Formula E second-generation cars
The ongoing electric racecar series kicked off with new, longer-range vehicles for the 2018/2019 season.
No car swapping
Doubling the size of the batteries means drivers can finish races on a single charge instead of swapping vehicles mid-race as they did during the first four seasons of Formula E.
Spark Racing Technology
174mph top speed (up 24% from Gen. 1 vehicles)
|Gen 1. Formula E||Gen 2. Formula E|
|Max. power output||200kW (268hp)||250kW (335hp)|
|Acceleration 0 to 100kph (0 to 62mph)||2.8s||2.8s|
|Max. speed||225km/h (140mph)||280km/h (174mph)|
|Battery weight||320kg (705 lb)||385kg (849 lb)|
|Min. weight (including driver and battery)||920kg (2,028 lb)||900kg (1,984 lb)|
|Length||5,000mm (16ft, 5")||5,160mm (16ft, 11")|
|Width||1,780mm (5ft, 10")||1,770mm (5ft, 10")|
|Height||1,050mm (3ft, 5")||1,050mm (3ft, 5")|
After a decade working together, Joe Gibbs Racing manufacturing team members say they’re still getting new technologies and capabilities from workholding pioneer SCHUNK.
“We want to be able to design parts in-house, so we have 29 CNCs, all equipped with SCHUNK workholding,” says Mark Bringle, technical sponsor and marketing director for Joe Gibbs Racing. “Those machines make about 90% of all of the parts that make us successful.”
SCHUNK assists Joe Gibbs Racing by developing workholding solutions that enable machining of track-specific modifications for racecars. By getting car parts cut quickly, SCHUNK ensures that Joe Gibbs Racing stays competitive on the racetrack.
Gibbs machinists point to specific SCHUNK components that have made the difference in machining parts. Machinist Steve LaRoche says SCHUNK’s VERO-S quick-change pallet system dramatically changed how team members approached machining.
“We use the VERO-S system for ease of setup and more accurate setups,” LaRoche says. “We can go from machine to machine with the same fixture and save a lot of time. Before the VERO-S, we would use clamps and T-nuts and clamp them down. We’d have to indicate parts for machining. With the VERO-S, we can take our fixture, set them down on the modules and just be done.”
LaRoche also worked with SCHUNK when he ran into a problem maintaining parallelism when machining hollow tubes. Traditional workholding solutions were bending the parts.
“We were trying to figure out a way to manufacture these tubes better, so we contacted SCHUNK on a Tuesday,” LaRoche says. “They had a [magnetic gripping system] here on Thursday, and we were able to put parts in the car – the way we wanted them – on the racetrack on Sunday.”
Keith Nance, also a CNC machinist at Gibbs, says SCHUNK’s ROTA-THW power chucks have supported the need to move workpieces between multiple machines without refixturing.
“It allows us to change from one job to another. The setup time is cut nearly in half – to a matter of minutes,” Nance says.
Joe Gibbs Racing www.joegibbsracing.com
In 2003, Jack Roush and Robert Yates partnered with Ford Motor Co. as the exclusive Ford Engine builder for NASCAR. Now led by President and CEO Doug Yates, the company Roush Yates Engines was founded in Mooresville, North Carolina. Achieving 23 Championships, 357 combined wins, and 325 poles in the NASCAR, IMSA, and FIA, the partnership has been a vast success.
Roush Yates Engines has gone from success to success, with countless achievements and records broken along the way. For Roush Yates Engines, speed is the bottom line. In 2013, Michael Shank Racing, with Roush Yates Engines’ horsepower, set a new speed record in a Daytona Prototype car, of 222.971mph, at Daytona International Speedway with the twin-turbo Ford EcoBoost V6 race engine.
Ahead of the curve
A company obsessed with speed understands its importance, not just on the race track, but in developing the latest technological innovations. In such a highly competitive environment, it is vital to meet tight timelines and have the latest equipment on the track ahead of rivals.
