2. FLORIDA INSTITUTE OF TECHNOLOGY COLLEGE OF ENGINEERING
Design Presentation
Project: 2007 R.E.V. Team
Presented By:
Elizabeth Diaz Jason Miner Jared Doescher Josh Wales
Kathy Murray AJ Nick Dave Wickers Oliver Zimmerman

3. Project Scope: Promote community awareness of electric vehicles
Design and Build an electric racing vehicle
Promote community awareness of electric vehicles
Electric Car designed to compete in SCCA Autocross
and Formula Hybrid competition
- Competing as “Hybrid-in-Progress” vehicle for one year only
- Electric Car designed to compete in Autocross, Acceleration and Endurance races
Will meet requirements for the 2007 Formula Hybrid
competition and NEDRA race competition
The Racing Electric Vehicle, or R.E.V., is an electric car designed to compete in the 2007 Formula Hybrid competition. This competition is for IEEE student members to redesign, modify, and compete with hybrid Formula SAE racing cars. The students are encouraged to make use of previous years Formula SAE cars so that the knowledge, creativity, and imagination of the students are challenged. The cars are built with a team effort over a period of about one year and are taken to the annual competition for judging and comparison with other modified Formula SAE vehicles from colleges and university throughout the United States. The end result is a great experience for aspiring engineers in a meaningful project as well as the opportunity of working in a dedicated team effort.
The R.E.V. team will design, manufacture, assemble, test, and present their electric car in the 2007 Formula Hybrid competition.

4. Engineering Objectives:
Acceleration from 0 to 60 mph in under 5 seconds
Top speed of 80 mph
Maximum power available between 20 and 40 mph
Lightweight (under 650lb without driver)
15 minute battery life for continuous draw

5. Driver Interface & Ergonomics
Team Organization:
Team Lead
Design Teams
Development Group
Procurement Group
Manufacturing Group
Integration Team
Chassis & Body
Chassis Redesign
Body Redesign
Mounting Points
Aeros/Ground Effects
Drive System
Motor
Drivetrain
Control System
Battery System
Cooling System
Shielding System
Electrical
Battery Management
Instrumentation
Data Transfer System
Power Management
Vehicle Dynamics
Suspension System
Steering System
Braking System
Driver Interface & Ergonomics
Cockpit Design
Safety Equipment
Driver Interface

6. Team Organization: REV Design Teams
Team Lead:
Elizabeth Diaz
Design Teams
Drive System Team:
Vehicle Dynamics Team:
Chassis & Body Team:
Josh Wales
AJ Nick
Kathy Murray
Jason Miner
AJ Nick
Dave Wickers
Jason Miner
Dave Wickers
AJ Nick
Jared Doescher
Kathy Murray
Electrical Team:
Driver Interface Team:
Matt Reedy
Valerie Bastien
Audrey Moyers
Kristi Harrell
Oliver Zimmerman
Dave Wickers

7. Major Goals of the Team Complete the car
Create/Integrate Lithium-Ion pack
More publicity
Autocross racing
More EV events
Local advertising
Funding

8. Florida Tech REV Overall Length, Width, Height: 107in x 60in x 46in
Wheelbase: 68.5in
Front Track: 52in
Rear Track: 50in
Weight: 795lbs (without driver)

9. Engineering Specifications
Design: Chassis
Engineering Specifications
Static deflection – Less than .333”
Torsional Rigidity – above ft-lbs/deg
Wheelbase – between 60” and 70”
Designed to fit 95 percentile person
Withstand stresses under dynamic and static loading with factor of safety of 3
UPDATE, and is this the original set of objectives? 9

10. Design: Chassis Side Pods act as impact structure
Upper side impact structure member attached too high to main hoop
As requested by Formula Hybrid, new cross member had to be constructed to protect driver
UPDATE, and is this the original set of objectives? 10

11. Static Stress Analysis Max deflection: -.0098 inches
Static Analysis
Deflection Analysis
Static Stress Analysis
Max deflection: inches
Max stress: 5361 psi
Factor of safety:11.9

12. Dynamic Stress Analysis
Using MSC ADAMS to get forces at A-Arm attachments
Braking ( in 3 sec)
Lane change at 50 mph
60 mph radius turn of 343 feet
Applied loads in ANSYS to find stress
Braking
Cornering
Max stress: psi
Max stress: psi

