Raresh Pascali- Instructor Marcus Gamino- Faculty Advisor William Hesser - Industry Advisor Matt Walsh- Underclassman Ayazhan Zhakhan- Alumni Team Members Daulet Urkenbayev Paul Orieukwu Jonathon Fulbright Rajeev Bhattacharya Advisors Project Manager Mechanical System Designer Frame & Body Designer Electrical System Designer

Outline 1. Competition Objective 2. Team Goals 3. What is a Hybrid Vehicle? 4. 3D Model of the Car 5. Frame Material 6. Frame Design 7. Finite Element Analysis 8. Aerodynamics Devices 9. Internal Combustion Components 10. Calculations 11. Electrical Components 12. Project Management 3

Competition Objective  To challenge teams of university students to design, fabricate and build a formula hybrid-powered vehicle and compete at the annual Competition in Loudon, New Hampshire on April 27, Open 24 Registered 19 Competed 12 Hybrid 7 Electric Formula Hybrid 2014 Projection for Formula Hybrid Open 30 Registered 19 USA 1 Australia 1 Turkey 1 Pakistan 3 Canada 4 India 1 South Korea 4

Competition Events & Scoring DYNAMIC STATIC 5

Team Goals  Register before slots fill.  Implement switchable hybrid drive.  Curb weight not to exceed 650 lbs.  Implement data logging system.  Complete unrestricted 246 ft acceleration run in 5.4 sec or less.  Complete the final assembly by April 1. 6

What is a Hybrid Vehicle? Series Hybrid LayoutParallel Hybrid Layout High EfficiencyLow Efficiency Low Driving PerformanceHigh Driving Performance 7

Illustration of the FH Car To design system with the ability to switch between the series and parallel hybrid systems. 8

Frame and Body Outline 1. Frame Material 2. Frame Design 3. Finite Element Analysis 9

Frame Material Steel Carbon Fiber Aluminum Yield Strength = 710,684psi Modulus of elasticity = 33,000ksi Density:.055g/in 3 Price: $106.5/ft Yield Strength = 31,000psi Modulus of elasticity = 10,000ksi Density:.0975 lb/in 3 Price: $20/ft Yield Strength = 50,800psi Modulus of elasticity = 29,700ksi Density: 2.48lb/in 3 Price: $44/ft 10

Frame Design Design #1 Design #2 Design #3 11

Finite Element Analysis (FEA) Front Impact Results (Von Mises)(psi)Side ImpactResults (Von Mises)(psi) 12

Aerodynamics Devices  All of the components should increase the downforce on the vehicle by manipulating the air flow. BodyDiffuserFront Wing 13

Mechanical Outline 1. Internal Combustion Engine 2. Calculations 3. Differential 14

Internal Combustion Engine Specification: Engine: Four-Stroke, DOHC, Parallel Twin Displacement: 249 cc Compression: 11.6 : 1 Cooling: Liquid Ignition: Electrical Transmission: Six Speed Final Drive: 14 in Chain Sprocket Cooling type: Liquid Kawasaki Ninja 250R Power Output: 37 Hp Price (used): $450- $650 Subaru EX21 Power Output: 7 Hp Price (New): $ Lifan 250cc V-Twin Engine Power Output: 16.5 Hp Price (used): $625 15

Calculations 16

Differential Torsen Traction-JTEKTTaylor Industries Westgarage Engineering Torque: 800 ft-lb Weight: 10 lb Cost: $2600 Torque: 600 ft-lb Weight: 15 lb Cost: $415 Torque: 680 ft-lb Weight: 10 lb Cost: $

Electrical Outline 1. Electric Motors 2. Controllers 3. Batteries 4. BMS 5. CCU 18

Front Electric Motors Specification: Type: PMDC Weight: 24.8 lb Torque Max: 28 ft-lb Perm PMG-132 PMDC Power Output: 19 HP Price:Donated ME0909 Brushed DC Power Output: 20 HP Price (New): $385 Liquid Cooled BLDC Motor Power Output: 13 HP Price (New): $918 19

Rear Electric Motor 12.9kW PMAC ME1118 Specification: Type: AC Induction Weight: 46 lbs. Torque Max: 100 ft-lb AC 12 Power Output: 44 HP Price:Donated ME 1118 PMAC Power Output: 19 HP Price (New): $1895 ME0909 PMDC Power Output: 20 HP Price (New): $385 20

Controllers Kelly KDZ12401 Regen: Yes Price: $479 Curtis 1239E Regen: Yes Price: $1,562 (Donated) Front Rear 21

Battery Li Polymer Specifications: Cell Capacity: 2.8 Ah Size: Cost: $3000 Lead Acid Specifications: Cell Capacity: 12 Ah Size: 6” x 2” x 3.7” Cost: $1000 LiFePO4 Specifications: Cell Capacity: 8 Ah Size: Cost: $

Battery Management System (BMS) MBS-EP128 Price: $425 Orion BMS Price: $890 Lithiumate Price: $795 Specifications: USB and RS232 Ports CAN Bus Capable Analog and Digital I/O 23

Central Control Unit (CCU) Arduino Mega I/O: 54 Price: $30 Rasberry Pi B+ I/O: 40 Price: $70 myRio Specification: I/O: 40 Analog out: 10 Analog in: 6 Input power: 6-16 V Clock speed: 667 MHz Price :$250 24

Budget ComponentsLowHigh Frame and Body $300$2,500 Steel Tubing$300$600 Fiberglass ShellDonated$400 Cost of ConstructionDonated$1,500 Internal Combustion $630$2,700 Engine$450$2,000 Upgrades and ModificationsExcluded$300 Hoses and Connections$80$100 Exhaust$100$300 Electrical System $5,650$16,200 DC Electric MotorsDonated$2,000 DC Electric Motor Controllers$1,400$2,000 AC Induction MotorDonated$1,200 AC Induction Motor ControllerDonated$3,000 Input/output Transducers$800$2,000 Cables and Connections$200$500 Batteries and Battery Management System$3,000$5,000 Central Controller$250$500 Drivetrain and Suspension $1,800$7,200 Axels, Bearings, and CV Connections$500$2,000 Chains and Sprockets$300$600 Differential and Electric Clutch$1,000$3,000 Wheels and TiresDonated$1,600 Travel Expenses $0$4,400 Truck and Trailer RentalDonated$1,200 Lodging and FoodDonated$1,200 GasDonated$2,000 Entry Fee $2,150 Total$10,530$35,150 25

Gantt Chart 26

Work Breakdown Structure 27

Risk Matrix 28

Questions ? 29