no compromises
This project combined both high downforce with low drag to give us an aero package that wouldn't drain our pack. In a 16 lap race, we save an entire lap's worth of energy by using low-drag on the straights where cornering grip isn't needed
I built the position controller for the motor from scratch using an ARM cortex M4 processor controlling a TI H-bridge driver while reading position feedback from a PWM absolute rotary encoder. The code was written in C, and features a PID loop for position control. The motor board interfaces with the control system over CAN, where a paddle is pulled to activate the DRS system.
The mechanism is based on the classic 4-bar (thanks Dr. Hutcheson!). Both elements are driven by the middle rocker. I wrote a Python simulation/optimizer to calculate the forces, and designed the mechanism to minimize driving force. Part of the clever design is that the forces from the airfoils cancel to make both operating points stable!
The rockers have a cool, alien look because they were developed using topology optimization. I have learned how to use ANSYS FEA software, and this takes the design to the next level by iteratively removing unstressed material in the design space. The end result is a structure 70% of the weight and over twice as strong!