DJS Racing
DJS Racing (DJSR) is a formula-student racecar design team from Dwarkadas J. Sanghvi College of Engineering. The team is currently based in Vile Parle, Mumbai, India and was conceptually founded in 2012 with the purpose to represent its university at the international Formula Student and national Formula Bharat competitions.
 | |
| Full name | DJS Racing |
|---|---|
| Base | Vile Parle, Mumbai, India |
| Faculty Advisor | Vinit Katira |
| Team Captain | Abhishek Deshpande |
| Team Manager | Karan Vora |
| Finance Manager | Meherdev Gudela |
| Marketing Manager | Aanchal Gandhi |
| Manufacturing Head | Viraj Shah |
| Vehicle Dynamics Technical Head | Ishaan Maurya |
| Powertrain Technical Head | Saurabh Pednekar |
| Website | www |
| Formula Student Competitions | |
| Debut | 2014 Formula Student Germany |
| Latest race | Formula Bharat 2020 |
| Competitions competed | Formula Student Germany- 2014, 2017, 2019 Formula Student Austria- 2018 Formula Student India- 2016 Formula Bharat- 2017, 2018, 2019, 2020 |
The team went on to make its first international appearance at the Formula Student Germany competition in 2014. It has won a total of three international titles and six national titles from 2014-2020. DJSR has become one of the most successful Indian teams in recent Formula Student history, being the best overall ranked Indian team in FSG17 and the only Indian team to have designed and manufactured 2 cars in the 2018-19 season. It hence became the first Indian Team to participate in Formula Bharat in the electric, as well as combustion category. It was bestowed the special recognition, "Never Give Up" award in FSG19.
The competition requires students to use their engineering concepts to design and manufacture a single-seater high performance race car in the most cost efficient manner and the team designs and manufactures at least one model every year.
Racing seasons
Season 1 (2014)
DJS Racing debuted in Formula Student Germany 2014 with its first prototype DJSR 01. With a group of 20 students and limited resources the team successfully managed to come up with a single cylinder open wheel racing car which was among the fastest teams to clear scrutineering. The team also placed 24th in the business event, making it 5th among the Indian teams overall, a remarkable feat for a debutant.[1] Due to minor technical glitches the team couldn't compete in the dynamic events but learned a lot from the experience which paved the way for future advancements.
Technical specifications of DJSR 01
| Car Number | •77 (FS Germany) |
|---|---|
| Chassis | •AISI 1020 Steel Tubular Space Frame
•TIG welding with 1020 steel filler material |
| Body | •Glass Fibre |
| Wheels | •Custom 3 Piece Aluminium center wheels |
| Tyres | •Hoosier 205x55 R13 racing slicks |
| Engine | •2010 Royal Enfield Bullet 500
•498.8 cc (30.43 cu in) air-cooled single cylinder •3D Printed Intake Manifold |
| Power | •27.2BHP@5250RPM (on wheels) |
| Torque | •41.3N-m@4000RPM (on wheels) |
| Brakes | •Wilwood GP310 Calipers with 220mm rotors |
| Suspension | •Double unequal length A-arm
•Pullrod actuated horizontally oriented spring and damper,Pull type actuated vertical |
| Steering | •Steering Ratio: 12:1 |
| Transmission | •Torsen Type 1 Differential
•1:3 Bias Ratio •Chain Drive with Halfshafts |
| Total Weight | •248 kg |
Season 2 (2015-16)
The DJSR 02 was built using a KTM Duke 390 engine, with the aim of reducing weight and thus boosting accelerating capability. The second prototype weighed just under 200 kilograms, achieving a 30% weight reduction over the previous variant. With this car the team competed at Formula Student India 2016, securing a 6th position overall despite being a first-year team at the competition.[2] The all-inclusive transmission and suspension design, along with the compact packaging of the car, led the team to securing a coveted 4th position in the design finals. The team's well-maintained finances and budgeting resulted in the team placing 2nd in the cost event. DJSR 02 was among 9 teams who competed in the endurance event. The judges acclaimed the team's design methodology and saw great potential in the team.
