Team Lead, Electrical Lead TEAM MOTOTRON Team Lead, Electrical Lead Mechanical Lead Brian Lynn Nam Nguyen Instructor Alumnus Advisor Professional Advisor Raresh Pascali Jonathan Fulbright Huda Abbas, P.E. Electrical Engineering Dept. Manager at Zachry Engineering

Outline Overview Hybrid Design Frame & Suspension Design Component Selection Project Management http://www.bestitnewssite.org/photos/f1-2015-quick-play

Overview Objective Goals Competition Acceleration Analysis

Objective To design and fabricate a hybrid vehicle for the 2017 SAE Formula Hybrid competition.

Goals Implement a functional series/parallel hybrid drivetrain Have a curb weight under 600 lbs. Have an acceleration time under 5.5 seconds in both acceleration events Incorporate regenerative braking system Have vehicle operational by October 2016 Compete in the 2017 competition Formula Hybrid Competition

Acceleration-electric Acceleration-unrestricted Competition Held in Loudon, New Hampshire at the Loudon International Speedway The SAE Formula Hybrid competition is sanctioned each year by SAE International as part of their Collegiate Design Series Challenges students to innovate across engineering disciplines such as mechanical, electrical, computer and aerodynamic engineering Static Events Scoring Presentation 100 Engineering Design 200 Dynamic Events   Acceleration-electric 75 Acceleration-unrestricted Autocross 150 Endurance 400 Total 1000

Constant Acceleration Acceleration Analysis Constant Acceleration Newton’s Second Law Σ 𝐹 𝑥 =𝑚 𝑎 𝑥 𝑣 2 = 𝑣 𝑜 2 +2 𝑎 𝑜 (𝑠− 𝑠 𝑜 ) 𝑎 𝑥 =27.4 𝑓𝑡/𝑠𝑒𝑐2 𝑠= 1 2 𝑎 𝑜 (𝑡− 𝑡 𝑜 ) 2 + 𝑣 𝑜 𝑡− 𝑡 𝑜 + 𝑠 𝑜 𝑎 𝑜 𝑟 =𝛼=31.3 𝑟𝑎𝑑/𝑠𝑒𝑐2 Σ 𝑀 𝑜 = 𝐼 𝑜 𝛼=16.3 𝑓𝑡−𝑙𝑏𝑠 Assumptions: μs = 0.85 μk = 0.7 Vehicle weight with driver = 850 lbf Io based on solid disc for wheel and tire Constant acceleration and rolls without slip

Hybrid Design Hybrid Systems Series/Parallel Design Wiring Diagram http://greenliving4live.com/wp-content/uploads/2013/08/hybrid-cars-electric-vehicle-buying-guide_electric-vehicle-buying-guide_00-1.jpg

Hybrid Systems A hybrid vehicle utilizes two or more types of power, such as internal combustion engine (IC engine) and electric motor Can be configured to improve fuel economy, increase power, or additional auxiliary power Hybrid vehicles combine the benefits of gas engines and electric motors Three types of hybrid systems include: series, parallel, and series/parallel System Advantages Disadvantages Series Simple drivetrain Efficient power transfer Less efficient at high speeds Electric motor only moves vehicle Parallel Powered by motor or IC engine Better suited to meet instantaneous power requirements Complex transmission required Requires larger IC engine than series Series/Parallel Motor and IC engine work together or independently Increased range Complex programming and control scheme Increased cost

Series/Parallel Design Requires 2 motor-generators (MG) Planetary gear set divides power between MG’s and IC engine Provides the benefit of a Continuously Variable Transmission (CVT) https://gr8autotech.wordpress.com/2013/05/31/working-of-a-power-splitter/

Series/Parallel Design http://www.thunderstruck-ev.com/hr-33-12.html/ http://curtisinstruments.com/images/homepage/motor_controllers.png http://www.electriccarpartscompany.com/assets/images/ac-35-kits-main-pic-with-controller.jpg Type: AGM Voltage: 12 V Power: 31Ah @ 10 hr. Rate Weight: 22 lbs. Cost: $95 ea. Controller: Curtis Current: 650 A Output: 70 hp Voltage: 130 V Weight: 12 lbs. Cost: $1250 (Donated) Motor: AC-12 Voltage: 72 V Current: 550 A Efficiency: 89 % Power: 30 hp Weight: 46 lbs. Cost: $1100 (Donated) http://www.kawasaki-cp.khi.co.jp/mcy/street/images/12my/12_EX250JK_F_1-1.jpg Engine: Ninja 250R Description: Parallel twin, four-stroke, liquid cooled, DOHC Displacement: 249cc Weight: 90 lbs. Power Output: 25Hp Torque: 13.67 ft-lb Cost: $650 (Donated) Generator: Mecc Alte S15W Power: 1200 W Power: 30 hp Weight: 18 lbs. Cost: $200 Power Split Device http://prius.ecrostech.com/original/Understanding/PowerSplitDevice.htm

