1. 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.

2. OBJECTIVE
To design and fabricate a hybrid vehicle for the 2017 SAE Formula Hybrid competition.

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. FRAME DESIGNS University of Victoria (2015)
Design Score:178.29
University of Houston (2015)
Design Score: N.A
University of Waterloo (2015)
Design Score

10. 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
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

11. 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 $
$600.00
Ninja 250R
Honda Grom
Honda CBR250R

12. 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 $ $
Torsen
Drexler
Taylor

13. 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 $ $ $
AC-12
WarP 9
PMG-132

14. 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

15. 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

16. 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 $ $
$200.00
Orion
Lithiumate
MiniBMS

17. 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 $
$20.00
myRIO
Compact RIO
Arduino Due

18. 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

19. 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

20. 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

21. Total with ~25% Contingency
BUDGET
Components
Cost
Chassis Materials $
Internal Combustion Engine $
Electrical Components $
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 $
Registration Fee $
Total
$17,244.00
Total with ~25% Contingency
$22,000.00

22. 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

23. QUESTIONS?