Team Lead, Electrical Lead Suspension and Braking Lead TEAM MOTOTRON Team Lead, Electrical Lead Frame and Engine Lead Suspension and Braking Lead Brian Lynn Nam Nguyen Andrew San Juan Instructor Alumnus Advisor Professional Advisor Raresh Pascali Jonathan Fulbright Huda Abbas, P.E. Electrical Engineering Dept. Manager at Zachry Engineering

Outline Objective Goals Hybrid Systems Frame Design Finite Elemental Analysis Suspension Geometry Component Selection Project Management http://www.bestitnewssite.org/photos/f1-2015-quick-play

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 Held in Loudon, New Hampshire at the Loudon International Speedway The SAE Formula Hybrid competition is sanctioned each year by SAE International as part of their Collegiate Design Series Challenges students to innovate across engineering disciplines such as mechanical, electrical, computer and aerodynamic engineering 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 (IC engine) and electric motor Can be configured to improve fuel economy, increase power, or additional auxiliary power Hybrid vehicles combine the benefits of gas engines and electric motors Three types of hybrid systems include: series, parallel, and series/parallel System Advantages Disadvantages Series Simple drivetrain Efficient power transfer Less efficient at high speeds Electric motor only moves vehicle Parallel Powered by motor or IC engine Better suited to meet instantaneous power requirements Complex transmission required Requires larger IC engine than series Series/Parallel Motor and IC engine work together or independently Increased range Complex programming and control scheme Increased cost

Series/Parallel Design Requires 2 motor-generators (MG) Planetary gear set divides power between MG’s and IC engine Provides the benefit of a Continuously Variable Transmission (CVT) https://gr8autotech.wordpress.com/2013/05/31/working-of-a-power-splitter/ https://gr8autotech.wordpress.com/2013/05/31/working-of-a-power-splitter/

Frame Designs First Iteration Material Steel Length 80in Height 40in Width 30in Mass 74lb Total Length 1212.4in Cross Section Round 1in x.065in Second Iteration Material Steel Length 84in Height 36in Width 30in Mass 62lb Total Length 1176.9in Cross Section Round 1in x.065in

Finite Elemental Analysis First Iteration Force Applied 12kN Total Deformation 17.661mm Direct Stress 105.76Mpa Maximum Combine Stress 699.17Mpa Minimum Combine Stress 88.98Mpa Second Iteration Force Applied 12kN Total Deformation 7.9mm Direct Stress 109.9Mpa Maximum Combine Stress 415.56Mpa Minimum Combine Stress 98.14Mpa

Suspension Double Control Arm Unequal Length 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 Double Control Arm Unequal Length Consists of two unequal length control arms (shorter on top). MacPherson Strut Consists of single control arm Beam Axle Wheels connected by a single beam Type Advantages Disadvantages Double Control Arm Versatility – Shock placement Keeps tire perpendicular to the road in a turn with roll – camber gain Complexity – increased cost and weight vs less complex suspensions MacPherson Strut Lighter / cheaper than double wishbone due to decreased complexity No camber gain in a turn – decreased tire contact surface with road Beam Axle Rigid / robust design – long term durability One wheel affects the other – upsets balance of car

Preliminary Suspension Geometry Design Considerations Kingpin Angle Angle formed from steering axis to the centerline of wheel 5-10 degrees is common Scrub Radius Distance from where Kingpin axis and tire centerline axis intersect ground Aim is to minimize to improve steering/handling Roll Center Reduce distance between Roll Center and Center of Gravity to minimize body roll. Measurements Track Width (center to centerline of wheels): 48” Wheel Dimensions: 13” Diameter Tire Dimensions: 20” Diameter

Internal Combustion Engines 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 Engine: Ninja 250R Description: Parallel twin, four-stroke, liquid cooled, DOHC Displacement: 249cc Weight: 90 lbs. Power Output: 25Hp Torque: 13.67 ft-lb Cost: $650 Engine: Grom Description: Air-cooled single-cylinder four-stroke Displacement: 234.9cc Weight: 35 lbs. Power Output: 18Hp Torque: 7.36 ft-lb Cost: $1700 Engine: CBR250R Description: Liquid-cooled single-cylinder four-stroke Displacement: 249.6cc Weight: 90 lbs. Power Output: 25Hp Torque: 12.7 ft-lb Cost: $600 Selection Matrix Factor Ninja 250R Grom Honda CBR250R Cost (1) 3 1 4 Weight (2) 5 Power output (4) Torque (3) 2 Total 43 29 41 Rating Scale: 1 - 5

Differential Mfg: Torsen Type: Torque Bias Torque: 383 ft-lbs https://grabcad.com/library/torsen-differential http://s632.photobucket.com/user/SCOTTY1982/media/newdiff.jpg.html http://www.autotechdriveline.com/images/drexler/drexler_fsae_250.jpg Mfg: Torsen Type: Torque Bias Torque: 383 ft-lbs Weight: 8.6 lbs. Cost: $500 Mfg: Drexler Type: Limited Slip Torque: 885 ft-lbs Weight: 8.0 lbs. Cost: $3000 Mfg: Taylor Type: Torque Bias Torque: 550 ft-lbs Weight: 8.3 lbs. Cost: $2725 Selection Matrix Factor Torsen Drexler Taylor Torque (2) 3 5 4 Weight (1) Cost (3) 1 Total 24 18 15