Wiring Diagram

Frame and Suspension Design Material Selection Frame Designs Frame Analysis Suspension Geometry Suspension Upright Upright Analysis

Material Selection Selection Matrix Aluminum Carbon Fiber Steel Tensile Strength: 31000 psi Density:101.5 lb/in3 Cost: $6.50/ft Tensile Strength: 710684psi Density: 56.7 lb/in3 Cost: $47.00/ft Tensile Strength: 50800 psi Density: 283.6 lb/ in3 Cost: $9.00/ft Selection Matrix Factor Aluminum Carbon Fiber Steel Strength (4) 2 5 4 Weight (1) 3 Cost (3) 1 Feasibility (2) Total 33 32 41

Fourth Design Iteration Frame Design Fourth Design Iteration Frame Construction Specifications Length 92 in Width 30 in Height 42 in Material Steel Calculated Weight 66 lb Actual Weight 68 lb First Iteration Second Iteration Third Iteration

Main Hoop Analysis Boundary Conditions Results Previous Results Fourth Design Previous Design Boundary Conditions Load Applied 12kN Application Point Main Hoop Constraints Fixed Bottom Hoop Results Total Deformation 11.76 mm Maximum Combine Stress 474.3 MPa Previous Results 8.2 mm 352.3 MPa

Suspension Design Double Control Arm (Unequal length) Advantages Offers more flexibility in shock placement Increases or decrease camber in a roll Decreases weight and reduces complication to design. Disadvantages Design process is little complicated and costlier than the peers. Upper Control Arm http://120.img.pp.sohu.com/images/blog/2007/11/7/10/2/116b37a5c76.jpg Rotor Wheel Spacer Upright Upper Control Arm Bearing Wheel Hub Wheel Shock Absorber Lower Control Arm Suspension Mounts

Suspension Geometry Design Considerations Measurements C.G Kingpin Angle Angle formed from steering axis to the centerline of wheel 5-10 degrees is common Scrub Radius Distance from where Kingpin axis and tire centerline axis intersect ground Aim is to minimize to improve steering/handling Roll Center Reduce distance between Roll Center and Center of Gravity to minimize body roll. Measurements Front Track Width: 50” Rear Track Width: 48” Wheel Base: 65” Wheel Dimensions: 13” Diameter Tire Dimensions: 20” Diameter Kingpin Angle: 7o Scrub Radius: 1.4” Roll Center Height: 2.6” Ride Height: 1.5”

Upright Design Considerations First Second Third

Upright Analysis Boundary Conditions Results Free Body Diagram Load Applied 12 kN Application Point Spindle Constraints Upright A-Arm Mounts Maximum Allowable Stress 300 Mpa Safety Factor 1.6 Results Total Deformation .18 mm Maximum Combine Stress 190 MPa

Component Selection Generator Accumulator Selection Programmable Controller

Generator Motor: Manta Voltage: 48 V Efficiency: 94 % Power: 10 hp http://www.hydrogenappliances.com/manta.html http://www.robotmarketplace.com/products/EMS-PMG132.html http://http://www.ebay.com/itm/Belt-Driven-MeccAlte-3000-Watt-Generator-Head-With-Outlets-S15W-85BD-/261134116174 Motor: Manta Voltage: 48 V Efficiency: 94 % Power: 10 hp Weight: 22 lbs. Cost: $650 Motor: PMG-132 Voltage: 72 V Efficiency: 88 % Power: 19 hp Weight: 25 lbs. Cost: $1,300 Generator: S15W Voltage: 115/230 V Efficiency: 69% Power: 1,200 W Weight: 18 lbs. Cost: $200 Selection Matrix Motor/Generator Manta PMG-132 S15W Voltage (1) 3 4 5 Peak Power (1) 1 2 Weight (2) Cost (3) Total 21 16 32

