TEAM MOTOTRON BRIAN LYNN: TEAM LEAD, ELECTRICAL LEAD INSTRUCTOR: RARESH PASCALI NAM NGUYEN: FRAME AND ENGINE ALUMNUS ADVISOR: JONATHAN FULBRIGHT ANDREW SAN JUAN: SUSPENSION AND BRAKING PROFESSIONAL ADVISOR: HUDA ABBAS, P.E.

OBJECTIVE To design and fabricate a hybrid vehicle for the 2017 SAE Formula Hybrid competition. http://www.dartmouth.edu/~news/releases/2009/04/images/formula2.jpg http://www.greencardesign.com/site/sites/default/files/Ferrari_Teaser_FR.jpg

GOALS Implement a functional series/parallel hybrid drivetrain Have a curb weight under 600 lbs. Have an acceleration time under 5.5 seconds in both acceleration events Incorporate regenerative braking system Have vehicle operational by October 2016 Compete in the 2017 competition Formula Hybrid Competition

Acceleration-electric Acceleration-unrestricted COMPETITION The SAE Formula Hybrid competition is held each year by the Society of Automotive Engineers (SAE) Collegiate Design Series Challenges students to innovate across engineering disciplines such as mechanical, electrical, computer and aerodynamic engineering The team’s goal is to earn as many points as possible for the different event categories over a three day period Static Events Scoring Presentation 100 Engineering Design 200 Dynamic Events   Acceleration-electric 75 Acceleration-unrestricted Autocross 150 Endurance 400 Total 1000

HYBRID SYSTEMS A hybrid vehicle utilizes two or more types of power, such as internal combustion engine (I.C.E) and electric motor Hybrid vehicles combine the benefits of gas engines and electric motors Can be configured to improve fuel economy, increase power, or additional auxiliary power Three types of hybrid systems include: series, parallel, and series/parallel

SERIES HYBRID Advantages The engine is not coupled to the wheels Motors are more efficient than Internal Combustion Engines (I.C.E.) Can be run strictly on electric Simple drive train Disadvantages All power must come from the motor Energy conversion leads to decrease efficiency Not as efficient at high speeds compared to parallel hybrids

PARALLEL HYBRID Advantages Disadvantages Can meet instantaneous power needs (ICE is main power source, electric motor assists) Able to rely solely on electric motor or ICE Disadvantages Complex transmission required to couple the ICE and electric motor Typically requires a larger ICE than series

SERIES-PARALLEL HYBRID Advantages Engine and motor can provide power independently or in conjunction with one another Increased vehicle range Engine can supplement the motor when additional power is required Disadvantages Complicated control scheme Requires complex programming Increased cost

FRAME DESIGNS University of Victoria (2015) Design Score:178.29 University of Houston (2015) Design Score: N.A University of Waterloo (2015) Design Score 144.43 http://www.hybrid-autos.info/images/stories/RWTH_Aachen/Ecurie_Aix_2012/Team2_gross.jpg http://www.uhreddevils.com/wp-content/uploads/2014/10/red-devils-team-logo.png http://www.bulletin.uwaterloo.ca/images/2005/Waterloo-F05-Iso-Front.jpg

MATERIAL SELECTION Considerations Weight Workability Strength Cost Tensile Strength Modulus Of Elasticity Density Cost Aluminum 31000 psi 10000 ksi 101.5 lb / in3 $6.50 / ft Carbon Fiber 710684 psi 33000 ksi 56.7 lb / in3 $47.00 / ft Steel 50800 psi 29700 ksi 283.6 lb / in3 $9.00 / ft Aluminum Carbon Fiber Steel http://www.trident-metals.com/wp-content/uploads/aluminumtubing.jpg http://img.talkandroid.com/uploads/2013/06/Carbon_Fiber.jpg http://www.chenrysteel.com/steel-pipe.jpg