13. Analysis Changes: Chassis
Torsional Rigidity Analysis
Constrained back of frame and added forces to front hoop
Measured deflection at nodes on hoop
Calculated Torsional rigidity by:
4900 ft/lbs per degree

14. Manufacturing: Chassis
Frame was constructed on campus
Weld analysis proved welds will hold
Intersections with many multiple welds were hardest to cope
Pro-e drawings, or calculations that were done 14

15. Lessons Learned: Chassis
Have more than one designer on the chassis
Design and analysis together
Consideration of weight versus strength
Pro-e drawings, or calculations that were done 15

16. Suspension Design Allow 1” travel jounce and rebound
Achieve maximum tire contact at all times
Optimize handling
Non-equal, Non-parallel A-arms
Push rod actuated coil-overs
Variable dampers

17. Suspension Design Specifications
Table 3.7: Front Suspension Geometry
Static Camber
-1.5˚
Camber Gain in Jounce
-.95˚/1"
Camber Gain in Rebound
.89˚/1"
Caster 5˚
Kingpin Offset
.915"
Kingpin Inclination 0˚
Toe In
Ground Clearance
2"
Static Roll Center
1.23"
Roll 1" Jounce
-.18"
Roll 1" Rebound
2.65"
Front Track Width
52"
Table 3.8: Rear Suspension Geometry
Static Camber 0˚
Camber Gain in Jounce
-1.05˚/1"
Camber Gain in Rebound
1.02˚/1"
Caster 3˚
Kingpin Offset
0.02"
Kingpin Inclination
Toe In 1˚
Ground Clearance
2"
Static Roll Center
1.34"
Roll 1" Jounce
0.4"
Roll 1" Rebound
2.75"
Rear Track Width
50"

18. Front Suspension BELLCRANK POSITION CHANGE FOR CLEARANCE ISSUES
Pro-e drawings, or calculations that were done
BELLCRANK POSITION CHANGE FOR CLEARANCE ISSUES

19. Rear Suspension COILOVER ACTUATION DESIGN COILOVER ACTUATION BUILD
Here we want something about the design specs of the suspension
COILOVER ACTUATION BUILD

20. Suspension Adjustability
Roll Center
Shims between clevis

21. Suspension Spring Rates
Any other info about the suspension
FRONT SPRING RATE ≈ 350 LB/IN REAR SPRING RATE ≈ 372 LB/IN

22. Adjustable damping in jounce and rebound Preload adjustment
Dampers
Nitrogen Charged
Adjustable damping in jounce and rebound
Preload adjustment
Cost effective
Jupiter 5 by Risse Racing

23. Full Ackermann geometry
Steering Geometry
Rack and Pinion
Lower rear placement
Full Ackermann geometry
Any other info about the suspension

24. Testing and Improvements
Final car setup and fine tuning
Ride Height
Camber
Toe
Add anti-roll bars
Add sensors
Pro-e drawings, or calculations that were done

25. Lessons Learned: Suspension
Check more thoroughly for clearance issues
Use proper bolts
Change clevis design

26. Design: Differential Brute Force Kawasaki ATV front differential
Limited Slip with a selectable locker
gear reduction
General information about the differential, why it was chosen, what specs it helped to fulfill

27. Differential & Mounting
Tensile Yield Stress of Aluminum: 47000 psi
3/8” thick aluminum
Max Von Mises stress: psi
Factor of safety of 1.3
Not sure if we want to use a set up like this with pro-e and ansys on one slide or leave it like before separated

28. Differential & Mounting
Instead of remanufacturing with 1/2” aluminum an additional mount was added
Max Von Mises stress: psi
Factor of Safety of 1.8

29. Design: Electrical Integration
Warp 9” motor, 80hp peak, 140ft-lbs
32.3 continuous horsepower (versatile)
600amps, 144volts from Zilla 1K-HV (with power conversion)
2 min full throttle run time, 15min at 35mph
Top Speed 6000 rpm
Pic to PLC to LCD
Something on here about motor choice

30. Power Source & Containment Area
Lead Acid Batteries 232lbs, 13.6 usable Ah (17ah, up to 80% discharge) at 192V (Nominal)
16 cells, cost approx. $1500
Odyssey PC680 Lead-acid batteries
Diagonal Support tube thickness increased to .095” (full X)
Battery Layout
Strapped together then strapped to supports
Plexiglas to cover connections (with High Voltage Warning Label)
Nomex fabric on walls and bottom for electrical insulation and fire protection
Odyssey Battery,
Model PC680

