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Project Overview Primary Goal – Design and build a working electric vehicle Accelerated design cycle – Modification of previous designs.

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Presentation on theme: "Project Overview Primary Goal – Design and build a working electric vehicle Accelerated design cycle – Modification of previous designs."— Presentation transcript:

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2 Project Overview Primary Goal – Design and build a working electric vehicle Accelerated design cycle – Modification of previous designs

3 Project Overview 1 st electric vehicle for Ram Racing – Create the platform for future years of Ram Racing to iterate on Integration of electrical and mechanical engineers – Adds expertise of electrical systems which will allow addition of more complex systems like: Regenerative braking The use of high voltage systems

4 Background FSAE is the largest international competition involving engineering and automotive design FSAE competition is comprised of 7 scored events Static Events include: Cost report Design Judging Presentation Dynamic Events include: Acceleration Skidpad Autocross Endurance

5 Background Progression of cars 2011 CSU FSAE RR CSU FSAE RR Ram Racing FSAE RR CSU FSAE RR12 Photo courtesy: Ram Racing

6 Design Constraints ConstraintMethod of MeasurementLimits Driving Factor Wheelbase Length in inches: from the centerline of front to rear tires >60in. FSAE Rule T2.3 Track Width Width in inches: from the centerline of side to side tires >75% front track to rear track FSAE Rule T2.4 Power Output Kilowatts: Drawn from high voltage battery<80kW FSAE Rule EV2.2 High Voltage Battery Pack Volts: overall voltage from any two points300 V DC Max FSAE Rule EV1.1.2 Roll Plane Measured by tangent line between Main and Front Roll Hoops 2in, min clearance to driver helmet FSAE Rule T Suspension Inches of bounce and jounce 1in in both directions, min FSAE Rule T6.1 Battery Pack Pack must withstand external loading 20g long. 20g lat 20g vert FSAE Rule AF4.8.2 Safety Determined by Electrical safety officers Determined by Technical Inspectors at FSAE For Car safety to prevent Serious injury or death 0FSAE Rules/ Team Driven

7 Design Objectives Objective Priority Rating 5-Highest 1-Lowest Method of Measurement (Theoretical) Method of Measurement (Actual) Objective Direction Target Battery Pack Capacity 4 Hand calculations, lap simulations Endurance simulation at test site increase +10% of endurance distance Battery Pack Mass 3 Spec Sheet with hand calculations Scaledecrease <140lbs Compared to other FSAE EV teams batteries Lap times: Autocross 1Lap simulations Vehicle testing details TBD decrease < 1min 20sec from the Michigan 2013 track layout Endurance Completion 5Lap simulations22km endurance testincrease +10% of endurance distance Light Weight1Hand calculationsScaledecrease<700lbs w/out driver

8 Design Summary Due to the complications of integrating an electric drivetrain, the team has decided that getting the car done early is the biggest concern – Getting the car done earlier will allow for more testing time – The electrical system will be tuned primarily based off of driver feel

9 Final Concept Image: Ram Racing

10 Final Concept Units (Deg) Function – Main structure – Protects driver – Transmits loads Feasibility – Modeling in CAD – Installed torsional stiffness test DFX – Manufacture – Packaging – Safety Details – FEA stiffness: 998 lb-ft/deg – 17% correction factor (overestimate): 828 lb-ft/deg – Mass (est.): 90.7 lbs Tubes: 83.7 lbs Filler Rod: 2 lbs Tabs: 5lbs Image: Ram Racing

11 Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s)/Mechanism(s) of Failure Current Design Controls Recommend Actions 1 Chassis Primary Structure Weld Failure Disabled Vehicle, Driver Injury, Loss of Control 10Bad Weld Quality6 Visual Inspection % Inspect All Chassis Welds 2 Chassis Secondary Structure Motor Support Failure Driver Injury, Damage to other systems 10 Bad Weld Quality, Incorrect Geometry 6 Visual Inspection % Inspect All Chassis Welds 3 Chassis Primary Structure Tube Failure Loss of Stiffness, Damage to Other Systems 6Undersize Wall Thickness in Tube4 Manufacturer Certifications, Visual Inspection % Inpsect all Chassis Tubes Before Welding 4 Chassis Secondary Structure Tab Failure Damage to Other Systems, Loss of Control 7 Bad Weld Quality, Incorrect Geometry 6 Visual Inspection % Inspect All Chassis Welds 5 Chassis Tertiary Structure Battery Support Failure Driver Injury, Diasbled Vehicle 10 Bad Weld Quality, Improper Support 2 Visual Inspection, Manufacturer Certifications, Additional Battery Containment % Inspect All Chassis Welds