Technical specifications of DJSR 02
| Car Number | •77 (FS India) |
|---|---|
| Chassis | •AISI 1020 Steel Space Frame
•TIG welding with carbon steel filler material •FEA validated |
| Body | •Glass Fibre |
| Wheels | •10" 3 piece Aluminium Keizer Rims
•Custom Aluminium Wheel Centre. |
| Tyres | •Hoosier 18x6x10" racing slicks |
| Engine | •2013 KTM Duke 390
•373.2 cc (22.78 cu in) liquid-cooled single cylinder •3D Printed Intake Manifold and SS Exhaust Manifold |
| Fuel type | •95 RON gasoline. |
| Power | •43BHP@ 9500RPM |
| Torque | •35N-m@ 7250RPM |
| Brakes | •ISR Calipers with 180mm rotors |
| Suspension | •Penske Quarter Midget from Kaz Technologies
•Double unequal length A-arm •Pullrod and Pushrod actuated horizontally oriented spring and damper |
| Steering | •Steering Ratio: 3.96:1
•Carbon Fibre and Foam Steering Wheel with 3D Printed Handles. |
| Transmission | •Torsen Type Limited Slip Differential
•Electronic Button Shifting with Clutchless Upshifting. •Chain Drive with unequal length Halfshafts |
| Electronics | •Performance Electronics PE3 ECU
•Custom Wiring Harness •Real-time LED RPM Display |
| Ergonomics | •Adjustable Pedal Box |
| Total Weight | •199.5 kg |
Season 3 (2016–17)
DJSR 03's first competition was Formula Bharat 2017 held in Coimbatore where they finished 6th overall. They were awarded 1st Prize in Design Event because of their excellent skills on validating the concepts behind designing the car. Along with this, they performed really well in static events and were 2nd best in Static events and 3rd most fuel efficient car at the competition.
The team even qualified for Formula Student Germany by being the 10th fastest team to clear the quiz all around the world. For this event, the car was upgraded after its Indian competition by implementing Drexler Differential, Data Acquisition System, etc. It was acclaimed the Best Indian team at the competition and was the 2nd best Asian team too. They secured 41st position overall with 13th place in Cost event, 16th place in Design event and 23rd place in Business Presentation. Also, it was the sole Indian team to complete all Dynamic events
Technical Specifications of DJSR 03
| Car Number | •347 (FS Germany), Formula Bharat |
|---|---|
| Chassis | •AISI 1020 Steel Space Frame
•TIG welding with carbon steel filler material •FEA validated |
| Body | •Carbon Fibre |
| Wheels | •10" 3 piece Aluminium Keizer Rims
•Custom Aluminium Wheel Centre. |
| Tyres | •Hoosier 18x6x10" racing slicks |
| Engine | •2016 KTM RC 390
•373.2 cc (22.78 cu in) liquid-cooled single cylinder •3D Printed Intake Manifold and SS Exhaust Manifold |
| Fuel type | •95 RON gasoline. |
| Power | •27 BHP at 8500 rpm |
| Torque | •30 Nm at 7500 rpm |
| Brakes | •ISR Calipers with 184mm rotors |
| Suspension | •Penske Quarter Midget from Kaz Technologies
•Double unequal length A-arm •Pullrod and Pushrod actuated horizontally oriented spring and damper |
| Steering | •Steering Ratio: 3.18:1
•Carbon Fibre and Foam Steering Wheel with 3D Printed Handles. |
| Transmission | •Drexler Limited Slip Differential
•Electronic Button Shifting with Clutchless Upshifting. •Chain Drive with unequal length Halfshafts |
| Electronics | •Performance Electronics PE3 ECU
•RaceCapture Pro DAQ and Wireless Telemetry •Custom Wiring Harness •Real-time LED RPM Display |
| Ergonomics | •Adjustable Pedal Box |
| Total Weight | •181 kg |
Season 4 (2017-18)
The team redesigned most of their components to improve the car's performance and explored upcoming materials and manufacturing techniques to optimize the overall construction of the car. The team introduced ergonomically designed components, CF Undertray and much more and with extensive testing and driver training. As for DJSR E01, it was the first electric race car by DJS Racing. This car was a result of a year and a half of study and research and focuses on developing a reliable powertrain for the upcoming cars. At Formula Bharat from that season, DJSRacing was the only team that had brought two cars to the competition(One Team- Two Cars). The team won the first prize at Formula Student Austria 2018's cost event with this season. For the 2018 season, it also achieved the 16th rank in business plan presentation, 17th in the design event and 23rd overall. As for Formula Student Austria 2019, the team placed second in the design event, third in the cost event, fourth in endurance and fourth overall.