Tractive Motor Motor: PMG-132 Voltage: 72 V Current: 200 A http://www.electriccarpartscompany.com/assets/images/ac-35-kits-main-pic-with-controller.jpg http://www.go-ev.com/images/WarP_9.jpg http://www.robotmarketplace.com/products/EMS-PMG132.html Motor: PMG-132 Voltage: 72 V Current: 200 A Efficiency: 88% Power: 19 hp Weight: 25 lbs. Cost: $1300 Motor: AC-12 Voltage: 72 V Current: 550 A Efficiency: 89 % Power: 30 hp Weight: 46 lbs. Cost: $1100 (Donated) Motor: WarP9 Voltage: 72 V Current: 500 A Efficiency: 89% Power: 40 hp Weight: 165 lbs. Cost: $2100 Selection Matrix Factor AC-12 WarP9 PMG-132 Voltage (2) 3 Current (2) 4 2 Efficiency (1) Power (3) 5 1 Weight (4) Cost (5) Total 68 64 57

Motor/Generator Motor: Manta Voltage: 48 V Current: 200 A http://www.hydrogenappliances.com/manta.html http://www.robotmarketplace.com/products/EMS-PMG132.html Motor: Manta Voltage: 48 V Current: 200 A Efficiency: 94 % Power: 10 hp Weight: 22 lbs. Cost: $650 Motor: PMG-132 Voltage: 72 V Current: 200 A Efficiency: 88 % Power: 19 hp Weight: 25 lbs. Cost: $1,300 Selection Matrix Motor/Generator Manta PMG-132 Voltage (1) 3 5 Current (1) 4 Peak Power (2) Weight (2) Cost (3) 2 Total 34 31

Motor Controller Selection 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 Controller: Curtis Current: 650 A Output: 70 hp Voltage: 130 V Weight: 12 lbs. Cost: $1250 (Donated) Controller: Sevcon Current: 350 A Output: 80 hp Voltage: 80 V Weight: 6 lbs. Cost: $875 Controller: WarP Current: 1,000 A Output: 670 hp Voltage: 160 V Weight: 23 lbs. Cost: $2350 Selection Matrix Model Curtis Sevcon WarP Current (1) 3 2 5 Output (3) Voltage (1) 4 Weight (2) Cost (5) Total 47 38 39

Accumulator Selection http://www.electrorobotech.electrogroups.org/shop/batteries/lead-acid-battery/ http://www.lonestarevconversions.com/#!batteries/c38v http://www.mouser.com/images/maxwelltechnologies/lrg/BMOD0500-A_lo_med.jpg Type: Lead Acid Voltage: 12 V Power: 420 Wh Weight: 22 lbs. Cost: $100 Type: Li-Polymer Voltage: 45 V Power: 225 Wh Weight: 6 lbs. Cost: $250 Type: Super Cap Voltage: 16 V Power: 18 Wh Weight: 12 lbs. Cost: $600 Selection Matrix Type Lead Acid Li-Po (LiCo) Super Capacitor Voltage (2) 1 5 3 Watt-hours (2) 2 Weight (3) Cost (4) 4 Total 35 47 28

Accumulator Management Selection http://www.evsource.com/tls_bms.php http://www.evsource.com/tls_bms.php http://www.evsource.com/tls_bms.php Model: Orion Configuration: 48 Cells CAN Capable: Yes Programmable: Yes Cost: $1000 (Donated) Model: Lithiumate Configuration: 200 cells CAN Capable: Yes Programmable: Yes Cost: $1600 Model: Mini_BMS Configuration: 16 cells CAN Capable: No Programmable: No Cost: $200 Selection Matrix Model Orion Lithiumate MiniBMS Configuration (3) 3 5 1 CAN Capable (2) Programmable (1) Cost (4) 2 Total 44 38 26

Programmable Controller Selection http://www.ni.com/myrio/ http://www.ni.com/myrio/ http://store-usa.arduino.cc/products/abx00003 Model: myRIO Speed: 667 MHz OS: Linux RAM: 512 MB Cost: $500 w/ Accessories I/O: 16 Analog 40 Digital Model: CompactRIO Speed: 1.33 GHz OS: Linux RAM: 512 MB Cost: $2000 I/O: Up to 8 Modules Model: Arduino Zero Speed: 48 MHz OS: None RAM: 96Kb Cost: $50 I/O: 7 Analog 14 Digital Selection Matrix Model myRIO Compact RIO Arduino Due Processor Speed (2) 3 5 1 Operating System (1) Ram (3) 4 Cost (5) I/O Count (4) 2 Total 51 42 39

Project Timeline

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

Total with ~25% Contingency Budget Components Budgetary Cost Chassis Materials $1,000 Internal Combustion Engine $1,100 (Donated) Drive Motor Motor / Generator $1,300 Motor Controller $1,250 (Donated) Display $100 Accumulator Monitoring System $1,000 (Donated) Accumulators $1,200 Suspension Steering $400 Wheels Differential $500 (Donated) Tires $720 Transponder $520 Ground Fault Monitors $25 (Donated) Fire Extinguishers $150 Travel Fee $2,000 Registration Fee $2,200 Remaining Costs $11,590 Total with ~25% Contingency $14,488

Risk Matrix PROBABILITY SEVERITY Risk Risk Element Mitigation 1 Very Likely   Likely 9  8 Possible 7, 10  2 Unlikely 5   3  6 Highly Unlikely 1 4  Minimal Minor Medium Severe Catas-trophic SEVERITY Risk Risk Element Mitigation 1 Parts Delay Order Early 2 Hybrid Function Will Not Work Early Programming, Bench Testing 3 Fabrication Equipment Failure Alternative fabrication methods 4 ICE Fails Alternative engine 5 Defective Parts Reorder 6 Failure to Submit Documentation Prepare documentation early 7 Time Management Weekly progress reports 8 Compliance with Rules Discuss with Formula Hybrid 9 Fundraising Begin fundraising early 10 Injuries Use Proper PPE

QUESTIONS?