Motor Coupling Design Review The 2004 Idaho Future Truck needs a system to couple the AC induction motor to the power train. + = Motor Future Truck Happy Frank

Khurram Kemal Khurram Kemal Josh Roy Josh Roy Richard Statler Richard Statler Jeremy Forbes ~ Mentor Jeremy Forbes ~ Mentor The Motor Boys

System Operation Concept

Two Wheel Drive Deceleration – Motor provides regenerative braking by producing a counter torque. The energy captured is stored in ultra capacitors. Acceleration – Motor provides boost by producing a torque. The energy used is drawn from the ultra capacitors.

Four Wheel Drive Generator – Motor operates as a generator constantly charging the ultra capacitors. The capacitor bank then transfers energy to the DC motor on the front axle.

The 3-phase AC induction motor produces 18hp, 81 ft-lb, and will operate rpm

Requirements At least 90% efficient At least 90% efficient Handle reversible load conditions Handle reversible load conditions Handle 81 ft*lbs, 18 HP, rpm from motor Handle 81 ft*lbs, 18 HP, rpm from motor Handle 1200 ft*lbs, 250HP, rpm from drive train Handle 1200 ft*lbs, 250HP, rpm from drive train Run 10 drive cycles without maintenance Run 10 drive cycles without maintenance Cost less than $3000 Cost less than $3000 Limited modifications to frame Limited modifications to frame Volume less than 2 cubic feet Volume less than 2 cubic feet Weigh less than 100 lbs Weigh less than 100 lbs Located in designated regions Located in designated regions Installation complete and ready for testing February Installation complete and ready for testing February

Design Alternatives 1. Through shaft on drive train 2. Rear differential with second pinion 3. Chain to driveshaft

Through shaft on drive train

Rear differential

Chain to Driveshaft

Solution Concept Front View Top View

Selection Criteria Attainability Attainability Given the resources available and basic parameters, such as geometry, is it possible to build a working version. Efficiency Efficiency How efficient is a design compared the stated objective of 90%. Safety Safety In normal operation, how safe is a design for the user and maintenance personnel. This is only an initial assessment; further analysis using DFMEA will be conducted on the selected design (s). Failure Affects Failure Affects If this design fails, what will be the affects? This includes safety to users and maintenance personal and mechanical damage to the vehicle. Consumer Acceptability Consumer Acceptability How acceptable will this device be to consumers? This includes both device maintenance and appearance; the consumer must look at it and perceive it as both safe, maintainable, and attractive.

Selection Criteria continued Cost Cost Does this device fit within our budget constraints? Reliability Reliability This encompasses two areas. For the FT team the concept chosen must be reliable enough to survive pre-competition, competition, and any future use (another competition?) without failure or degradation in performance. For consumer acceptability it must ‘appear’ reliable to the end user. Appearance Appearance How professional and OE does this design appear to be? This is a tangent to consumer acceptability. Space Constraints Space Constraints Will this fit easily in the space available under the vehicle. Testing Testing How easy will this concept be to test? Weight Weight How much does this concept weigh?

ConceptMultiplier Transfer Case Chain or belt Second Pinion Front of Engine Through ShaftGears Selection Criteria Attainability Efficiency Safety Failure Affects Consumer Acceptability Cost Reliability Appearance Space Constraints Testing0 Weight (lb, not 1-5 scale) Totals After Multiplier Totals

Timeline November November Drawing Package Drawing Package Order Parts Order Parts December December Machine parts Machine parts Sub-assemble Sub-assemble January January Mount on vehicle Mount on vehicle Full assemble Full assemble

Questions ? + = Motor Future Truck Happy Frank