To reduce costs and increase accuracy and repeatability, Roush Yates Engines installed a new iNEXIV Vision system. The system is now being used to measure various NASCAR engine components including gaskets, clips, O-rings, and radii on rollers – around 50 individual parts, totaling 50,000 parts per year. To deal with the workload, the speed and accuracy of the Vision system are irreplaceable. A major benefit is that it can access features of these small, fragile parts without contact for more reliable results.
“This system is extremely fast at measuring parts and gathering data. The greatest benefit to the speed is through CMM-Manager, programming new parts is extremely fast. With the touch probe, simultaneously programming vision and touch is easy and accurate,” says Alexander Morothy, Quality Control Technician & Vision Programmer, Roush Yates Engines.
The Vision system has had a major impact in evaluating a multitude of data points much faster than before. This means they can provide quicker answers for the Production and Engineering departments to respond to, address concerns and implement improvements. An example of this is pin checking small holes. The Quality department is now able to check very small holes on 100 pieces in 12 to 14 minutes, while simultaneously performing other inspection steps. This would previously take 20 to 30 minutes before any other steps could be performed, representing a 50% reduction in inspection time, and an enormous 97% reduction in labor time.
By reducing workflow bottlenecks, the Quality department is increasingly efficient in obtaining the most accurate results in a short span of time. The fast and accurate, highly repeatable measurements enable a shorter feedback loop between the Quality department, Production, and Engineering. This efficiency of teamwork is vital for bringing the latest innovations to fruition, quicker. Roush Yates Engines is winning both on and off the track with fast production, facilitating faster track performances.
Roush Yates Manufacturing Solutions, a division of Roush Yates Engines, has also leveraged the speed and accuracy of the iNEXIV Vision system to measure machined parts for the Aerospace, Defense, and High-Tech industries.
Roush Yates Engines
Mazak’s supportive involvement with Team Penske has continued to expand since its sponsor relationship began in 1994. Every Mazak machine tool in the Team Penske shop serves a unique purpose, but each offers consistent precision, speed, and performance, along with the versatility to adapt vehicle components to ever-changing tracks and series.
Speed, accuracy, automation capabilities, straightforward processing, workplace safety, and cost per part: Every advantage takes on even greater importance in the face of increasingly precise race technology and growing parity among competitors.
“To stay ahead, we rely on Mazak machines with multi-tasking, 5-axis, and DONE IN ONE® capabilities as well as large tool storage capacities, pallet changers, and easy programming for even our most-complex parts,” says Matt Gimbel, Team Penske Production Manager.
Mazak Multi-Tasking part-processing capabilities help Team Penske quickly and accurately generate wide-ranging production including cams, crankshafts, flywheels, pistons, steering arms, and knuckles, as well as components for drive trains, transmissions, and brakes. To reduce weight, some parts require up to 95% material removal, while other complex workpieces with multiple contoured surfaces can involve up to 30 tool changes during a 12-hour machining cycle time.
Within Team Penske’s North Carolina base of operations, its Mooresville machine shop supports 14 teams in five racing series, including Monster Energy NASCAR Cup, NASCAR Xfinity, NTT IndyCar, IMSA WeatherTech SportsCars, and Virgin Australia Supercars. That diversity means the shop operates like a high-mix, low-volume manufacturing facility.
Team Penske’s focus on ever-shorter lead times reflects constant production for its multiple teams. As race-day parts replacements respond to rule changes or on-track emergencies, Team Penske’s operations must turn on a dime.
“Without our Mazak machines, we would really be hard pressed to truly benefit from producing a part in-house,” says Team Penske Machine Shop Manager Rick Huneycutt.
Mazak’s support for Team Penske continues beyond the 11 Mazak machines on the shop floor all the way to training and application support.
“We don’t just partner with any organization,” Gimbel notes, adding that “They must be industry leaders that can get the job done and work with us in a win-win situation.”
Mazak’s regionally based support network, well-established machine service infrastructure, expert industry partners, and complete understanding of racing’s unique machining challenges enable the company to revolutionize the production of parts that must meet exacting standards – and survive grueling competition. As Team Penske continues to build its racing legacy, Mazak technology stands behind every competitive car and event.