1. Team Hybrid  Daniel Farley  John Hoyt  Sean Frost Hoyt

2. Background Information Hoyt Conventional drive train- torque is applied from an internal combustion engine Hybrid vehicle drive train- An electric motor and/or an internal combustion engine can apply torque to the drive wheels ICE Axle Assembly Power Split Device ICE Generator Electric Motor Axle Assembly Battery Bank Generator Electric Motor Axle Assembly ICE ConventionalHybrid- ParallelHybrid- Series

3. Problem Statement: Vermont Technical College would like to compete in the Dartmouth Thayer School of Engineering Formula One Hybrid Racing Competition, but we do not currently have a vehicle that meets the specifications. Farley

4. Solution Statement: To develop and demonstrate a hybrid propulsion system which meets the following requirements 1. Comprises both an internal combustion engine (ICE) and an electrical storage unit with electric drive 2. The system shall meet all electrical specifications and requirements for the 2007 Dartmouth Thayer School of Engineering Formula One Racing Competition. 3. The drive system may deploy the ICE and electric motor(s) in any configuration including series and parallel. 4. Final design will allow the drive train system to be adapted to a chassis developed in a separate effort. Farley

5. Frost Hybrid Propulsion System Overview Low Pressure Feedback Battery Bank ICE Generator Electric Motor Power Split Device Axle Assembly Accumulator V+ Hydraulic Pumps 4 port, 2 way valve Check valves The rotational input from both the electric motor and ICE will drive hydraulic pumps to pressurize the accumulator. The hydraulic pressure will act on hydraulic motors positioned at the drive wheels to power the vehicle. Regenerative braking will allow the hydraulic motors to pressurize fluid back into the accumulator for future use. Hydraulic Motors Accumulator

6. Frost Generator Electric Motor FB1-4001A V+ +120 VDC Belt connection To the ICE Raptor 1200 Motor Controller Manzanita Micro PFC-20 charge controller Electrical charge accumulator Electrical Motor/Generator & Controllers Subsystem (Control Sub-System) Hydraulic Pump Frost

7. Hoyt Generator FB1-4001A #1 Belt connection To the ICE Hydraulic Pump ICE Internal Combustion and Clutch/Pump Subsystem (Hydraulic Drive Sub-System) Electric Clutch V+ Electric Clutch Clutch Control Signal FB1-4001A #2 Hydraulic Pump Battery Bank

8. Accumulator 2 4 Port, 2 Way Electronically Controlled Valve Hydraulic Pump Accumulator 1 Reservoir ICE Input Check Valve 4 Port, 2 Way Electronically Controlled Valve Electronically Controlled Flow Valve Hydraulic Motor Hydraulic Subsystem Overview (Hydraulic Driven Sub-System) Farley Electric Motor Input

9. Accumulator 1 Reservoir Electric Motor Input ICE Input Check Valve 4 Port, 2 Way Electronically Controlled Valve Electronically Controlled Flow Valve Accumulator 2 4 Port, 2 Way Electronically Controlled Valve Hydraulic Pump Hydraulic Motor Hydraulic Subsystem Overview (Regenerative Braking Sub-System) Farley

10. Modes of Operation Standby OFF Full Acceleration ICE Elec. motor Accumulator Tire ICE Elec. motor Accumulator Tire Efficiency ICE Elec. motor Accumulator Tire Regular Drive Pressure (energy) Pressure (energy) Pressure (energy) INPUTS -Shutoff switch -Battery Voltage -Motor Speeds -Fuel Supply -Mode selector -Brake switch -TPS -Regen. Braking switch µ- Controller OUTPUTS -Throttle actuated sol. -Hydraulic flow valves -Regen. Braking Assembly -Electric Motor speed State Machine Frost

11. Control System Output Description S0- Efficiency Default S1- ICE Control S2- Electric Motor Feedback S3- Drive Valve S4- ICE Feedback S5- Generator Clutch S6- Electric Motor Control S7- ICE-Hydraulic Pump Clutch S8- Generator-Battery Relay S9- N.O. Electric Relay S10- ICE Shutoff S11- Regenerative Valve S12- Regenerative Motor Clutch Acceleration 0101001101000 Efficiency 1011111110010 Regen. Braking 1001100001011 Regen. Drive 1000100001010 Regular Drive 0111111111100 Standby 000000000000 HC08 Sensor Inputs Farley

12. Control System S4 S2 S6 * 100 S0 S1∑ * ∑ * S5 * Throttle Request S0- Efficiency Default S1- ICE Control S2- Electric Motor Feedback S3- Drive Valve S4- ICE Feedback S5- Generator Clutch S6- Electric Motor Control Frost Microcontroller Outputs *

13. Performance Curves for Mathematical Model Electric Motor/Generator curves Internal Combustion Curves Frost

14. System Simulation (Test for functionality and rationality) The system was mathematically modeled Using VisSim simulation software Frost

15. Team Hybrid Budget to date Mar. 19th

16. Proof of Concept Due to the high cost of hydraulic components and limited schedule we have decided to present two prototype demonstrations that represent the whole system Control of the ICE, electric motor, electronic clutches and power coupling Pneumatic model actuated by microcontroller which demonstrates drive mode and regenerative braking Hoyt

17. Proof of Concept - Systems Power Coupling HC08 GasBrake Stepper Motor Pneumatic Motor Hydraulic (pneumatic) Drive Concept ICE Electric motor Hydrostatic drive Clutch Assembly Battery Pack Farley Differential Generator Manifold Piston

18. Personnel Assignments MemberSubsystem Sean FrostElectric motor, motor controller, chargecontroller, charge accumulators Dan FarleyHydraulic component selection and implementation: Pumps, motors, valves, accumulators John HoytInternal Combustion Engine; Implementation of sensors; Design of clutches for ICE and electric motor Hoyt

19. Completed -Mathematical Modeling of Electric Motor and ICE subsystems -System overview diagram -All subsystems designed and defined; Hydraulic, Electrical, Regenerative Braking, ICE & clutch assembly -Located differentials for demonstration between the ICE and Electric motor -Chose electrical charge accumulators -Defined states for complete system control diagram In Progress -Control software programming for each subsystem -Physical model of the hydraulic subsystem using pneumatics -Physical model of the power coupling Major Milestones

20. Summary In order to compete in the Thayer School of Engineering Formula One Hybrid Competition, a hybrid drive-train is essential. Team Hybrid has designed a hybrid propulsion system that meets the required specifications. The drive train will be tested in two separate subsystems to demonstrate regenerative braking, switching between drive modes, power coupling and control of the ICE and electric motor. Farley