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The ever challenging fight between strength and weight

Hey guys, Sasha here! When I began working at the Eco-Runner Team, I (as mathematician and physicist) never imagined that some day I would be doing structural analysis. Yet here I am, as Chief Structures, doing the work classically associated with Mechanical and Aerospace engineers. In this blog I shortly would like to tell you what I have actually done in this role over the last period, and how my background in the Applied Maths and Physics Bachelor has played a role in this. As Chief Structures I am responsible for the complete structural integrity of the body of the EcoRunner 9. The challenge is to make the car as light as possible while keeping strong enough. That means accounting for al the possible scenario’s in which forces are applied on the vehicle, and performing simulations to make sure the body is strong enough to withstand the force. An example such a scenario is carrying the vehicle with two people or simply the driver sitting inside. As for how light I am aiming for: About as light as a cat! To perform the necessary simulations, I use FEM software called ‘MSC Patran’ provided to us by InSumma, which together with Solico provide assistance and consulting during the process itself. With that help I am able to perform very accurate analyses of our body and can optimize it for weight. That process consists of three main steps: Firstly, the body has to be translated into the model, after which the possible load scenarios are integrated into the software. The final step is to iterate different structural designs. This in general means changing the type and amount of carbon fibre and honeycomb used. Now, most of the specific knowledge and skills that are required for this job, for example the concepts of stress or FEM analysis, are not discussed in my Bachelors. However, the general knowledge of numerical analysis, modelling and debugging, which I gained especially gained during my Bachelor Applied Mathematics has proven to be of high importance. With that, as well as the skill to find new creative ways to solve problems and understanding connections, I was able to perform the tasks at a high level and able to safe weight compared to the previous design. Looking to the future, I will have to adapt my model a bit to account for the changed rear-suspension design. After this I will create the lamination plan which the Lamination Department will use to produce the body. Then my job is done, and we will be another step closer to the lightest EcoRunner ever produced!

Using Scrum

It’s almost Christmas. This means that the end of the detailed design phase is in sight. This is the phase where everybody designs their subsystem to meticulous details. I have been working on the height control as electronics engineer: this means I design and produce the electric system and write the software for the actuation of the wings. Without proper height control we would not be able to fly! The detailed design phase is eight weeks long, which means that beforehand you have to make a planning to ensure we all make our deliverables. To help with maintaining this planning we have one person in the team who is busy fulltime ensuring that all people stick to their planning. In the case of people not sticking to their schedule, he will help them get back to it or look into the consequences and re-plan the yearly planning. We do need to have a working boat in July for Monaco, so this is an important job! To assist the planning our team makes use of a combination of Scrum and Waterfall methodology. Scrum is used a lot in software engineering so I was already familiar with this technique. Waterfall is used a lot more in other engineering fields, because it deals with tasks having to be done sequentially rather than when you feel like it. Because we are a multidisciplinary team, it works really well to combine these techniques. We start the week with department meetings, in which we update the engineers in our department what we did last week. Then you we ask ourselves questions like: “what do I need to do now?”, “What can I do within this week?” and “do I need to do certain tasks sequentially or on a certain date?” Then everybody makes a list of their to-do’s, and write them on a post-it with an estimation of the time it will take and a date if needed. Then we hang them on our scrumboard. To end this phase, we also needed to make a list of deliverables: these are tasks or concrete things that need to be completed by the end of the phase. In my list you can find among others: PCB design, choosing PCB components, connecting and reading of sensors. I finished all my deliverables a week early, which means that I could start on my production and enter the christmas break without stress! Happy holidays!

Collaboration between departments

As a member of the Software department in the Forze Hydrogen Electric Racing team, making the car ready to race is not only a one department’s job. Communication with the other departments is of high importance, especially with the departments were software is directly in contact with: Electronics and Control & Simulations. Collaborating with Electronics is necessary where software has to be written for newly designed hardware. The last project that was finished was an iteration of a new Power Distribution Unit, PDU for short, that gives power to all low-voltage components in the car, such as the embedded nodes, cooling pumps and sensors. The newly implemented sensors had to be read out correctly in software due to changes in the schematics, for example, series and parallel resistors to sensors changed. When implementing control in the car that was made by Control & Simulation, the Simulink model of a control system in the car is compiled to C++ which is put in the car. In the software, it must be made sure that all inputs and outputs are connected and integrated into the rest of the software. It was not always that the communication went smooth. A couple times, this resulted in long days and very short nights to integrate and fix software on time for an important test. However, the dedication of the whole team really shows when the people involved in preparation are ready to not stop working until problems are fixed and the car is ready to drive!

