tubes generate turbulence. It would be much better to use oval tubing, or a tube fairing that creates an oval shape over top of the round tubing.

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5. SPECIAL FEATURES OF RACING CARS

5.1 KERS
The acronym KERS stands for Kinetic Energy Recovery System. The device recovers the kinetic energy that is present in the waste heat created by the cars braking process. It stores that energy and converts it into power that can be called upon to boost acceleration. There are principally two types of system - battery (electrical) and flywheel (mechanical). Electrical systems use a motor-generator incorporated in the cars transmission which converts mechanical energy into electrical energy and vice versa. Once the energy has been harnessed, it is stored in a battery and released when required. Mechanical systems capture braking energy and use it to turn a small flywheel which can spin at up to 80,000 rpm. When extra power is required, the flywheel is connected to the cars rear wheels. In contrast to an electrical KERS, the mechanical energy doesnt change state and is therefore more efficient. There is one other option available - hydraulic KERS, where braking energy is used to accumulate hydraulic pressure which is then sent to the wheels when required.

5.2 SEQUENTIAL SHIFT MANUAL GEAR BOX

A sequential manual transmission (or sequential manual gearbox) is a type of manual transmission used on motorcycles and high-performance cars for auto racing, where gears are selected in order, and direct access to specific gears is not possible. With traditional manual transmissions, the driver can move from gear to gear, by moving the shifter to the appropriate

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position. This type of transmission is often referred to as a H-pattern because of the path that the shift lever takes as it selects the various gears. A clutch must be disengaged before the new gear is selected, to disengage the running engine from the transmission, thus stopping all torque transfer. In auto racing, this process is slow and prone to human error; hence the development of the sequential transmission. A true sequential transmission will very often use dog clutch engagement rather than the more usual synchromesh as fitted to a normal Hpattern road car gearbox. Engagement using dogs only requires a very brief interruption of engine torque to complete a shift into any adjacent gear. This allows shifting between gears without the use of the clutch. The clutch would normally be used only for standing starts.

5.3 STEERING WHEEL

A race car's steering wheel is the drivers tool through which he feels every characteristic of the track as he guides his race car through the corners.

The steering wheel has all controls and instrumentation of that particular race car. These includes throttle and brake pedals, semi-automatic gear changes, boost button for KERS, race control communication via GPS marshalling system, displays warning lights, alert drivers to approaching hazards. The racing car`s steering wheel doesnt need a continuous rim, instead there are just two 'cut outs' for the driver's hands.

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