Shell Eco-Marathon FAMU-FSU 2014 Solar Car Milestone #3 Presentation Team #2

Introduction Registration Update General Problem Statement General Solution Approach Operating Environment Intended Use(s)/User(s) Race Track (Operating Environment) Francois Wolmarans Shell Stock Image Database

Presentation Overview Scheduling and Progress Comparison Matrix Mechanical Overview Mechanical Components Electrical Overview Electrical components Budgeting

Scheduling & Progress Components Completed on Schedule Additional Components Completed Incomplete Components Removed Components Phases Scheduling Risks Ordered Parts Required Equipment

Presentation Overview Introduction and Registration Update Scheduling and Progress Comparison Matrix Mechanical Overview Mechanical Components Electrical Overview Electrical components Budgeting

Comparison Matrix Optimization Legend: 1 least optimal Higher values correspond to a relatively more optimal solution Weight Legend: Safety = Cost = Weight = Implementation = Jose Cardenal Design Options Safety (0.432) Cost (0.208) Component Weight (0.187) Implementation (0.173) Total Design Design

Presentation Overview Introduction and Registration Update Scheduling and Progress Comparison Matrix Mechanical Overview Mechanical Components Electrical Overview Electrical components Budgeting

Mechanical Overview James Croasmun

Mechanical Overview

Steering System James Croasmun

Front Wheels James Croasmun

Front Wheels Bicycle Tires Wheel Hubs have preinstalled bearings Connects easily to steering assembly 0.5” hub bolt can handle all applied forces Safety Factor of 20.2 for aluminum 0.5” diameter hub bolt James Croasmun Front Wheels

Front Wheel Mounts James Croasmun

Front Wheel Mounts Simple design can be machined in house Can handle all applied forces with a factor of safety of Dimensions: 1.5”x1.5”x0.25” James Croasmun Front Wheel Mounts

Tie Rods Wael Nabulsi

Tie Rods Adjustable length Easy to install Low cost Light weight Wael Nabulsi Adjustable Tie Rods

Rack and Pinion Wael Nabulsi

Rack and Pinion Wael Nabulsi Rack and Pinion

Front Braking System Wael Nabulsi

Front Wheel Rotor Enables the use of calipers Front wheel rotor width, determined by braking caliper Secured to front wheel Allows for higher braking forces Can be built in house or come attached to front wheel hub Wael Nabulsi Front Wheel Rotor

Calipers Higher stopping forces than bicycle brakes Utilizes a simple mounting system Requires balancing for stopping forces on each front wheel Wael Nabulsi Calipers

Solar Car Seat David Jolicoeur

Solar Car Seat Standard 20 ° layback position Design will be mounted on rails All team members will be capable of driving the vehicle 5-Point Harness Padding David Jolicoeur Seat Design

Roll Bar & Motor Mount David Jolicoeur

Roll Bar & Motor Mount Meets all requirements for the competition Strong enough to handle forces imposed by the rear wheel and load of the car Allows for easy motor mounting David Jolicoeur Roll Bar & Motor Mount

Static Load Analysis: Stress David Jolicoeur Stress Analysis and Modified Roll Bar

Static Load Analysis: Displacement David Joliceour Displacement Analysis

Roll Hoop David Jolicoeur

Roll Hoop Increases the safety of the vehicle and integrity of the chassis Allows support for the steering column and wheel Can be used to support solar panel encapsulation Incorporate the front bulk head David Jolicoeur Roll Hoop

Presentation Overview Introduction and Registration Update Scheduling and Progress Comparison Matrix Mechanical Overview Mechanical Components Electrical Overview Electrical components Budgeting

Overview of Electrical System Fritz Jeanty

Motor’s Maximum Parameters Fritz Jeanty Sustain max torque of 22.63Nm Max Output of W Max Current of 19.18A Motor

Overview of Electrical System

Motor Controller Block Diagram Fritz Jeanty

Board Fritz Jeanty “RDK-BLDC." Data Sheet. Texas Instruments, n.d. Web. 14 Nov Initially, TI RDK board Controller Does not comply with competition rules (Disqualification) “Yes. The team does not need to purchase components from different suppliers. They must, however, integrate the components together into a MC system. This includes doing both hardware and software ” Preset Power and Driver Stage Board Controller

Board Fritz Jeanty “RDK-BLDC." Data Sheet. Texas Instruments, n.d. Web. 14 Nov Initially, TI RDK board Controller Does not comply with competition rules (Disqualification) Preset Power and Driver Stage

