Formula Manipal
Formula Manipal is a Manipal Academy of Higher Education-based student project which aims to design, build and test a Formula-style race car. It started as an abstract idea in 2007, and today has become the biggest and most successful student initiative of Manipal University. The team consists of over fifty inter-disciplinary undergraduates who aim to conceive, design, fabricate, develop, and compete with other Formula style vehicles at International Formula Student events.
Formula Manipal has been competing in the international Formula Student competitions for the past ten years and made its debut in 2008 at FSAE Italy with the FM08. In the following year, 2009, the team participated in the Formula Student event in UK with the FM09. The team then had a successful participation in FS Austria with the FM-X, the season 2010 car. The year 2011 saw the development of the fourth prototype, the FMXI, which competed in FSAE Italy.
Season 2013 turned out to be the most amazing year for Formula Manipal in its history. For the first time, the team successfully participated in two FSAE events in the same calendar year with the FMX3. First, the team went to FS Germany and later to the FS Czech Republic.
FMX4, the season 2014 car scaled new heights at the Formula Design Challenge 2015 winning seven trophies in all after commendable performances in the Formula Student Germany and Formula Student Czech Republic 2014.
FMX6, the season 2016 car participated in 3 events which consisted of 2 international, FS Germany 2016 and FS Czech Republic 2016 and the first national Formula Student event, in the year 2017.
FMX8, the season 2018 car competed in 1 International Formula Student Competition-Formula Student at Austria where the team stood 26th internationally and 1 National Competition Formula Bharat in Coimbatore where the team stood 3rd overall making Formula Manipal one of the best nationally. This season also marked the first ever Formula Manipal Electric Vehicle, the FMX8e.
FM20 and FM20e is the newest addition to the fleet of Formula Manipal Racecars which participated in Formula Bharat 2020 and secured a position of 8th out of 51 participating teams.
Racing Seasons
Season 2007-08
FM08 participated at FSAE Italy in 2008 at the Ferrari Fiorano Circuit in Italy. It was the only Asian team participating at the competition. The car cleared all the static events. The team secured an overall position of 28th and stood 17th in the cost event.Comments
Awards
Technical Specifications of FM08
----Season 2008-09
Post season 2008, the team started its plan of action with the review of the last year's prototype, its shortcomings and its plus points, and setting the goals to be achieved by the technical and management teams. The team put all its efforts in examining the tiniest details to be taken care of, and thus laying a solid foundation for a fruitful year to follow. FM09 was sent to U.K. to ablaze the Silverstone F1 track. The team managed to reduce the wheelbase by 25% and the weight of the car by 16% compared to last year. Every design decision was taken keeping in mind the reliability, cost-effectiveness and ease of manufacturing of the component. The team secured an overall position of 65/88 and 10/88 in the cost event.Comments
Technical Specifications of FM09
----Season 2009-10
The FM-X participated in FS Austria held at Wachauring, Austria in 2010. The design process of FM-X began with the aim of completing all dynamic events with competitive scores. Performance improvements were made with the utilization of facilities like TTC tyre data, extensive dyno tuning and track testing along with an improved data acquisition system. Non-traditional methods like laser cutting and water jet cutting were used extensively for manufacturing components. The team obtained an overall position of 27th and secured the 4th position in the cost event. Also the FM-X was the “Lightest Indian FSAE car” at the competition.Awards
Technical Specifications of FM-X
----Season 2010-11
The team participated at FSAE Italy 2011 held at Riccardo Paletti Circuit, Italy in 2011 with the FMXI. After receiving the award for the ‘Most Motivated Team’ at FS Austria in 2010, the teamed returned to India and began work on the car for season 2011. The design focus was on weight reduction, improving handling and enhancing the overall performance of the car. The team did a lot of tuning and testing on the car and even held several track days. As an outcome of the installation of a new braking system, a reliable DAQ system, improved aerodynamics and testing, the team performed well at the event and stood 16th in the cost event.Technical Specifications of FMXI
----Season 2012-13
