1. MSD P15280 RIT HOT WHEELZ TEST BENCH

3. AGENDA ❖ Detailed Design Review ➢ Competition Benchmarking ➢ Mechanical ●Motor Mount & Baseplate ●Modular Cart Design ●Motor Coupling Design ➢ Electrical ●Dyno Interface ●Sourced Components ●KGCOE Dynamometer Lab Quick Start Guide

4. Formula Hybrid Competition 2015- Benchmarking ❖ Variety of Designs ❖ Lack of Preparation ❖ Strenuous Inspection Procedure ❖ Attention to Detail is Critical

5. Formula Hybrid Competition 2015- Benchmarking ❖ 2+ Teams using Emrax Electric Motors ❖ Benchmarking the Motor Mounting

6. Formula Hybrid Competition 2015- Benchmarking ❖ Suggestion to use Rinehart Controller ➢ User Friendly ➢ Isolation Built-in ❖ PM100 - 100kW Class ➢ 300 Arms Continous ➢ 350Arms Peak ➢ 160-360VDC

7. MECHANICAL

8. UPDATED DESIGN CONCEPT CONT.

9. Mounting Design Concept- Revision 1 Issues ❖ Easily change position to mount to the chain ❖ Adaptable to different configurations ❖ Failed FEA under maximum loading conditions ❖ Covered critical ports into the motor

10. Mounting Design Concept- Revision 2 ❖ More robust design ❖ 304 Stainless Steel ➢ 0.25” Baseplate ➢ 0.5” Upright Mount ❖ Incorporates proper hole pattern of the motor

11. Mounting Design Concept- Revision 2 ❖ Added Gussets for Strength in Bending at the base ❖ Fillet Welds will be used to join the gussets, the base plate and the upright mount

12. Mounting Design Concept- Assembly

13. Mounting Design Concept- Base Plate ❖ Slotted Base Plate to Match Current Dyno Mounting ❖ Allows for adjustability when lining up the chain ❖ 0.25” X 10” X 10” 304 Stainless Steel

14. Mounting Design Concept- Motor Mount ❖ 100 N/m Torque on Each Bolt Hole ~800 N/m combined loading ❖ 0.03 mm of Maximum Displacement ❖ Does not exceed yield strength of 304 Stainless Steel ❖ Minimum Factor of Safety of 2.5

15. Mounting Design Concept- Assembly

16. Mounting Design Concept- Moving Forward ❖ Detailed Budget ❖ Weight Minimization to use the same design on the car

17. DETAILED CART DESIGN ❖ A 30” X 60” cart was sourced from Global Industrial bases on the cost saving between building a cart and buying one. ➢ ~$700 for raw materials & mounting accessories ➢ ~$500 for base cart & mounting accessories ❖ Cart Specifications ➢ 1000 lb capacity ➢ 5” Wheel Diameter ➢ Removeable Handle can be mounted on either side http://www.globalindustrial.com/p/material-handling/platform-trucks/wood/steel-bound-wood-deck-truck-60x30-1000-lb-capacity

18. DETAILED CART DESIGN CONT. Cart Components & Mounting Controller

19. DETAILED CART DESIGN CONT. Battery Enclosures & Mounting Battery Specifications Width (in):9.65 Depth (in):14.09 Height (in):11.22 Quantity:4.00 Weight (kg):24.00 Weight (lbs)52.91 Total Weight (kg):96.00 Total Weight (lbs):211.64

20. DETAILED CART DESIGN CONT. Battery Enclosures & Mounting Battery AssemblyMounting Plate

21. ❖ Waiting on CAD files & more dimensions of the Cart to finalize Motor Mount design dimensions ❖ Finish mounting hole pattern ❖ Finalize layout options for the Hot Wheelz Components NEXT STEPS

22. MOTOR COUPLING DETAILED DESIGN Current Dyno Existing Idler / tensioner system

23. MOTOR COUPLING DETAILED DESIGN ●Chain ○Heavy Duty, ⅝” pitch, 1620 lb working load ○Length TBD ●Idler Sprocket ○OD not critical ○Built-in bearing for ease of mounting to shaft *images from McMaster-Carr

24. MOTOR COUPLING DETAILED DESIGN ●Transmission Sprockets ○Hot Wheelz team gear ratio (2) ○Pinion (~4” OD) ■Keyway to fit motor output shaft ●Multiple keyways in consideration ●Unknown bore size ■http://www.mcmaster.com/#6280K259 (20 teeth)http://www.mcmaster.com/#6280K259 ○Gear (flat, ~8” OD) ■Machinable to fit existing dyno mount ■http://www.mcmaster.com/#2299K57 (40 teeth)http://www.mcmaster.com/#2299K57

25. MOTOR COUPLING DETAILED DESIGN Pinion *images from McMaster-Carr Gear *images from McMaster-Carr

26. MOTOR COUPLING DETAILED DESIGN ●Idler ○Creating our own

27. MOTOR COUPLING DETAILED DESIGN ●Idler ○Fits existing dyno table hole pattern ■Slots allow for position adjustment ○Two springs provide tension to chain ○Height adjustable to take up chain slack ■Locked in place with 4 screws

28. ELECTRICAL

29. Sensor Sourcing

30. Overall Preliminary Wiring Diagram Dyno RoomControl Room Dedicated thermocouple DAQ

31. Custom PCB Diagram 1N5818: Schottky diode with maximum reversed voltage of 30V, and nominal forward voltage of ~0.5V L78S10CV: Linear 10V 2A voltage regulator Equivalent Resistances determined by maximum supply current for corresponding sensors

32. Wiring Harnesses Dyno-Control Harness Dummy Connector Sensor Terminal Harness Sensor-PCB Harness PCB-DAQ Harness -Twisted pairs for signal paths -Molex or APP connectors -18 AWG

33. ❖ Quick Start Guide ■Document can be found on the P15280 edge site under /public/Final Documents ■Overview of the environment ●Dyno room & Controller room ■Steps to operate the Dyno without a DUT ●Manually with push buttons on Dyn-Loc IV Controller ●Digitally with RealTerm software. ■Problems encountered and discrepancies with official manual KGCOE Dynamometer Lab Quick Start Guide

34. QUESTIONS? FEEDBACK? SUGGESTIONS?