AMZ News

www.amzracing.ch
AMZ News
March/April 2013
Interior view of the monocoque negative mould of julier
Main Sponsors
Premium Sponsors
Sponsors
Favourers
3M AG
Argotec AG
ASTORIT AG
Axpo Holding AG
Bender GmbH & Co. KG
BIONTEC
Bossard AG
C. Cramer GmbH & Co. KG (ECC)
CADFEM AG
Centre of Structure Technologies
Durovis AG
Dynamic Test Center AG
FE-DESIGN GmbH
Georg Utz AG
Gigatronik Technologies
H.A. Schlatter Fonds
HABA AG
Henkel & Cie. AG
HUBER+SUHNER AG
ILSEBO Handels AG
Jenny + Co. AG
Kronoswiss
KTR Kupplungstechnik AG
Labor Spiez
Leuthold AG
Pohland AG
Rheinmetall Air Defence
Rigi-Kühler AG
Rofam GmbH
RoViTec GmbH
SATW
Schreinerei Maag + Takacs AG
SKF Schweiz AG
suter-kunststoffe ag
tissa Glasweberei AG
Toho Tenax Europe GmbH
TRUMPF Maschinen AG
von Allmen AG – Kunststofftechnik
julier is rolling towards the starting line…
The production is in full swing and «julier» is taking shape.
The new AMZ M3 motor has turned for the first time and
the monocoque has been removed from the mould. The
battery box is mechanically ready and the suspension
parts are flowing in from our production partners. Read
more about the progress of the production on the following pages.
Main Sponsors with
confidence in the AMZ
Valuable support by
Premium Sponsors
We are very pleased that our six main sponsors from the
last few years have continued and expanded their cooperation with the AMZ. BMW Group, Caterpillar, EKZ, SR
Technics, RUAG and ThyssenKrupp Presta are all supporting AMZ Racing team again this season.
Many complex and sophisticated components and systems such as the inverter, motor an carbon parts could
not have been realised without the support of our premium sponsors and we are confident that, thanks to our
partners, we can expect a very successful season.
Rim at post production
Suspension
«julier’s» suspension consists of
many complex machined parts, that
are currently being manufactured in
the workshops of our partners SR
Technics, Polygona, libs, Rheinmetal
and Mecaplex
This year, the development of the
uprights, among other things, was
under the spotlight. The new requirements presented by the integrated
planetary gearbox in the upright,
have required us to develop a topologically optimized upright, which will
be cast at Georg Fischer.
Our partner Qualicut produced our
bell cranks, brake discs, inserts and
some other small parts with water-jet
cutting.
As soon as the parts arrive in mid
April, gluing of the A-Arms and assembling of the other suspension
parts will begin. At the same time,
Mecaplex are busy with the milling
and processing of the cores for our
new single piece CFRP rims. After
different tests on stiffness and behaviour under stress, we will continue
laminating until 14 rims are ready to
be used, so that we will have enough
rims for our race set, a set of wets as
well as a spare set and a few backup
rims.
Cell connections
Batteries
After an intensive manufacturing process, our cell packages are now almost complete. Each of the 16 cell
packages consists of 21 individual
cells and each one has the same
structure. This modular design simplifies the assembly on the one hand
and on the other hand ensures that
in case of failure, the cell packs can
be replaced without too much effort
and time.
Within a cell packet, the cells are
connected to each other through a
conductor pattern made of copper,
which has been optimized for the
anticipated flows. By using a laser
welding process, we have ensured
a low contact resistance and a minimal heating of the cells during welding. Finally the packages are merged
within the battery box by screws.
Parallel to the production of the cell
packets, the housing of the accumulator box has also been completed
and is thus ready for the assembly of
the cell packets, the cooling system
as well as the electronics of the battery management system.