Technical Specifications of DJSR 04
| Car Number | •77(FS Austria), 04(Formula Bharat) |
|---|---|
| Chassis | •AISI 1018 Steel Tubular Spaceframe.
•Self-Designed and Optimised Aluminium 7075 Removable Rear Bulkhead •Ergonomically designed according to the needs of the drivers •Compact and lightweight Aluminium Honeycomb Impact Attenuator |
| Steering | •3D Printed Ergonomic Steering Wheel
•Carbon Fibre Steering Column •Krontec Quick Release •Carbon Fibre Tie and Toe Rods •Newly Incorporated Gear Shifting and Clutch Actuation Paddles |
| Aerodynamics and composites | •In-house manufactured CFRP Bodyworks and Undertray
•CFRP seat designed specifically for the drivers •All components manufactured using Vacuum Bagging process •Lantor Soric Core Material incorporated for stiffness |
| Electronics | •Custom Programmable Performance Electronics PE3 ECU
•Custom Wiring Harness •Custom Power Distribution Module •Paddle Controlled Servo Motor Actuated Clutch •RaceCapture Pro MK3 Data Logger and Telemetry |
| Suspension | •Double Unequal Length CFRP A-Arms
•Push/Pull Rod Actuation at the Front and Rear •Ohlins TTX125 Adjustable Damping System •Hoosier R25B 18 x 6 – 10” Racing Tires •Keizer Aluminium Rims •3 Way Adjustable Stiffness Z Type Anti-Roll Bar |
| Brakes | •Self-Designed Custom Rotor
•Driver Adjustable Ergonomic Pedal Box Assembly •ISR Front Calipers and Custom Calipers for Rear Wheels |
| Engine | •Water Cooled KTM RC 390 Engine
•Self-Designed Cooling System •Intake Manifold 3D Printed with HP Multi Jet Fusion Technology •Custom Made Lightweight Titanium Exhaust Header and Muffler •High Performance In-line Fuel System •ECU : PE3 |
| Transmission | •Power Transmission via Chain on Rear Axle
•6 Speed Sequential Transmission System •Paddle Controlled Electro-Pneumatic Gear Shifting System •Drexler Limited Slip Differential |
| Power | •33.5 BHP at 8000rpm |
| Torque | •32 N.m. at 7500rpm |
Technical Specifications of DJSR E01
| Car Number | •02 |
|---|---|
| Chassis | •AISI 1018 Steel Tubular Spaceframe.
