Continuous and coordinated effort over a period of time to bring improvements to the purpose of playing Formula One is a constant improvement. Every weekend of racing, each lap on the track, each day in the factory.
The total sum of this improvement, in every single department within the Tea, is aimed at improving efficiency on the track. Indirectly or directly, every single task done in the factories can make an impact.
Making the perfect F1 automobile, then getting that speed to the track, is a complicated procedure. We’ve broken it into pieces and made it easy to comprehend by presenting seven key steps.
Table of Contents
1. Evaluation
In the course of the season, the car, along with our knowledge of it, is constantly changing. This is due to the work that is done in the factory and on the race track, as you’ll read in this article. It’s a constant, circular process, and we begin with assessing ways in which we can enhance the car by using the data and tools available. In essence, this could be accomplished in two different ways.
The first section examines the aerodynamics, which refers to the surfaces that are ‘wetted’ of the car that are visible from the outside. exterior bodywork and downforce-generating elements of the vehicle.
The second component is the development of the chassis, which comprises the fundamental components underneath the bodywork, like suspension and steering, as well as cooling and brakes. Aerodynamics and the development of the chassis can have an impact on both, with an effort to improve both.
Alongside the overall speed of development that the vehicle is undergoing, we also look at specific improvements for events like rear wings with low downforce for tracks such as Spa-Francorchamps, as well as Monza. The direction of development for the car is also subject to change; however, we always aim to achieve the highest performance.
We must operate within two significant constraints in terms of the time frame and our budget. We must optimise our resources in order to focus on areas that result in the greatest efficiency. Due to the cost cap, it is also impossible to look at every option or aspect, which suggests it could bring efficiency. In this article, we’ll opt to focus on what it looks like when we introduce aerodynamic improvements via the method.
2. Aerodynamics
The Aero Department the initial step is to decide what we’d like to do to enhance the airflow that flows around the vehicle. After deciding on the areas we’d like to investigate, the team then looks into ways to implement these improvements within the guidelines we’ve set.
It’s then about evaluating the various options to determine whether we can alter the flow field in a manner we’d like to. If it’s a success in the Computational Fluid Dynamics (CFD) tests, it will then be sent through the Wind Tunnel, where it will be incorporated into our model at a 60% scale car and put to its tests. This is when we will have a better idea about whether it has better performance or not. As part of the effort to improve the performance of the grid closer, there is a limited duration of the wind tunnel duration, which teams are permitted to utilise based on their current performance on the track.
This is the place where the next step comes in…
3. Simulations
A growing area in recent times is computer-generated simulations.
We can simulate the effects of the changes we make to the vehicle, since changes both externally and internally influence the way it performs. We would not wish to divulge too much information at this point; however, there are a myriad of ways to model this and a myriad of data points that we can analyse.
A few of the most significant or exciting updates will be evaluated in our Driver-in-Loop simulator, which will give us real-time feedback and also delve deeper into the data to determine whether the update is performing exactly as we expected. You may have seen videos inside our simulator, showing drivers engaged in virtual laps in order to improve our understanding of the latest updates before moving to the next step in the procedure.
4. Sign Off and Manufacturing
A lot of the parts on the F1 car are manufactured at our own facility. The process of making these is very extensive. Some are able to be manufactured quickly, often within a single day in some instances, but others may take a few weeks to finish.
In the case of an aerodynamic piece, if the information that we have gathered indicates that it can bring about gains in performance and is effective in terms of reducing lap times, it is deemed to be approved. The surfaces are transferred to Aero for a Design group, which creates a model or drawing that is sent directly to manufacturing. The moulds and patterns are designed for the component before it is put into the Composites.
Then, they layer the carbon fibre part and cure it in autoclaves, then machine it into the desired shape and then test the product using Test & Development or Non-Destructive Testing, based on the piece. They’re cut and glued (if they’re composed from multiple parts) and then taken to an examination for final approval, and then on to the Build department to be prepared to be used on the track.
For parts that are not carbon fibre, they are subject to similar stages of design, production (in the Machine Shop, for instance), as well as testing and final assembly. They are all tested to extremely small tolerances, and with astonishing precision to ensure they provide the necessary performance and endurance.
It’s a massive departmental effort in order to get the parts on the right track. We can react in the event that parts get damaged or need to advance an item that performs, with the time required to make the item work in relation to its dimensions and its complexity.
For a bigger upgrade, several months will be spent preparing manufacturing, testing and assembling the upgrade program before it ever reaches the destination of its flight: the track. It doesn’t end there, either.
5. On-Track Analysis: Data
When the update is on track, we have to determine if the update is working as we had hoped. There are hundreds of sensors throughout the car that can assist in this. Aerodynamic engineers working at the track, as well as within Brackley’s Race Support Room in Brackley, will be looking over the data at a real-time pace while the car is in motion and evaluating whether it is functioning exactly as it is supposed to. Particularly for smaller components or for a single component that is new.
When working with large update packages, it’s harder to analyse their performance over one race weekend. It is also important to ensure that we’re recording data from previous races in order to assess the results against.
We’re also looking for specific changes, such as enhancements at certain corners or in particular phases of a corner. The engineers will also be comparing the results to the Wind Tunnel data to see whether it is in line with.
6. On-Track Analysis: Drivers
Sometimes described as the most crucial sensor inside the car, drivers play an important role in helping us comprehend the car, as well as any updates that we send.
The trackside engineers collaborate with them to optimise the configuration of the vehicle that is impacted by upgrades. However, in a major upgrade, the feedback from drivers is crucial to understand the modifications in the car’s behaviour and if it’s providing the handling and performance desired.
Drivers have to identify particular events in the lap which indicate how the car behaves and then relay those observations to engineers after and during the session. We are fortunate to have two pedallers who excel at this!
7. Debrief and Progress
The reasons uncovered by engineers and drivers will be discussed throughout the weekend to decide whether the upgrade is working.
The work is carried out in the factories throughout the weekend and into the days following. Many departments examine the data, report the findings, and then decide on what next steps to take from there.
Now we’re back to the beginning! The process continues through the entire season when we compete on the track and back at the base to beat our opponents.
