Powertrain for RIT EV Team TT- Zero Race Bike R12900 Sean Harriman 5/20/2012

Updated Mission Statement  To design, bench test and implement an electric drive system on a rolling chassis provided by the Electric Vehicle Team that operates at race speeds and has a just enough range to finish the TT-Zero around the Isle of Man Road Course while maximizing the power of the electric motor to the road through the use of a traction controller.

Place of Innovation  “the Isle of Man TT, the toughest motorcycle race in the world. The technology at work is so advanced, so unprecedented, that we may be looking not just at the future of motorcycles, but of all electric vehicles." From the article "Inside Story Motoczysz E1PC Worlds Most Advanced Electric Motorcycle"  Electric Motorcycle Racing 3 rd year already approaching lap times of low end 1000cc Grand Prix Bikes

TT-Zero Race Details  "The technical concept is for motorcycles (two wheeled) to be powered without the use of carbon based fuels and have zero toxic/noxious emissions." -REGULATIONS TT ZERO  £10,000 for the first entrant to exceed the prestigious 100 mph (22 minutes and seconds) average speed there are also awards for the first ten teams to break the record  Top competing university which is offered a prize of £5,000

Snaefell Mountain Course Length: miles 200 Corners 60 Named Corners TT-Zero: 1 Lap Isle of Man TT: one of the most prestigious motorcycle races in the world

Constraints:  Race Date: May 28, 2013 (Assumed same date as 2012)  Race Electrical Safety Regulations  Input Charging Power: 240 V single phase 13 amp max  Vehicle Total Weight: 100kg-300kg (220lbs-660lbs)  Powertrain Weight Allowance (exclude batteries/motor): 60lbs (Subject to change)  Course Length miles  Qualifying time: 50 mins average course speed 45.3 mph  Must perform standing start on 18% incline

Changes in Design Problem/Objective Needs  Essentially Same Design Problem: Push Performance of Electric Vehicle Design  From reach spec of Range of 140 miles to easy miles  From easy spec of operating speeds mph to reach spec of 150+ mph  Still high emphasis on fuel efficiency  No longer constrained to road registered vehicle  Still focus on powertrain  More defined scope, meet race safety regulations and constraints  More integrated design with Traction Controller

Functional Decomposition: Flow Diagram

Benchmarks Motorcycles:  Honda CBR1000RR (Course Record)  MotoCzysz E1pc (2010/11 Winner)  MIT EV Team eSuperbike  Brammo Empulse R (1 st time Competitor)  Honda Mugen EV (1 st time Competitor) Specifications Compared:  Motor: Style/output/operating Volts/amps  Controller Style  Battery Pack: Chemistry/volts/amps  Weight  Range/Top Speed/Course Average Speed  Transmission

Honda CBR1000RR  Motor : ICE 999cc inline 4  178 hp/82.6 lb-ft  Wet Weight: 441 lbs  Top Speed: mph(stock) 200+ mph (race)  Course Average: mph 17’12.3 min’sec  Holds Course Record

MotoCzysz E1pc  Motor: DC perm magnet ‘D1g1tal Dr1ve’  100 hp / 250 lb-ft  Battery: LiPo  500 V/ 125 Kwh  Top Speed: 140 mph  Direct Drive  Course Average: mph 22' min'sec  Current EV course record, winner 2010/11  Focused on developing fastest bike with sufficient capacity buffer. Finished w/ 60% charge left

MIT eSuperbike  Motor: 2x Lynch DC Thin-Gab Axial Flux Motors  Battery: A123 Automotive LiFePO4 Prismatic Modules  Top Speed: 100 mph  Direct Drive  Course Average Speed: mph 28' min'sec

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House of Quality

Staffing Ideal Scope Discipline How Many? Anticipated Skills Needed EE2 EE1: Main Circuit Design, onboard/accessory circuit design and assembly EE2: Power system optimization, battery management, controls system design ME3 ME1: CAD Drawing, Interfacing w/ Traction Controller, Physical mounting ME2: Transmission Modification/Optimization, Final Drive Design ME3: Machining/Assembly Experience/Test Design CE1 CE1: Embedded real time system, fuzzy logic control algorithm. Device programming. Signals Processing

Feedback From Electric Vehicle Team  Scoping  Ideal Situation: Top Speeds 200 mph Course average mph 17'12.30 min'sec Goal: Beat Course record  Powertrain Budget: $15,000  Medium Scope: Top Speeds 140 mph Course average 100 mph 22'38.33 min'sec  Goal: Beat 100 mph EV course record win 10,000 pounds prize and top competing university win 5,000 pounds prize  Powertrain Budget: $7,500  Smallest Scope: Bench Test scaled components and have Course Simulation of Ideal Scope  Powertrain Budget:$500 MSD Funding

Feedback From Electric Vehicle Team  Specifications:  The Electric Vehicle Team will Develop a Course/Race Model over summer  Provide MSD I with more specific and optimized specification values  Battery/Motor selection  Staffing:  Sean Harriman Electric Vehicle Team Powertrain Project Manager: Lead Engineer-ME1 MSD Team  Dan Brownlee Electric Vehicle Team Vice President: ME2 MSD Team  Andrew Robison Course/Race Model Developer: ME3 MSD Team

Questions?