Printed Circuit Board Advantages Custom build for motor being used Avoid wire wrapping Avoid using multiple Board controllers Cost efficient Can be built in house Order PCB design through University Implementation Eliminate possibility of competition disqualification Fritz Jeanty

Overview of Electrical System

Isolated DC-DC Converter Previously an accessory battery was going to be used instead of an isolated DC-DC converter Built in safety Cheaper Less weight Julia Clarke DC-DC Converter Implementation Plan

Isolated DC-DC Converter Converter chosen was the Texas Instruments LM25017 The converter specifications aligned with the specifications of the battery. Minimum input voltage 9V and maximum input voltage is 48V The minimum output voltage is 1.25V with a maximum output voltage of 40V and a maximum output current of 0.65A "LM25017(ACTIVE)48V, 650mA Wide Vin Synchronous Step-down Regulator with Integrated MOSFETs." Converter (Integrated Switch). N.p., n.d. Web. 14 Nov Julia Clarke Isolated DC-DC Converter

Overview of Electrical System Fritz Jeanty

Ventilation System The ventilation system chosen is the Sanyo Denki fan Fairly cheap Met specifications of isolated DC- DC converter Julia Clarke "SANYO DENKI - SANACE FANS - 109BF12HC2 - DC BLOWER, 120 X 32MM, 12V." 109BF12HC2. N.p., n.d. Web. 14 Nov Ventilation Fan

Overview of Electrical System Fritz Jeanty

Battery System The battery chosen by the previous years solar car team was a 24V lithium ion battery from Electric Rider Small size Low weight Cost under $500 including shipping Julia Clarke FAMU-FSU 2012 Solar Car Final System Design Review Report, Bosworth et al, April Battery and Battery Management System

Battery System In addition to the battery the team purchased a Turnigy Watt- Meter and Power Analyzer to measures: batteries performance health while in use Julia Clarke FAMU-FSU 2012 Solar Car Final System Design Review Report, Bosworth et al, April Watt meter and Power Analyzer

Overview of Electrical System

Stage 1 Steval ISV005V2 Board SPV1020 MPPT Algorithm Worst Case Scenario Vout=10V "ISV005V2." Data Sheet for ISV005V2. Steval Microelectronics, n.d. Web. 14 Nov < Zachary Barr Stage 1 DC-DC Converter

Overview of Electrical System

Stage 2 Texas Instruments LM5000 Surface mounted Range of Input 3.1V– 40V Range of Output 1.259V – 75V LM5000. Digital image. Texas Instruments, n.d. Web. 14 Nov (.) Zachary Barr Stage 2 DC-DC Converter

Stage 2 In order to set the output voltage: LM5000. Digital image. Texas Instruments, n.d. Web. 14 Nov (.) Zachary Barr

Solar Panels Competition Limitations Design Selection Solution Implementation Risks Francois Wolmarans FAMU-FSU 2012 Solar Car Final System Design Review Report, Bosworth et al, April Solar Panel Implementation

Presentation Overview Introduction and Registration Update Scheduling and Progress Comparison Matrix Mechanical Overview Mechanical Components Electrical Overview Electrical components Budgeting and Estimates

Budget Update Personnel & Misc. Recap Materials Selection Materials Estimates Francois Wolmarans ExpenditureCost Personnel$92, Fringe Benefits$26, Expenses$ Equipment 1 $0.00 Sub-Total$119, Overhead Costs$53, Total Estimated Project Cost $173,250.93

Estimating Material Volumes per Part Materials Pricing Materials Estimates Aluminum Plate Price per 1 in³ Grade2011-T32024-T36061-T66262-T6511 Price Estimate $ $0.96 Part:Quantity: Volume (in³) Total Volume (in³) Desired Material: Front Brake Base Aluminum Front Wheel Mount Aluminum Francois Wolmarans

Questions

Center of Gravity Calculating Weight Ratio

Static Vertical Wheel Load Calculations

Calculating Stresses

Lateral Braking Force Assumptions: Stopping Distance from 15mph: 32 ft Center of Gravity Height: 8 in Starting Velocity: 15 mph = 22 ft/s Calculated Variables: Curb Weight: 470 lbs Front Weight Ratio: 35% Rear Weight Ratio: 65% Front Static Load: lbs Rear Static Load: lbs Wheel Base: 82 in

Calculating Turning Radius

Motor’s Max Parameters Performance Data Fritz Jeanty “Magic Pie Motor." Performance Data. Golden Motor, n.d. Web. 14 Nov