12 Final Concept (Budget) Chassis BudgetCostSourceDonation? Chassis Tubes and Profiling$2,900Cartesian VR3No Remachining Fixture Plates$500WoodwardYes Fixturing Stock$400McMasterNo Fasteners$100Suburban BoltNo Welding Filler$100Arc-ZoneNo Tab Stock$100Online MetalsNo Total:$6,600 Cost After Donations:$3,600

13 Final Concept Function – Keep tires in contact with pavement – Keep tires in condition for optimum accelerations Feasibility – Modeling in CAD/FEA – Optimum Kinematics Analysis DFX – Manufacture – Reliability – Performance Accelerated Design Cycle – Adaptation of design features from last 3 years Creo Solid Model Optimum K Kinematics Model Image: Ram Racing

14 Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s)/Mechanism(s) of Failure Current Design Controls Recommend Actions 1 Outer Suspension Ends Stress Concentration in Bending Damage to other systems, Loss of control 10Manufacturing Error1 Visual Inspection 220 Inspection by recipiant 2Uprights Stress Concentration in Bending Damage to other systems, Loss of control 8Manufacturing Error2 Visual Inspection 7112 Inspection by recipiant 3RockersPanel Delamination Damage to other systems, Loss of control 8Manufacturing Error1 Visual Inspection 648None 4Carbon TubesBuckling/Bending Damage to other systems, Loss of control 10 Incorrect Geometry1 Pre-testing Visual Inspection 550 Pre and Post- Testing Inspection 5 Pull/Push Rod Tubes & A- arm Tubes Adhesive Failure in Shear Damage to other systems, Loss of control 10 Improper Bonding Procedure, Insifficient Bonding Area 4 Visual Inspection 7280 Tighter Control of layup process

15 Final Concept (Budget) Suspension BudgetCostSourceDonation? Brake Discs$200In houseNo Brake Pads$75In houseNo Brake Calipers$150In houseNo Bearings (spindle)$150SKFNo Bearings (rod ends)$400AuroraNo Carbon tubes$200In houseNo Stock$200Metal DistributorNo Tires$170 x 4HoosierNo Dampers$1,720In houseNo Springs$250In houseNo Total:$9,025 Cost After Donations:$1,430

16 Final Concept Function: – Transfers Torque to rear wheels – Accelerates car Feasability: – Modeling in CAD – FEA analysis DFX: – Efficiency – Reliability – Packaging Details: – Torque: 210 Nm – Chain pull 6700N – 4:1 gear ratio – Up to 80% Torque bias to one wheel: 624 NM Image: Ram Racing

17 Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s)/Mechanism(s) of Failure Current Design Controls Recommend Actions 1Half Shaft Torsional Shear Disabled Vehicle 8 Poor design, Machining Imperfections 4 FEA, Previous cars' Performance 9288 FEA, Stronger Spares 2Chain Elongation, Break Disabled Vehicle 8Improper Maintenance/tensioning2 Professional Help, Math 696 Spare Sprockets, Spare Chain 3 Differential Mounts Fatigue, Bending, Shear Disabled Vehicle 8 Poor design, Machining Imperfections 3FEA7168 Spare Mounts, Material Evaluation 4 Motor Mounts Fatigue, Shear Disabled Vehicle, Driver Injury 10 Poor design, Machining Imperfections 3FEA7210 Spare Mounts, Material Evaluation 5 Motor Cooling Oil Starvation Disabled vehicle, Motor Failure 8Improper Flow Rate, Pump Failure2 Specialty Pumps, Professional Help 232 Monitor Pumps Closely, Safety Shutoff

18 Final Concept (Budget) Drivetrain BudgetCostSourceDonation? Motor$9,000.00Remy, IncYes Differential$1,000.00HPF PerformanceNo Inboard Tripod Carriers $370.00RCVNo Tripods$140.00RCVNo Cooling Pumps$1,000MeziereYes Half Shaft Stock$300.00Metal DistributorsNo Aluminum Mount Stock$200.00Metal DistributorsNo Chain$60.00EbayNo Sprockets$120.00Sprocket SpecialistsNo Total$12, Cost After Donations$2,190.00