INTERNAL COMBUSTION ENGINES Ninja 250R Honda Grom Honda CBR250R Description Parallel twin, four-stroke, liquid cooled, DOHC Air-cooled single-cylinder four-stroke Liquid-cooled single-cylinder four-stroke Displacement 249cc 234.9cc 249.6cc Weight 90 lbs. 35 lbs. 92 lbs. Compression Ratio 12.4:1 9.3:1 10.7:1 Transmission Six speed Four speed Ignition Electronic Power Output 25Hp 18Hp Final Drive Chain Cost $650.00 $1700.00 $600.00 Ninja 250R Honda Grom Honda CBR250R http://www.kawasaki-cp.khi.co.jp/mcy/street/images/12my/12_EX250JK_F_1-1.jpg http://www.rubbersideup.com/honda-grom-msx125-msx-125 http://pictures.topspeed.com/IMG/crop/201305/2013-honda-cbr250r-17_600x0w.jpg

DIFFERENTIAL SELECTION Transmits power to wheels Allows one wheel to spin faster in turns Brand Torsen Drexler Taylor Type Torque Bias Limited Slip Weight 8.6 lbs. 6.0 lbs. 8.3 lbs. Cost $415.00 $3000.00 $2725.00 Torsen Drexler Taylor https://grabcad.com/library/torsen-differential http://www.autotechdriveline.com/images/drexler/drexler_fsae_250.jpg http://s632.photobucket.com/user/SCOTTY1982/media/newdiff.jpg.html

ELECTRIC MOTORS AC or DC Induction, synchronous, or permanent magnet Motor / generators are common in production vehicles Motor AC-12 WarP 9 PMG-132 Voltage 48 – 72 V 72 V 24 – 72 V Current 300 – 550 A 500 A 110 – 200 A Efficiency 89 % 88 % Peak Power 30 Hp 40 Hp 19 Hp Weight 46 lbs. 165 lbs. 25 lbs. Cost $2350.00 $2100.00 $1300.00 AC-12 WarP 9 PMG-132 http://www.electriccarpartscompany.com/assets/images/ac-35-kits-main-pic-with-controller.jpg http://www.go-ev.com/images/WarP_9.jpg

MOTOR CONTROLLER SELECTION ​ Controls motor speed or torque output Converts DC to AC for AC motors Provides thermal & short circuit protection Programmable Model Curtis Sevcon WarP Max Current 650 A 350 A 1,000 A Rated Output 70 Hp 80 Hp 670 Hp Input Voltage 72 – 130 V 72 – 80 V 8 – 160 V Weight 12 lbs. 6 lbs. 23 lbs. Cost $2,000.00 $875.00 $2,900.00 Curtis Sevcon WarP http://curtisinstruments.com/images/homepage/motor_controllers.png http://www.ev-power.com.au/IMG/png/gen4-pic.png http://www.envirotechcoating.com/wp-content/uploads/2014/04/WarP_Drive_Industrial_500.jpg

ACCUMULATOR SELECTION ​ Maximum operating voltage = 300V Primary energy source for motor Type Lead Acid Li-Ion (LiFePO4) Super Capacitor Voltage 12 V 16 V Watt-hours 420 Wh 300 Wh 18 Wh Weight 22 lbs. 6 lbs. 12 lbs. Cost $100.00 $250.00 $600.00 Lead ACID Li-Ion (LiFePO4) Super Capacitor http://www.electrorobotech.electrogroups.org/shop/batteries/lead-acid-battery/ http://www.batteryspace.com/images/products/detail/6852.png http://www.mouser.com/images/maxwelltechnologies/lrg/BMOD0500-A_lo_med.jpg

ACCUMULATOR MANAGEMENT ​ Monitors battery health Controls charge and discharge rates Programmable for customization Model Orion Lithiumate MiniBMS Supply Voltage 8 - 16V 12 V Variable Configuration 48 Cells 2 – 200 Cells 4 16 cells Canbus Compatible Yes No Cost $1000.00 $1600.00 $200.00 Orion Lithiumate MiniBMS http://www.evsource.com/tls_bms.php http://www.evsource.com/tls_bms.php http://www.evsource.com/tls_bms.php