After the successful season of FMXI, the 2013 Season team decided to take a break for a year to build a light weight, faster and more ergonomic car. The team was able to successfully incorporate electro-pneumatic gear shifting along with a self-designed driveline. The team also improved its data acquisition system and a lot of components for the 2013 car were manufactured in-house.In 2013, Formula Manipal team aced the registration quiz for Formula Student Germany 2013 by clearing it in less than 72 seconds, thereby becoming the first team in the world to qualify for the event. The event was held at Hockenheimring, Germany in the end of July. The team stood 2nd in the cost report, becoming the first Indian team to get a podium finish in that season. The team cleared technical inspection on the very first day and performed well in the dynamic events. The FMX3 achieved an acceleration timing of 4.62 seconds. The team produced a better result in Formula Student Czech Republic 2013. Here the team created history by becoming the only Indian team to complete the endurance event while incorporating electro-pneumatic gear shifting, fetching an overall rank of 9th in the competition. Furthermore, it was the fastest Indian car in the competition with an acceleration of 4.51 seconds improving its best performance by 0.11 seconds. This was the first time in the history of Formula Manipal that their car participated in and completed all events at a Formula Student Competition.
Technical Specifications of the FMX3
----Season 2013-14
After a podium finish at Formula Student Germany 2013 in the Cost Analysis Event, the season 2014 team successfully completed the registration for both Formula Student Germany and Formula Student Czech Republic 2014. The team headed to Hockenheimring, Germany in the end of July 2014 where they easily cleared the Technical Inspection and the Tilt Test and also competed successfully in all the static events and finished 31st out of the 74 participating teams in the Business Plan Presentation. The FMX4 could not compete in the Dynamic events due to a sudden and unfortunate engine failure which could not be fixed in time. However, the team bought another engine in Germany as it was easily available and more economically feasible. The FMX4 then went to CzechRing, Czech Republic with a new engine aiming to blaze through all events. The team cleared all parts of the Technical Scrutiny with ease and also completed all the static events with commendable results. The car completed the Acceleration event with a timing of 4.81 seconds and Skidpad event with a timing of 8.120s. The car blazed through AutoCross with a timing of 71.710s. Unfortunately, the team could complete only half of the endurance due to a bent suspension bolt in the rear LHS pick-up point. Having competed at two international competitions, the team set about testing the car rigorously after it arrived home.At the next competition for the 2014 Season, Formula Design Challenge 2015, which was held at Kari Motor Speedway, Coimbatore, Formula Manipal became the first team to complete all parts of the Technical Scrutiny. Their performances in the Static events were commendable having attained a healthy 5th and 6th position in Business Presentation and Cost Analysis events and also bagging a podium in the Engineering Design with a 3rd Place finish. The FMX4 went on to break the existing National Record among all Indian FSAE Teams for Acceleration with a timing of 4.19s. The very next day, FMX4 clocked another great time of 5.76s in Skidpad where all the competitors could only manage 6+ sec. The same day, Formula Manipal finished 3rd in the Autocross event. On the last day for dynamic events, Formula Manipal stood 2nd in the Endurance and Efficiency events becoming the only team at the event to complete all the Static and Dynamic events and also finishing on the podium for all Dynamic events. During Endurance, the FMX4 was also the fastest car on track with the best lap time of 83.95s. Formula Manipal went on to win the most number of trophies, a total of seven and clinched the 2nd Position overall.
Technical Specifications of the FMX4
----Season 2016-17
After taking a break for Season 2015, and having won many laurels at the Formula Design Challenge 2015, Formula Manipal's next car, the FMX6 participated in Formula Student Czech Republic 2016 and Formula Student Germany 2016. The FMX6 design wise was far superior to its predecessors, having switched to 10 inch rims and successfully implemented a self-designed, Aluminum Honeycomb Impact Attenuator and dry sump lubrication system.The competition in Czech started out very well with Formula Manipal clearing the technical inspection and completing all static events successfully. In the Autocross event, there was an unfortunate complication with an engine causing it to fail. This resulted in the FMX6 not being able to compete in the autocross and endurance events. The team was the best Indian team in the competition securing an overall position of 16th in the competition with 5th place in the cost event.