Drivetrain
Great progress is being made in the
Powertrain module. The first of the six
AMZ M3 engines is complete, and is
now in test mode. Made up of many
0.1 mm thick, cobalt sheets, the rotor
and stator were made by our partner
Vacuumschmelze GmbH. The wiring
and winding of the stator as well as
the taping of the rotors took place
at Gebrüder Meier AG. The motor
shafts, which have axially extended
fins that transfer the torque from the
rotors, were manufactured by polygona AG and Argotec AG through
several lathe and wire erosion steps.
A spiral-shaped channel, milled into
the stator casing, holds the coolant
for the motor. The complicated stator
casing was also made by Polygona
AG. Durovis AG produced the housings of the motors.
The controller for the motors will be
made available by Lenze Schmidhauser, who will also support us
with the commissioning of the motors. The factory controller case has
been replaced by a self-made carbon
case, which leads to a considerable
reduction in weight. Likewise, a new
cooling plate was developed, which
is with water. Sauter Bachmann pro-
duces the oil-lubricated transmission
– which will be located in the wheel
hub. This concept allows a high ratio
in the smallest space. The gears will
be ready for installation in early April.
All bearings, as last year, will be supplied by SKF.
Impact attenuator at crash test
Chassis
AMZ‘s new race car, «julier» is literally taking shape. The team members
are working long hours to finish the
new one-piece CFRP-Monocoque.
The monocoque has already been
removed from the mould.
The boot lid and seat frame are finished and crash-tests with the new
nose have already been conducted.
The prepreg used this year is new
and the carbon fibres exhibit improved mechanical properties, and
allowed for further weight reducuction.
So far, the production of CFRP parts
has run according to schedule. This
is thanks to the support of our Partners Maag & Takacs, CNC Dynamix
and Connova who provide us with infrastructure and know-how throughout the manufacturing. Next we will
start with the production of the highly
anticipated aerodynamic parts.
We have documented the entire production of the monocoque and would like to carefully take you through the production steps of a CFRP part.
Production of our CFRP monocoque starts in the carpentry
Maag & Takacs. There, the MDF boards are cut to a rough
basic measurement, glued and then pressed together.
The rough MDF forms are then taken to CNC Dynamix,
where they are milled and brought into their final form.
Subsequently, the surface is repeatedly sanded, primed
and finally sealed with a clear coat.
The original forms are then used to manufacture a negative
mold using special tooling prepreg. The two half-shells also
undergo numerous procedures in order to ensure a high
quality surface. After the first layers have been laminated,
the negative forms are screwed together and then baked
in an autoclave.
An adhesive film is then inserted to insure the connection
between the aluminum honeycomb core and the outer layers. During this step, all of the carbon inserts are fitted and
placed carefully in their respective positions. Subsequently, the inner layers are laminated and the monocoque is
once again put into the autoclave to cure the prepreg. The
monocoque can then be removed from the mould!
Acknowledgement
We would kindly like to thank all of
our sponsors for their support without which we wouldn’t be able to
build «julier».
Main Sponsors
Premium Sponsors
Sponsors
Favourers
3M AG
Argotec AG
ASTORIT AG
Axpo Holding AG
Bender GmbH & Co. KG
BIONTEC
Bossard AG
C. Cramer GmbH & Co. KG (ECC)
CADFEM AG
Centre of Structure Technologies
Durovis AG
Dynamic Test Center AG
FE-DESIGN GmbH
Georg Utz AG
Gigatronik Technologies
H.A. Schlatter Fonds
HABA AG
Henkel & Cie. AG
HUBER+SUHNER AG
ILSEBO Handels AG
Jenny + Co. AG
Kronoswiss
KTR Kupplungstechnik AG
Labor Spiez
Leuthold AG
Pohland AG
Rheinmetall Air Defence
Rigi-Kühler AG
Rofam GmbH
RoViTec GmbH
SATW
Schreinerei Maag + Takacs AG
SKF Schweiz AG
suter-kunststoffe ag
tissa Glasweberei AG
Toho Tenax Europe GmbH
TRUMPF Maschinen AG
von Allmen AG – Kunststofftechnik