31. Power Source & Containment Area
Full High Voltage Accumulator Containment
Dual Contactors default to Open
3 Emergency Stop Buttons
Fuse Backup
High power lines outside Battery Area held in rubberized conduit
Ferraz-Shawmut
Fuse
Albright SW200
contactor

32. Design: Performance Calcs
Motor, Battery, gear ratio combination was essential decision.
Excel Spreadsheet used to compare and optimize.
Takes into account specs and calculates 0-60 time, voltage drop, runtime, and more.
Final Configuration:
0-60mph in 4.5 seconds (calculated)
Something on here about motor choice

33. Design: Brakes Design Criteria Alterations in Design
Braking system that acts on all four wheels and is operated by single control
Two independent hydraulic circuits
Alterations in Design
New master cylinders were purchased due to a leak in the old ones

34. Design: Brakes Design Calculations
To optimize handling the front wheels should lock up first in a full braking situation
To ensure this a bias was applied to master cylinders
Front 60% and rear 40%
Full Braking from 60 mph
Calculated stopping distance: ft

35. Design Changes: Steering Wheel
Previous Design
Design Criteria
Must be able to hold the touch screen
Comply with SAE rules
Designed to be as light as possible while remaining rigid enough to protect touch screen
Shaped for driver’s comfort
Alterations in Design
Changed because of the method of mounting provided from manufacturer
Created a new wheel to be fully closed loop IAW SAE rules
Current Design

36. Design Changes: Steering Wheel
Design Criteria
Structurally Rigid and Reliable
Previous Steering Wheel did not fit design criteria
Also did not need touch screen for competition

37. Design Changes: Acceleration Pedal
Previous Design
Design Criteria
Ergonomic to fit driver
Highly reliable
Alterations in Design
Design Simplified to increase reliability
More ergonomic for driver
Current Design

38. Design: Safety Design Criteria How we meet/exceed criteria
Must have a 5-point or 6-point harness
Driver Must Be Isolated from High-voltage
Front Impact attenuator
Side impact structure
Must have at least 3 Large Emergency Shut Off buttons
How we meet/exceed criteria
We have a 5-point harness that corresponds to Formula SAE regulations
High-voltage wires are isolated in Side Pods and conduit outside of Side Pods
Impact attenuator fits FSAE regulations
Our Side Impact structure Approved Structural Equivalency
Two Emergency Shut off buttons on either side of roll hoop and one on driver’s dash board, also one main switch
Hairball Controller Interface allows user to limit power

39. Emergency Stop Switches
Design: Safety
Main Switch
Safety Harness
Emergency Stop Switches
Hairball – Controller Interface
Safety Suit & Helmet

40. Design: Impact Attenuator
HRH-10/OX – 3/16 – 4.0 HexWeb Honeycomb
7 – 1” layers separated by steel sheet
650psi Typical Stabilized Strength
Designed to absorb K.E. of 945lb, 15mph car & driver at less than 20G’s (capable of stopping greater mass than required by Formula Hybrid)
Something on here about motor choice

41. Design Changes: Body Recommendations
Body covers from front tip back to the main roll bar
Side Pods fully enclosed
Molded body to fit over front shocks and allow room for the impact attenuator
Floor and side panels around the motor to protect the motor from debris
Recommendations
Start Early
More than one committed person involved

42. Performance Testing
Testing has been done for several different aspects of the car
Acceleration
Autocross
Endurance
Testing still needs to be completed for
Braking
Testing is also serving the purpose of acquainting the drivers with the handling of the car
Car ran week after spring break

43. Performance Tests: Acceleration & Braking Completed Testing Results
Tests were preformed to see if the car can reach the design specifications set with the higher weight
These tests allow the drivers to learn the sensitivities of each of the pedal systems
Completed Testing Results
Max Speed of 67 mph
Test completed within 0.1 mile

44. Performance Tests: Autocross Completed Testing Results
This testing is used to demonstrate that the car can fulfill the turning radius requirements that have been set
Autocross testing is also used so that the drivers know how the steering will handle
Completed Testing Results
Slalom runs completed to test the suspension and steering
Resulted in sheered grade 2 bolts, all bolts replaced with grade 8 bolts

