Design and Implementation of a Six-Element Autonomous Active Aerodynamics System for Formula SAE

Abstract

This paper presents the design, fabrication, and validation of a fully autonomous active aerodynamics system for the 2025 University of Maryland internal combustion Formula SAE (FSAE) vehicle, also known as the Terps Racing TR25. The autonomous active aerodynamics system was showcased at the 2025 Michigan FSAE competition, receiving the Second Place Innovation Award. To resolve the conflict between high downforce required for cornering and low drag required for longitudinal acceleration and good fuel economy, a six-element active wing package was developed, comprising four actuated flaps on the front wing and two actuated flaps on the rear wing. The system is governed by a finite state machine algorithm that processes data from wheel speed, steering angle, throttle position, brake pressure, and inertial sensors to estimate vehicle states and execute coordinated actuation. To ensure reliability and adaptability, the system incorporates robust failure mitigation protocols and a driver interface for on-the-fly sensitivity tuning to match driver styles and track conditions. Computational fluid dynamics and track testing demonstrate a 49% reduction in drag coefficient (𝐶𝐷 from 1.44 to 0.73) between the high and low-drag configurations. Validated lap time simulations predict a 1.47-second and 42.4-second (2.6%) improvement in Autocross and Endurance dynamic events (based on the 2024 competition tracks), respectively, alongside a 7.2% increase in fuel efficiency, and a 0.08-second (1.9%) improvement in the Acceleration dynamic event. Additionally, the system enables a longitudinal center of pressure migration from 78% to 20% (% of total downforce on front tires), providing a foundation for active balance control through dynamic track states.