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The ever challenging fight between strength and weight

Hey guys, Sasha here! When I began working at the Eco-Runner Team, I (as mathematician and physicist) never imagined that some day I would be doing structural analysis. Yet here I am, as Chief Structures, doing the work classically associated with Mechanical and Aerospace engineers. In this blog I shortly would like to tell you what I have actually done in this role over the last period, and how my background in the Applied Maths and Physics Bachelor has played a role in this. As Chief Structures I am responsible for the complete structural integrity of the body of the EcoRunner 9. The challenge is to make the car as light as possible while keeping strong enough. That means accounting for al the possible scenario’s in which forces are applied on the vehicle, and performing simulations to make sure the body is strong enough to withstand the force. An example such a scenario is carrying the vehicle with two people or simply the driver sitting inside. As for how light I am aiming for: About as light as a cat! To perform the necessary simulations, I use FEM software called ‘MSC Patran’ provided to us by InSumma, which together with Solico provide assistance and consulting during the process itself. With that help I am able to perform very accurate analyses of our body and can optimize it for weight. That process consists of three main steps: Firstly, the body has to be translated into the model, after which the possible load scenarios are integrated into the software. The final step is to iterate different structural designs. This in general means changing the type and amount of carbon fibre and honeycomb used. Now, most of the specific knowledge and skills that are required for this job, for example the concepts of stress or FEM analysis, are not discussed in my Bachelors. However, the general knowledge of numerical analysis, modelling and debugging, which I gained especially gained during my Bachelor Applied Mathematics has proven to be of high importance. With that, as well as the skill to find new creative ways to solve problems and understanding connections, I was able to perform the tasks at a high level and able to safe weight compared to the previous design. Looking to the future, I will have to adapt my model a bit to account for the changed rear-suspension design. After this I will create the lamination plan which the Lamination Department will use to produce the body. Then my job is done, and we will be another step closer to the lightest EcoRunner ever produced!

Using Scrum

It’s almost Christmas. This means that the end of the detailed design phase is in sight. This is the phase where everybody designs their subsystem to meticulous details. I have been working on the height control as electronics engineer: this means I design and produce the electric system and write the software for the actuation of the wings. Without proper height control we would not be able to fly! The detailed design phase is eight weeks long, which means that beforehand you have to make a planning to ensure we all make our deliverables. To help with maintaining this planning we have one person in the team who is busy fulltime ensuring that all people stick to their planning. In the case of people not sticking to their schedule, he will help them get back to it or look into the consequences and re-plan the yearly planning. We do need to have a working boat in July for Monaco, so this is an important job! To assist the planning our team makes use of a combination of Scrum and Waterfall methodology. Scrum is used a lot in software engineering so I was already familiar with this technique. Waterfall is used a lot more in other engineering fields, because it deals with tasks having to be done sequentially rather than when you feel like it. Because we are a multidisciplinary team, it works really well to combine these techniques. We start the week with department meetings, in which we update the engineers in our department what we did last week. Then you we ask ourselves questions like: “what do I need to do now?”, “What can I do within this week?” and “do I need to do certain tasks sequentially or on a certain date?” Then everybody makes a list of their to-do’s, and write them on a post-it with an estimation of the time it will take and a date if needed. Then we hang them on our scrumboard. To end this phase, we also needed to make a list of deliverables: these are tasks or concrete things that need to be completed by the end of the phase. In my list you can find among others: PCB design, choosing PCB components, connecting and reading of sensors. I finished all my deliverables a week early, which means that I could start on my production and enter the christmas break without stress! Happy holidays!