Accumulator Selection http://www.thunderstruck-ev.com/hr-33-12.html/ http://www.thunderstruck-ev.com/calb-70ah.html http://www.mouser.com/images/maxwelltechnologies/lrg/BMOD0500-A_lo_med.jpg Type: AGM Voltage: 12 V Power: 31 Ah Peak Current: 420 A Total Weight: 132 lb. Total Cost: $570 Type: Lithium Voltage: 3.2 V Power: 70 Ah Peak Current: 700 A Total Weight: 138 lb. Total Cost: $2300 Type: Super Capacitor Voltage: 16 V Power: 3 Wh Peak Current: 1,900 A Total Weight: 72 lb. Total Cost: $2,750 Selection Matrix Type AGM Lithium Super Capacitor Voltage (1) 3 1 5 Peak Current (2) Weight (3) 4 Cost (4) Total 37 28 34

https://beagleboard.org/black Programmable Controller Selection http://www.ni.com/myrio/ http://www.ni.com/myrio/ https://beagleboard.org/black Model: myRIO Speed: 667 MHz OS: Linux RAM: 512 MB Cost: $500 w/ Accessories I/O: 16 Analog 40 Digital Model: CompactRIO Speed: 1.33 GHz OS: Linux RAM: 512 MB Cost: $2000 I/O: Up to 8 Modules Model: BeagleBone Black Speed: 1.0 GHz OS: Linnux RAM: 512 MB Cost: $50 I/O: 7 Analog 65 Digital Selection Matrix Model myRIO Compact RIO BeagleBone Black Processor Speed (2) 3 5 4 Operating System (1) Ram (3) Cost (5) 1 I/O Count (4) Total 56 42 64

Project Management Budget Project Timeline Work Breakdown Structure Work Packages Risk Matrix http://www.aiche.org/sites/default/files/images/courses/CH138_Image.JPG

Budget Components Estimated Cost - 3/2/2016 Revised Cost - 4/12/2016 Chassis Materials $1,000 $258 Internal Combustion Engine $1,100 Donated - Drive Motor Generator $1,300 $300 Motor Controller $1,250 Charger Contingency $140 $450 Display $100 $104 Accumulator Monitoring System MicroController w/ acc. $500 Accumulators $1,200 $600 Suspension $277 Brake Sys $754 Steering $400 Wheels Differential Tires $720 Transponder $520 Ground Fault Monitor $25 Fire Extinguishers $150 Travel Fee $2,000 Registration Fee $2,200 Electrical Components $46 $60 $85 Seat $93 Safety Harness $50 Race Suit $200 Power Splitter $40 $165 Welding/Fab. Consumables $230 Subtotal $17,065 $12,205 $10,839 $8,561 25% 20% 15% 10% Total Cost $21,331 $14,646 $12,465 $9,417 Budget $0 $1,510 $3,010 $8,010 Shortfall -$21,331 -$13,136 -$9,455 -$1,407

Timeline

Administrative / Logistics Work Breakdown Structure Team MOTOTRON SAE Formula Hybrid Research & Design Administrative / Logistics Fabrication Testing / Competition Research Fundraising & Sponsorships Material Requisitioning Frame Design Frame Fabrication Suspension Fabrication Mechanical Assembly Electrical Assembly Body Fabrication Test and Tune Register for Competition Document Submittal Shipping Preparations Travel Suspension Design Body Design Hybrid System Design Compete LEGEND Completed Task Task in Progress Task not Started

Work Packages

Risk Matrix PROBABILITY SEVERITY Initial Risks Previous Risks Current Risks Risk Element Mitigation 1 Parts Delay Order Early 2 Hybrid Function Will Not Work Early Programming, Bench Testing 3 Fabrication Equipment Failure Alternative fabrication methods 4 ICE Fails Alternative engine 5 Defective Parts Reorder 6 Failure to Submit Documentation Keep track of due dates 7 Time Management Weekly progress reports 8 Compliance with Rules Discuss with Formula Hybrid 9 Fundraising Begin fundraising early 10 Injuries Use Proper PPE PROBABILITY Very Likely   Likely Possible 4  7 6,8,10  2 Unlikely  3 5,9  Highly Unlikely 1 Minimal Minor Medium Severe Catas-trophic SEVERITY

QUESTIONS?