1. 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

2. Outline Objective Goals Hybrid Systems Frame Design
Finite Elemental Analysis
Suspension Geometry
Component Selection
Project Management

3. Objective
To design and fabricate a hybrid vehicle for the 2017 SAE Formula Hybrid competition.

4. 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

5. 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

6. 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

7. 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)

8. 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

9. 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

10. Suspension Double Control Arm Unequal Length
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

11. 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

12. Internal Combustion Engines
Engine: Ninja 250R
Description: Parallel twin, four-stroke, liquid cooled, DOHC
Displacement: 249cc
Weight: 90 lbs.
Power Output: 25Hp
Torque: 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

13. Differential Mfg: Torsen Type: Torque Bias Torque: 383 ft-lbs
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

14. Tractive Motor Motor: PMG-132 Voltage: 72 V Current: 200 A
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

15. Motor/Generator Motor: Manta Voltage: 48 V Current: 200 A
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

16. Motor Controller Selection
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

17. Accumulator Selection
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

18. Accumulator Management Selection
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

19. Programmable Controller Selection
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

20. Project Timeline

21. 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

22. 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

23. 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

24. QUESTIONS?