1. MSD P15280 RIT HOT WHEELZ TEST BENCH

3. AGENDA ❖ Review Problem Definition Material ❖ Review System Design Material ❖ Sub-System Design Review ▪Motor Sourcing ▪Motor Coupling Solutions ▪Heat Transfer Analysis ▪Electrical Testing ▪Sensor Solutions ❖ Design Changes ▪Current Dyno Functions ▪Updated Problem Definition Material ▪Plans for Improvements & Changes

4. PROBLEM DEFINITION REVIEW

5. PROJECT BACKGROUND ❖ The RIT Hot Wheelz Electric Vehicle Team is a group of all female undergraduate engineers who come together to form a team of innovative and creative race enthusiasts. ❖ There focus is an environment of both learning and teaching with hands-on design and build experience. ❖ Previously, the team has competed in only Imagine RIT events ❖ 2012- Electric Dragster Competition ~ 1 st Place ❖ 2013- Electric Endurance Competition ~ 3 rd Place ❖ 2014- Electric Autocross Competition ~ 3 rd Place ❖ The team is ready to take their skills to the next level! ❖ 2016- Formula Hybrid-Electric only

6. PROJECT STATEMENT

7. CUSTOMER REQUIREMENTS

9. SYSTEM DESIGN REVIEW

10. Pugh Chart

12. BENCHMARKING- Example Test Benches ❖ Speed Control Test Bench (Left) ➢ Allows the study of the operation of a servodrive when a variety of loads are applied to the motor. ➢ Powder Brake to vary motor load ➢ Main Components: ■Motor Voltage ■Motor Temperature ■Load amount and type ❖ Motor Test Bench (Below) ➢ Robust, multi-compatible ➢ Flexibility through modular design ➢ Motor Torque, Power & Efficiency

13. SELECTED CONCEPT- MECHANICAL ❖ Two mechanical structures ➢ Mobile Cart to mimic Hot Wheelz Chassis ➢ Enclosed T-framed structure to house motors and moving parts ➢ UI will be located on top of the T-framed enclosure. ➢ All pieces are portable and compact Above: Preliminary CAD model of a 36in by 30in T-slot aluminum framing enclosure with two removable plexiglass panels for access and electrical attachment.

14. SUB-SYSTEM DESIGN REVIEW

15. MOTOR SOURCING ❖ Enstroj Emrax 228 Sourced to Vary Load on the Hot Wheelz Powertrain ➢ AC Electric Motor ➢ 3000-5000 Continuous RPM ➢ 35-55 kW Continuous Motor Power ➢ 240 Nm Max Torque ; 125 Nm Continuous Torque

16. MOTOR COUPLING SOLUTIONS Concerns: ❖ Vibration ❖ Durability ❖ Modularity ❖ Safety

17. MOTOR COUPLING SOLUTIONS Initial Concept: ❖ Subject Matter Experts ➢ Dr. Ghoneim (vibration) ➢ Prof. Humphrey (power transmission) ❖ Multi V-Belt ➢ Absorbs vibrations ➢ No slip is not critical ❖ Sheave (Pulley) ➢ Supported by a bearing on each side ➢ Fully enclosed for safety

18. HEAT TRANSFER ANALYSIS ❖ Energy Dissipation Method Using Resistor Banks ➢ TE Connectivity Wirewound Resistors ■Power Rating 2.5kW ❖ Assumptions ➢ Continuous Run Time 10 Minutes ➢ Room Size: 18’ X 18’ X 12’ ➢ Initial Temperature is 23 degrees Celsius ➢ Using 14 Resistors to Dissipate 32kW of Power (Worst Case) ❖ Results ➢ Final temperature of Hot Wheelz Room After Testing → 146 degrees Celsius (296 degrees Fahrenheit)

19. ELECTRICAL MOTOR TESTING

20. ELECTRICAL TESTING Equivalent Resistance Analysis Schematic of Resistive Network s: Duty Cycle of PWM

21. ELECTRICAL TESTING Approximation Analysis When R1 >> R2, Relationship could be linearized by restricting range of s:

22. ❖ Voltage Sensor ➢ CR Magnetics - CR5310 - 600 ➢ Sensing voltage - 600Vdc ➢ $207.35 ------------------------------------------ ➢ CR Magnetics - CR4811 - 600 ➢ Sensing voltage - 600Vac ➢ $156.97 ❖ Current Sensor ➢ Honeywell Sensing and Control CSLA2EL ➢ Sensing current - 550A max AC/DC ➢ $50.00/sensor ❖ Temperature Transducer ➢ Microchip Technology MCP9701A-E/TO ➢ Sensing temperature - Local -10°C ~ 125°C ➢ $0.37/sensor SENSOR SOLUTIONS

23. ❖ Ultrasonic Proximity Transducer ➢ Sparkfun Ultrasonic Range Finder - LV-MaxSonar-EZ1 ➢ Sensing Range - 255 inches (0 to 6.45m) in 1 inch increments ➢ $25.95/sensor ❖ Encoder ➢ ams AS5048 Magnetic Rotary Encoder ➢ Sensing Range - 30mT to 70mT ➢ $6.60/IC ❖ Out of price range: ➢ Torque Transducer ➢ Price upwards of $1,000+ (Acquire data from Hot Wheelz sensors instead)

24. UC FLOW DIAGRAM 1.Make connection with computer 1.Obtain test parameters - manual test or simulated 1.Check interlocks 1.Begin test 1.Collect data

25. UC FLOW DIAGRAM Sampling ISR - Handles same rate and sampling from different Sensors Interlock/ESTOP Fault ISR - Automatically stops Hot Wheelz and loading motor Incoming Message from Computer ISR - Interpret message and execute appropriate code

26. DESIGN CHANGES

27. CURRENT KGCOE DYNAMOMETER

28. CURRENT KGCOE DYNAMOMETER-CONTROLS ROOM

29. UPDATED CUSTOMER REQUIREMENTS

30. UPDATED ENGINEERING REQUIREMENTS

31. UPDATED CONSTRAINTS

32. UPDATED DESIGN CONCEPT

33. UPDATED DESIGN CONCEPT CONT.

36. MOTOR COUPLING SOLUTIONS Current Dyno A similar system will be adopted for our motor.

37. UPDATED RISK ASSESSMENT

38. PROGRESSION TIMELINE

39. QUESTIONS? FEEDBACK? SUGGESTIONS?