Collaboration between departments

As a member of the Software department in the Forze Hydrogen Electric Racing team, making the car ready to race is not only a one department’s job. Communication with the other departments is of high importance, especially with the departments were software is directly in contact with: Electronics and Control & Simulations. Collaborating with Electronics is necessary where software has to be written for newly designed hardware. The last project that was finished was an iteration of a new Power Distribution Unit, PDU for short, that gives power to all low-voltage components in the car, such as the embedded nodes, cooling pumps and sensors. The newly implemented sensors had to be read out correctly in software due to changes in the schematics, for example, series and parallel resistors to sensors changed. When implementing control in the car that was made by Control & Simulation, the Simulink model of a control system in the car is compiled to C++ which is put in the car. In the software, it must be made sure that all inputs and outputs are connected and integrated into the rest of the software. It was not always that the communication went smooth. A couple times, this resulted in long days and very short nights to integrate and fix software on time for an important test. However, the dedication of the whole team really shows when the people involved in preparation are ready to not stop working until problems are fixed and the car is ready to drive!
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Students Amos Yusuf, Mick Dam & Bas Brouwer winners of Mekel Prize 2024

Master students Amos Yusuf, from the ME faculty (Mick Dam, from the EEMCS faculty and graduate Bas Brouwer have won the Mekel Prize 2024 for the best extra scientific activity at TU Delft: the development of an initiative that brings master students into the classroom teaching sciences to the younger generations. The prize was ceremonially awarded by prof Tim van den Hagen on 13 November after the Van Hasselt Lecture at the Prinsenhof, Delft. They received a statue of Professor Jan Mekel and 1.500,- to spend on their project. Insights into climate change are being openly doubted. Funding for important educational efforts and research are being withdrawn. Short clips – so called “reels” – on Youtube and TikTok threaten to simplify complex political and social problems. AI fakes befuddle what is true and what is not. The voices of science that contribute to those discussion with modesty, careful argument and scepticism, are drowned in noise. This poses a threat for universities like TU Delft, who strive to increase student numbers, who benefit from diverse student populations and aim to pass on their knowledge and scientific virtues to the next generation. It is, therefore, alarming that student enrolments to Bachelor and Master Programs at TU Delft have declined in the past year. Students in front of the class The project is aimed to make the sciences more appealing to the next generation. They have identified the problem that students tend miss out on the opportunity of entering a higher education trajectory in the Beta sciences – because they have a wrong picture of such education. In their mind, they depict it as boring and dry. In his pilot lecture at the Stanislas VMBO in Delft, Amos Yusuf has successfully challenged this image. He shared his enthusiasm for the field of robotics and presented himself as a positive role model to the pupils. And in return the excitement of the high school students is palpable in the videos and pictures from the day. The spark of science fills their eyes. Bas Brouwer Mick Dam are the founders of NUVO – the platform that facilitates the engagement of Master Students in high school education in Delft Their efforts offer TU Delft Master Students a valuable learning moment: By sharing insights from their fields with pupils at high school in an educational setting, our students can find identify their own misunderstandings of their subject, learn to speak in front of non-scientific audiences and peak into education as a work field they themselves might not have considered. An extraordinary commitment According to the Mekel jury, the project scored well on all the criteria (risk mitigation, inclusiveness, transparency and societal relevance). However, it was the extraordinary commitment of Amos who was fully immersed during his Master Project and the efforts of Brouwer and Dam that brought together teaching and research which is integral to academic culture that made the project stand out. About the Mekel Prize The Mekel Prize will be awarded to the most socially responsible research project or extra-scientific activity (e.g. founding of an NGO or organization, an initiative or realization of an event or other impactful project) by an employee or group of employees of TU Delft – projects that showcase in an outstanding fashion that they have been committed from the beginning to relevant moral and societal values and have been aware of and tried to mitigate as much as possible in innovative ways the risks involved in their research. The award recognizes such efforts and wants to encourage the responsible development of science and technology at TU Delft in the future. For furthermore information About the project: https://www.de-nuvo.nl/video-robotica-pilot/ About the Mekel Prize: https://www.tudelft.nl/en/tpm/our-faculty/departments/values-technology-and-innovation/sections/ethics-philosophy-of-technology/mekel-prize

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