PROGRAMMABLE CONTROLLER Model myRIO Compact RIO Arduino Due Processor Speed 667 Mhz 1.33 GHz 84 Mhz Operating System Linux Arduino Ram 512 MB 96 KB Cost $500.00 $2000.00 $20.00 myRIO Compact RIO Arduino Due http://www.ni.com/myrio/ http://www.ni.com/myrio/ https://www.arduino.cc/en/Main/ArduinoBoardDue

SUSPENSION Double Control Arm Consists of two unequal length control arms (shorter on top) Keeps tire perpendicular to the road in a turn with roll – camber gain Versatility – pushrod / pull road variations Complexity – increased cost and weight vs less complex suspensions MacPherson Strut Consists of single control arm Lighter / cheaper than double wishbone due to decreased complexity No camber gain in a turn – decreased tire contact surface with road. Beam Axle Wheels connected by a single beam Rigid / robust design – long term durability No camber gain in a turn One wheel affects the other – upsets balance of car https://i.kinja-img.com/gawker-media/image/upload/bkdep2ejmtescjtralc2.jpg http://cobrasprings.co.nz/system/files/images/macphersonstrut.gif http://designthedesire.blogspot.com/2015/06/suspension.html

PROJECT TIMELINE STAGE 1: RESEARCH AND DEVELOPMENT   2016 2017 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC STAGE 1 STAGE 2 STAGE 3 STAGE 4 TASKS RESEARCH 3D FRAME DESIGN STRESS ANALYSIS FUNDRAISING PROCUREMENT FABRICATION TESTING TUNING FINAL PREPARATION COMPETITION STAGE 1: RESEARCH AND DEVELOPMENT Studying SAE Formula Hybrid rules 3D frame design and stress analysis STAGE 2: FUNDRAISING AND PROCUREMENT Prepare and present proposals to potential donors Concurrent acquisition of parts and materials STAGE 3: FABRICATION AND TESTING Begin fabrication of vehicle Programming and installation of drivetrain components Finish vehicle assembly by the end of October STAGE 4: TUNING, FINAL PREPARATION AND COMPETITION Continued testing and further improvement Prepare vehicle for competition in April 2017

WBS Team MOTOTRON SAE Formula Hybrid STAGE 1 STAGE 2 STAGE 3 STAGE 4 Competition Research Market Research Hybrid Systems Research Fundraising & Sponsorships Material Requisitioning Frame Design Frame Fabrication Suspension Fabrication Hybrid Systems Design Mechanical Assembly Electrical Assembly Body Fabrication Test and Tune Register for Competition Shipping Preparations Travel Compete Suspension Design Body Design LEGEND Completed Task Task in Progress Task not Started

Total with ~25% Contingency BUDGET Components Cost Chassis Materials $1000.00 Internal Combustion Engine $1100.00 Electrical Components $8000.00 Suspension $600.00 Steering $400.00 Wheels $500.00 Differential Tires $250.00 Transponder $519.00 Ground Fault Monitors $25.00 Fire Extinguishers $150.00 Travel Fee $2000.00 Registration Fee $2200.00 Total $17,244.00 Total with ~25% Contingency $22,000.00

RISK MATRIX PROBABILITY SEVERITY RISK RISK ELEMENT 1 Parts Delay 2 Hybrid Function Will Not Work 3 Malfunctioning Electrical Components 4 ICE Fails 5 Defective Parts 6 Failure to Submit Documentation 7 Time Management 8 Compliance with Rules 9 Fundraising 10 Curb Weight Management PROBABILITY Very Likely   Likely 9  8 Possible 7  2 Unlikely 5   3  6 Highly Unlikely 1,10 4  Minimal Minor Moderate Severe Catas-trophic SEVERITY

QUESTIONS?