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F.8.2.1 The Anti Intrusion Plate must be one of the following:
a. 1.5 mm minimum thickness solid steel
b. 4.0 mm minimum thickness solid aluminum plate
c. Composite material per F.8.3
F.8.2.2 The outside profile requirement of the Anti Intrusion Plate depends on the method of attachment to the Front Bulkhead
a. Welded joints: the profile must align with or be more than the centerline of the Front Bulkhead tubes on all sides
b. Bolted joints, bonding, laminating: the profile must align with or be more than the outside dimensions of the Front Bulkhead around the entire periphery
F.8.2.3 Attachment of the Anti Intrusion Plate directly to the Front Bulkhead must be documented in the team’s SES submission. The accepted methods of attachment are:
a. Welding
All weld lengths must be greater than 25 mm
If interrupted, the weld/space ratio must be 1:1 or greater
b. Bolted joints
Using no less than eight 8 mm or 5/16” minimum diameter Critical Fasteners, T.8.2.
The distance between any two bolt centers must be 50 mm minimum.
Each bolt attachment must have pullout, tearout and bending capabilities of 15 kN
c. Bonding
The Front Bulkhead must have no openings
The entire surface of the Anti Intrusion Plate must be bonded, with shear and peel strength greater than 120 kN
d. Laminating
The Anti Intrusion Plate must be in front of the outer skin of the Front Bulkhead
The lamination must fully enclose the Anti Intrusion Plate and have shear capability greater than 120 kN
F.8.2.4 All Non Crushable Items inside the Primary Structure must have a minimum 25 mm clearance to the:
Explanation
The Anti Intrusion Plate is a plate that sits between the drivers feet and the Impact Attenuator. The purpose of the Anti Intrusion Plate is to prevent sharp objects from penetrating the front of the chassis and hurting the driver in case of a frontal collission.
Image of our Anti Intrusion Plate from the SES
This diagram shows (in 2D) how the Impact Attenuator and the Anti Intrusion Plate are mounted to the Front Bulkhead.
In this image you can see a steel Anti Intrusion Plate mounted on the front of a chassis. This plate would normally be covered by the Impact Attenuator.
F.8.2.1 The Anti Intrusion Plate must be one of the following:
a. 1.5 mm minimum thickness solid steel
b. 4.0 mm minimum thickness solid aluminum plate
c. Composite material per F.8.3
The material requirements for steel and aluminum are vauge, does it matter what type they are?
If the Anti Intrusion Plate is made of metal, it must be 1.5 mm minimum thickness solid steel or 4.0 mm thickness solid aluminum. Steel is significantly denser than aluminum, which is the reason that aluminum plate is required to be thicker than steel to achieve equivalent strength.
Composite material Anti Intrusion Plates (for some monocoque designs) must meet a separate set of material rules (F.8.3) with additional required testing data to prove their equivalent strength.
For a brief overview of Steel vs Aluminum as materials, check out this website, which is short and simple while making an effective comparison.
F.8.2.2 The outside profile requirement of the Anti Intrusion Plate depends on the method of attachment to the Front Bulkhead
a. Welded joints: the profile must align with or be more than the centerline of the Front Bulkhead tubes on all sides
b. Bolted joints, bonding, laminating: the profile must align with or be more than the outside dimensions of the Front Bulkhead around the entire periphery
The outside perimeter of the Anti Intrusion Plate must extend to a certain coverage over the Front Bulkhead, depending on the way that it is connected. The Anti Intrusion Plate can either be welded, bolted, bonded, or laminated to the Front Bulkhead.
Welded Anti Intrusion Plate
If the Anti Intrusion Plate is welded to the Front Bulkhead, the perimeter of the plate must sit along the center lines or extend further than the center lines of the Front Bulk Head tubing.
In the images below, the Front Bulkhead is annotated with red and blue lines. The red lines represent a projected Anti Intrusion Plate perimeter, and the blue lines represent the center line of the Front Bulkhead Tubing.
This Anti Intrusion Plate would not be rules compliant because its perimeter does not align with or extend past the center lines of the Front Bulkhead tubes.
This Anti Intrusion Plate would be rules compliant because its perimeter does align with the center lines of the Front Bulkhead tubes.
This Anti Intrusion Plate would be rules compliant because its perimeter does extend past the center lines of the Front Bulkhead tubes.
Bolted / Bonded / Laminated Anti Intrusion Plate
If the Anti Intrusion Plate is bolted, bonded, or laminated to the Front Bulkhead, the perimeter of the plate must sit along the outside perimeter or extend further than the outside perimeter of the Front Bulk Head tubing.
In the images below, the Front Bulkhead is annotated with red and blue lines. The red lines represent a projected Anti Intrusion Plate perimeter, and the blue lines represent the outside perimeter of the Front Bulkhead Tubing.
This Anti Intrusion Plate would not be rules compliant because its perimeter does not align with or extend past the outside perimeter of the Front Bulkhead tubes.
This Anti Intrusion Plate would be rules compliant because its perimeter does align with the outside perimeter of the Front Bulkhead tubes.
This Anti Intrusion Plate would be rules compliant because its perimeter does extend past the outside perimeter of the Front Bulkhead tubes.
SES Reference
F.8.2.3 Attachment of the Anti Intrusion Plate directly to the Front Bulkhead must be documented in the team’s SES submission. The accepted methods of attachment are:
a. Welding
All weld lengths must be greater than 25 mm
If interrupted, the weld/space ratio must be 1:1 or greater
b. Bolted joints
Using no less than eight 8 mm or 5/16” minimum diameter Critical Fasteners, T.8.2.
The distance between any two bolt centers must be 50 mm minimum.
Each bolt attachment must have pullout, tearout and bending capabilities of 15 kN
c. Bonding
The Front Bulkhead must have no openings
The entire surface of the Anti Intrusion Plate must be bonded, with shear and peel strength greater than 120 kN
d. Laminating
The Anti Intrusion Plate must be in front of the outer skin of the Front Bulkhead
The lamination must fully enclose the Anti Intrusion Plate and have shear capability greater than 120 kN
SES Reference
We are required to document the way we attach the Anti Intrusion Plate to the Front Bulkhead in the SES. This is done in the Front Protection tab of the SES, and the template helps you place this information in the correct space.
Each attachment method has its own set of rules, with the four recognized methods being: welded, bolted, bonded, and laminated.
Welded Attachments
All welds must be more than 25 mm in length. If the welds have gaps, the weld to gap ratio has to be a minimum of 1:1 (you can not have more gap space than welded space)
In the images below of the Front Bulkhead, the red perimeter represents a projected Anti Intrusion Plate, and the Blue lines represent weld patterns.
This welded Anti Intrusion Plate would be rules compliant because the welds are more than 25 mm each, and the weld to gap ratio is 1:1. There is not more gap than weld.
This welded Anti Intrusion Plate would be rules compliant because the welds are well over 25 mm each, and the weld to gap ratio is much greater than 1:1.
This welded Anti Intrusion Plate would not be rules compliant because while the welds are more than 25 mm in length, the weld to gap ratio is insufficent. There is much more gap space than there is weld space.
This welded Anti Intrusion Plate would not be rules compliant because while the weld to gap ratio is 1:1, the welded are not more than 25 mm in length.
SES Reference
Bolted Attachments
If the Anti Intrusion plate is bolted onto the front of the chassis, the bolts used must be Critical Fasteners which are high performance fasteners. The bolts used must be a minimum of 8 mm or 5/16 in (the distance of outer thread of one side to the outer thread on the other side) in diameter.
Bolts must be a minimum of 50 mm apart center to center.
SES Reference
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