•Self-Designed and Optimised Aluminium 7075 Removable Rear Bulkhead •Ergonomically designed according to the needs of the drivers •Compact and lightweight Aluminium Honeycomb Impact Attenuator |
| Steering | •3D Printed Ergonomic Steering Wheel
•Carbon Fibre Steering Column •Krontec Quick Release •Carbon Fibre Tie and Toe Rods •Newly Incorporated Gear Shifting and Clutch Actuation Paddles |
| Motors | •Saietta motors 119r (air cooled)
•Peak torque 64.69 N-m •58 rpm/volt |
| Suspension | •Double Unequal Length CFRP A-Arms
•Push/Pull Rod Actuation at the Front and Rear •Ohlins TTX125 Adjustable Damping System •Hoosier R25B 18 x 6 – 10” Racing Tires •Keizer Aluminium Rims •3 Way Adjustable Stiffness Z Type Anti-Roll Bar |
| Brakes | •Self-Designed Custom Rotor
•Driver Adjustable Ergonomic Pedal Box Assembly •ISR Front Calipers and Custom Calipers for Rear Wheels |
| Accumulator | •A123 pouch cells (90 cells)
•Cell configuration 45s2p •Available energy 6.840 kWh |
Season 5 (2018–19)
DJSR05 was the latest and final combustion car manufactured by DJS Racing. The best car manufactured so far, owing to the considerable amount of time spent on testing and prioritizing performance in this iteration. Equipped with a full aero package and data acquisation system had resulted in the better performance of '05 as compared to the previous prototypes. The car was built with a focus on data acquisition and reliability. In the face of an unforeseen critical failure on day zero of FSG 2019, the judges deemed the car to be not potent enough to be running. Following that, the team put in a tremendous amount of efforts to get the car back up and running. The car performed in dynamic events and it was the fastest car in the engine category in the autocross event in FSG 2019. DJSRacing was awarded the “Never give up” award in recognition of perseverance by the judges. It scored the fourth highest in the cost event at FSG19. In Formula Bharat 2020, the team landed first in the cost event, 8th in the business plan presentation and second in the skidpad event. It finished its season with Formula Bharat 2020. Keeping in mind the value of environmental sustainability, DJS Racing is going to manufacture and design only Electric Vehicles henceforth.
Technical Specifications of DJSR05
| Car Number | •347 (FS Germany) |
|---|---|
| Chassis | •AISI 1018 Steel Tubular Spaceframe
•Self Designed and Optimised Aluminium 7075 Removable Rear Bulkhead •Compact, light weight and self designed Carbon Fibre Impact Attenuator |
| Body | •Carbon Fibre |
| Wheels | •Keizer Aluminium Rims |
| Tyres | •Hoosier R25B 16X6 - 10" Racing Tyres |
| Engine | •Water Cooled KTM RC 390 Engine
•Self-Designed Cooling System Intake Manifold 3D Printed with HP Multi Jet Fusion Technology •Custom Made Lightweight Titanium Series Resonator •Muffler Exhaust System •High Performance In-Line Fuel System •ECU : PE3 |
| Fuel Type | •High Performance In-Line Fuel System, ECU : PE3 |
| Power | •33.5 BHP at 8000rpm |
| Torque | •32 N.m. at 7500rpm |
| Brakes | •Self-Designed Custom Rotor
•Driver Adjustable Ergonomic Pedal Box Assembly •ISR Front Calipers and Custom Calipers for Rear Wheels |
| Suspension | •Double Unequal Length CFRP
•A-Arms •Push Rod Actuation at Front and Rear •Ohlins TTX25 Adjustable Damping System •3-Way Adjustable Stiffness Z Type Anti-Roll Bar •Topology optimized Bellcranks |
| Steering | •Carbon Fibre Steering Wheel
•Carbon Fibre Steering Column •Krontec Quick Release •Carbon Fibre Tie and Toe Rods •Newly Incorporated Gear shifting and clutch actuation paddles |
| Transmission | •Power Transmission via Chain on rear axle
•6 Speed Sequential Transmission System, Paddle Controlled, Electro Pneumatic Gear Shifting System •Drexler Limited Slip Differential |
| Electronics | •Custom Programmable Performance electronics PE3 ECU
•Custom Wiring Harness •Digital driver display and shift lights •Custom Power Distribution Module •Paddle Controlled Servo Motor Actuated Clutch •RaceCapture Pro MK3 Data Logger and Telemetry |
| Total Weight | •180 kg |
References
- "FSG Results". formulastudents.de.
- "DNA Report". DNA Mumbai.