Project

Electrical Systems Designer

Sector

F-Class Motorsports

Project Type

Exploration, Design, Rapid Prototyping

Case Study: Electrical Systems Designer Rapid Prototype

Using Rapid Prototypes To Simplify Decision Making

About The Client

Our client is a leading team in premier F-Class motorsports with multiple grand prix victories, multiple World Championships, and multiple Constructors’ World Championships.
 
With every race season, the electrical systems within a race car evolve as the season progresses. Components and assemblies are upgraded and replaced throughout the year, and the sheer number of topologies, variations, and connections requires meticulous management.

The Client’s Challenge

Faster Design Process Without Sacrificing Accuracy

The department required a new system to allow electrical systems to be rapidly sketched, designed, explored, and validated before they are formalised into physical harnesses.
 
The problem space was one we had encountered previously within this sector (the virtual assembly of a race car and it’s constituent parts, so it may be explored in a digital environment). This process is similar to ‘wire-framing’ but demands higher fidelity and absolute accuracy. Any errors overlooked during this phase could result in incorrectly wired systems, potentially leading to unsafe physical harnesses.

Standard electrical diagramming tools proved to be too slow, as designers cannot map out the system until they know how the parts connect across the race car. A complete rethink was needed to deliver a solution that aligned with the department’s vision.

The Solution

From Ideas To Prototypes

The department’s vision encompassed an array of interconnected conceptual layers, incorporating elements that would be duplicated, reused, and versioned over time.
 
Phase 1: Exploration
We conducted an intense 1-day workshop to drill into their requirements. This deep-dive included visiting the manufacturing departments that were responsible for constructing the race car, where we were invited to inspect the car chassis and wiring, examine the physical electrical harnesses and observe their construction methods.

Phase 2: Solution Design & Prototype
Armed with a significant set of requirements, we initiated an intense time-boxed design session of just 10 days. The goal for this phase was to demonstrate the concepts from the workshop, and show how the system would allow their designs to evolve. Our previous experience in Electronics and Design methodologies provided the core base for our solution.

Using Domain Driven Design, we embarked on:
– Identifying and separating the layers into separate Contexts.
– Mapping relationships among elements within these contexts.
– Establishing taxonomies within the problem space.
– Decomposing and organising entities and aggregates.

As we iterated through our design process, we identified concepts that worked well, and found other ideas that needed further exploration with the client.

Phase 3: Demonstration, walkthrough, and deliverables
Our proposed solution was presented in a 1/2 day session, where we walked through each concept in detail. The client was provided with an executable prototype and video tutorial guide, allowing them to play and explore the proposed solution in their own time.

Selecting the Right Tools

Friction-Free Rapid Prototyping

With the level of complexity we had to address, we relied on our custom framework to help us clarify the problem space, connect the domain concepts, and visualise the potential capabilities of the solution.

Transitioning from paper sketches to code experiments allowed us to test various model concepts iteratively and with focus.

Domain Driven Design
Domain Modelling
Rapid Prototyping

Results

Hi-Fidelity Prototype in 2 weeks

Within a span of 10 days, we developed an interactive prototype that addressed multiple facets of the solution. We presented this prototype to the department, demonstrating the rapid assembly of elements and showcasing other capabilities based on their requirements. We also highlighted gaps in the concepts, where future exploration work would be needed.
 
The client was notably impressed with the results, reflecting confidence in our understanding of the problem space. We anticipate future collaboration to evolve the prototype into a comprehensive software system.

Inspired Outcomes Start Here

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