The problem was quickly solved and the car was up and running in time for Formula Student Germany. Formula Manipal showed commendable performances in all static events, technical inspection, autocross and acceleration. Unfortunately, competing in the endurance eluded the FMX6 again as a fuel leak that came to notice during the pre-endurance inspection couldn't be fixed in time.
The team headed back to Manipal and after working on the car, competed in . The team finished 9th overall in Formula Bharat 2017. This included a podium finish in the Engineering Design Event and 5th place in the Cost and Manufacturing Event.
Technical Specifications of the FMX6
| Car Number | • 296 • 96 |
| Chassis | • Steel tubular space-frame chassis. • AISI - 1018 round steel tubing • TIG welded with ER70-S2 low carbon alloy steel filler. |
| Body | • CFRP |
| Wheels | • 10 inch Aluminium Alloy Rim 6061 T6 Kiezer wheels with Aluminium 7075 self designed wheel centers |
| Tyres | • Hoosier 18 x 7.5 - 10 racing slicks |
| Engine | • 2006 model Honda CBR 600 RR PC-37 |
| Engine Displacement | • 599.36 cc |
| Fuel type | • 98 RON Gasoline |
| Power | • 80BHP@10000RPM |
| Torque | • 57N-m@8000RPM |
| Brakes | • Front and rear disc brake system with ISR 4 Piston and Wilwood PS1 2 Piston Calipers |
| Suspension | • Double unequal wishbone. front-pullrod and rear-pushrod actuated shocks with blade adjustable anti roll-bar |
| Steering | • Steering Rack Ratio: 6.33:1 |
| Transmission | • Drexler Clutch Type Limited slip Differential with 3 pairs of torque biasing ratio • Final Drive ratio of 34:11, titanium half shafts, DID 520 series X-ring chain and linear chain tensioning mechanism • Electro-pneumatic gear shifting for better shift time • Electro-pneumatic clutching for simpler pedal assembly and smaller front bulkhead |
| Electronics | • Motec M400 ECU • NI MyRio used in cojuction with AiM EVO4 for wireless data logging • Shifter light, button shifter and fuel indicator with customized power distribution for driver aid |
| Ergonomics | • Driver visibility- 210 degree side visibility |
| Total Weight | • 203 kg |
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Season 2018-19
The team began fresh for the new season and made the FMX8. The FMX8 participated in Formula Student Austria 2018 in which the team stood 26th internationally. This season Formula Manipal also manufactured its first ever Electric Vehicle, the FMX8e.The FMX8 and FMX8e also competed in Formula Bharat 2019 where it performed extraordinarily. The team stood 3rd overall out of the 72 teams that competed along with standing 1st in the Acceleration event, 1st in the Business Presentation and 3rd in the Endurance event in the Combustion category and 2nd in the Design Event in the Electric category.
'''Technical Specifications of the FMX8'''
'''Technical Specifications of the FMX8e'''
----'''Season 2019-20'''
Formula Bharat 2020 opened the tracks for Formula Manipal's latest cars the FM20 and the team's second electric car, FM20e. The 6 day event was ever ready to test the FM20 and FM20e vigorously. The Combustion Vehicle stood 8th overall out of the 52 competing team whereas the Electric Vehicle stood 6th out of 12 competing teams.FM20 topped the Autocross Challenge with a best time of 92.244 seconds. The team also won a couple of Special Awards by Ather Energy – the “Code Hatchers” and “YourSoftwareStory” awards in which Formula Manipal Combustion and Formula Manipal Electric team were both the finalists in each.