45. Performance Tests: Endurance Completed Testing Results
The endurance testing serves the purpose of finding out how long the batteries will last under constant draw
This section of the testing will also allow the team to find out how long it will take to charge the batteries during the halfway point of the endurance race at competition
Completed Testing Results
Time lasted : 20 minutes at 10 mph
Resolution: larger controller and more batteries

46. Testing: Conclusions
The testing that has been performed on the car has shown that we meet the design specifications for
Turning Radius
Maximum power available between 20 and 40 mph
We do not meet the requirements for
Lightweight (under 650lbs with driver)
We expect to meet, but have not yet tested
Acceleration from 0 to 60 mph in under 5 seconds (4.5seconds – calculated)
Top speed of 80 mph (85mph - calculated)
15 minute battery life (at constant speed of 35mph)

47. Project Management: Primary functions Budgeting Funding/Sponsors
Scheduling
Managing a Team
Assigning Tasks

48. Budget: Budget $13,265 Drive System Vehicle Dynamics Chassis and Body
$76
Potentiometer
$700
Differential
$1,440
Lead Acid Batteries
$2,860
Controller
$1,600
DC Motor
Chromoly Tubing
$86
Spherical Bearings
$460
Brakes
$160
Tires
$680
Chromoly Tubing
$740
Fiberglass
$80
Shielding
$180
Nomex
Miscellaneous
$250
Battery Management
PLC and Touch Screen
Driver Interface
PC Boards
$150
00 Guage Wire
$80
Master Switch
$155
Contactor
$240
Fuses
$66
Miscellaneous
$300
Ooop forgot about this one, going to change it out to the other budget
PLC and Modules
$286
Touch Screen
$810
Speed Sensor
$55
Safety Harness
$180
Driver Accessories
$430
Miscellaneous
$200

49. Resources: Resources Sponsors: Programs: Personnel: USA Grassroots EV
US Didactic
Charles Whalen (FLEAA)
Bob Steele Chevy
FLEAA
CV Restoration
C2 Design
Brevard Rentals
Pro/Engineer Wildfire 3.0
ANSYS
ADAMS
OrCAD
EZ Touch – EZ Panel Enhanced
EZ PLC Editor
LabView
PIC Basic
Dr. Larochelle – Team Advisor
Dr. Grossman – Team Advisor
Larry Buist – Electrical Support
Bill Bailey – Shop Supervisor/Welder
John Amero – Machinist
Bill Battin – Technical Support
Stephanie Hopper – Lab Director
Frank Leslie – Public Relations/EV Advisor

50. Recommendations: Scheduling Design completion
Give ample time for testing
Managing a Team
Set goals high
Keep the team going but give some time to relax
Assigning Tasks
Don’t overload one person to a task
Assign tasks to the appropriate person

51. Lessons Learned Interdisciplinary cooperation
Start early with incorporation of electrical systems
Stay in communication
Introduce each other systems to the other group
Leave enough time for testing and troubleshooting
Keep drawings updated as soon as something changes

52. Lessons Learned Examples Recycling of components Rims Cost saving
Shocks
Steering pinion gear
Seat
Wheel Brakes
Recycling of components
Cost saving
time savings
Analysis
Production
Implementation

53. Keep the car fully electric Run true performance tests
Recommendations:
Suspension:
Anti-roll bars
Data Logging
Keep the car fully electric
Run true performance tests
Keep electrical engineers on the team

54. Future Improvements To Do: Build Battery Management System
Check and Adjust Differential Mounting
Improve Real World Motor Performance
Locate Li-Ion/Li-Polymer Sponsor
Evaluate BMS (Battery
Management Systems) options
BS about the specs for integration, something that will not interfere with either system, but will satisfy the needs of both the mechanical and electrical specifications

55. Future Improvements For Future REV Form
Schedule testing time on a real track
Reintroduce Lithium Ion batteries as power source
Reincorporate PLC control system
Expand on sensors
- Temp, speed
- efficiency
Increase Data collection for evaluation of performance

56. Future Improvements For Future Formula Hybrid
Use IC as power generator
Use electric engine for propulsion
Reconsider Capacitors for rapid charging and discharging cycles
Redesign frame to fit all components

57. Questions?!?