19 Final Concept Function -Drivetrain power Feasibility – Modeling in CAD – Circuit schematics DFX – Packaging – Safety Details – 72S2P battery back – 300Vdc max, 266Vdc nom. – Capable of 375Adc continuous – Safe under failure – Weight: Est 104 lbs – 7.5kW hrs Image: Ram Racing

20 Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s)/Mechanism(s) of Failure Current Design ControlsRecommend Actions 1 Battery Cell for energy storage Single cell failure Higher chance of failure in parallel cell counterpart 2 Neglect, exceeding rated specifications, poor cell construction 3 Battery management system monitoring 212 Handle with care, operate within specifications 2 Battery Management System for monitoring cells Voltage, Current, or Temperature sensing failure of 25% of cells Fire, cell abuse, Estimation of sensed parameters (done automatically by BMS) 10 Exceed lifetime, bad soldering, extreme vibration 2 Visual inspection, isolate cell boards from vibration along with cells 7140 Inspect all solder work 3 High voltage controller for controlling the motor Control system failure Vehicle shutdown 8Misuse/neglect1 Care is to be taken with the controller 216 Handle with care, operate within specifications 4 Battery Cell for energy storage Two parallel cell failure Sudden loss of all power 8 Neglect, exceeding rated specifications, poor cell construction 2 Battery management system monitoring 232 Handle with care, operate within specifications 5 High voltage controller for controlling the motor HV cable disconnection Driver injury, total loss of power, fire 10 Improper torque for connection 2 Check all torque specifications 6120 Check torque applied to connection point

21 Final Concept Function – Technical Inspection – Safety shutdown circuitry –Power various sensors Feasibility – Circuit schematics simulations – Test and retest circuits for faults DFX – Build/wire circuits – Safety Image: Ram Racing

22 Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure Potential Cause(s)/Mechanism(s) of Failure Current Design Controls Recommend Actions 1 Torque Encoder Accelerometer Sensor FailureLoss of Control6 Sensor mounting error, loose wire/connections 4 Visual Inspection, Sensor fault test 390 Tighten connections, test with multimeter 2 Brake Encoder Brake Sensor Failure Loss of Control, 6 Sensor mounting error, loose wire/connections 4 Visual Inspection, Sensor fault test 390 Tighten connections, test with multimeter 3 Arduino Mega Microcontrolle r for low voltage controls Programming/ Power Failure Loss of Control, Signal error to motor controller 6Loose connections, lose of power5 Visual Inspection, Inspection of programming code, 4144 Tighten connections, test with multimeter, review program for errors 4 Sensata Crash Sensor Sensor Failure Driver Injury, due to improper shut down of tractive system 10 Impact upon crash does not activate sensor 5 Visual Inspection, Sensor fault test 3150 Shake the sensor to see if it opens the circuit 5 Bender Isometer Insulation Monitoring Device Tractive and Grounded low voltage system desegregation/ Sensor fault Driver Injury, Potential shock 10 No seperation between tractive and grounded low voltage systems 6 Visual Inspection, Manufacturer Certifications, Sensor fault test 6360 Check with multi- meter to see if tractive and grounded low voltage systems are isolated

23 Final Concept (Budget) Controls BudgetCostSourceDonation? HV Cables $400Champlain CableYes HV Controller $5,250 Rinehart Motion SystemsNo Batteries $12,500MelastaPart Sponser Bus Bar $250 Storm Power ComponentsNo Batter Management System $1,624ElithionNo Torque/Brake Encoder $229 x 3XT RacingNo Arduino Mega 2560n M3 $28ArdunioYes Misc. Components $500VariousMix Total$21,239 Cost After Donations$20,311

24 Validation Plan Majority of parts for final assembly or testing have been ordered or are currently on hand Assembly ongoing through winter break Image: Ram Racing

25 Validation Plan Evaluation – CAD – Hand Calculations – Modified Ram Racing Designs – Road Testing – Simulation Safety Circuit – Specific Component Testing Impact Attenuator Battery Cell Image: Ram Racing

26 Term II Work-Plan Main Goals – Finish manufacturing and assembly of vehicle – Begin testing and data collection of vehicle Secondary Goals and Contingency – Refine and fix any design flaws – Rework on systems that fail, break, or do not work as intended

27 [1] SAE International. (2014, September 1) Formula SAE® Rules [Online]. Available:http://www.fsaeonline.com/content/ %20FSAE%20Rules%20revision%20in%20progress%20kz% pdf

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