FM20
The car cleared the mechanical inspection, tilt test and noise test by Day 2 of Formula Bharat. The newest addition to the car, Brake System Plausibility Device helped in clearing the Brake Test on Day 3 which in turn caused a battery issue the following day. Due to this FM20 could not run in the Skid Pad and Acceleration events.
FM20e
In the accumulator inspection, the container cleared all the mechanical and circuitry points given in the technical inspection sheet but due to a component failure during the live test at the end stages of inspection, the team was unable to clear Technical Inspection. The team has taken all positive and negative aspects of the overall experience and are determined to come back stronger than ever.
'''Technical Specifications of the FM20'''
| Car Number | • 02 |
| Engine | • HONDA CBR600 RR PC-40 • 599 cc Displacement • Power: 79BHP • Torque: 53 N/m |
| Electronics | • MoTec M400 ECU. NI MYRIO and Mini M4 STM32 used for Data Acquisition and Telemetry • RPM LED Display, Auto Upshift and Auto Clutch Downshift for Driver Aid |
| Suspension & Steering | • Independent Double Wishbone Pull rod Front and Rear Suspension • Penske PS-78-PB Dampers • Adjustable Ackerman |
| Body | • Vacuum Bagged Carbon Fibre Bodywork |
| Tires & Wheels | • Keizer 10" Aluminium Wheel Centers • Aluminum 7075 Self Designed Wheel Centers • Hoosier R25B Slicks |
| Brakes | • Front and Rear Disc Brakes with ISR4 Piston • Wilwood AP Racing 2 Piston Calip |
| Ergonomics | • Driver Size Adjustments: • Fixed Seat and Steering Wheel • Pedal adjusts fore and aft 25mm from the center position • Seat: Wet Lay-Up Carbon, Padded Lumber and Knee Protection, 60mm Etha Foam Head Support • Driver Visibility: 210 degree Side Visibility |
| Transmission | • Drexler Differential with 3 Pairs of Torque Biasing Ratio • Electro-Pneumatic Shifting and Clutching • Final Drive Ratio of 30:11 Band Titanium Half Shaft |
| Total Weight | • 216 kg |
'''Technical Specifications of the FM20e'''
| Car Number | • e03 |
| Powertrain | • Water Cooled EMRAX 208 • Peak Power: 80kW • Peak Torque: 140 Nm • Air-Cooled Accumulator made up of 84 EPS Cells in 8451P Configuration • Maximum 352.8V and Maximum 7.7 kWh |
| Body | • Vacuum Bagged Carbon Fibre Bodywork |
| Brakes | • Front and Rear Disc Brakes with ISR4 Piston • Wilwood AP Racing 2 Piston Calip |
| Chassis | • Steel Tubular Space - Frame Chassis • Manufactured using AISI 1018 Ground Steel Tubing • Welded using TIG Welding with ER70 - S6 Low Carbon Alloy Steel Filler |
| Tires & Wheels | • Keizer 10" Aluminium Wheel Centers • Aluminum 7075 Self Designed Wheel Centers • Hoosier R25B Slicks |
| Electronics | • RMS PM100DZ Motor Controller with Robust Fault-Tolerant IGBT Stage and Active DC-Link Discharge • Custom LTC based BMS with efficient Self-Developed Cell Balancing • Custom Data Acquisition System with Inverter Data Logging |
| Transmission | • Epicyclic Planetary with 4.5 Gear Ratio • Titanium Half Shafts with Tripod CV Joints • 7 Series Aluminum Machined Spool and Spool Mounts |
| Total Weight | • 240 kg |
Formula Student Austria 2020
The Electric team qualified for FS Austria while the Combustion team cleared the quiz for both FS East and FS Austria. Choosing to focus our efforts on one competition, Formula Manipal made the decision to compete with our CV and EV at FS Austria 2020, which was to be held from the 26th to 30th July, 2020.
But in light of the COVID-19 outbreak, Formula Student Austria 2020 has been officially cancelled and the team's next competition is going to be Formula Bharat 2021 where the team is hoping to come back stronger than ever.