1. Brendan Flood, Gerard deBlasi, John Fedak IV Lafayette College
Formula Electric Vehicle - Energy Storage, Control, and Management System
Brendan Flood, Gerard deBlasi, John Fedak IV
Lafayette College

2. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

3. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

4. Introduction: Motivation
Design a system for Formula Hybrid competition
Electric Vehicle category
Focus on modularity
Can be used in any application that requires energy storage and control

5. Introduction: SAE Formula Hybrid Competition
Focuses on both performance and efficiency of designs
Events:
Endurance
Sprint
Autocross

6. Introduction: Simulation Results
Endurance
Expect continuous current of ~200A
Aggressive driving will drain the battery
Sprint
Expect peak currents of ~600A
Finish race in 6-8 seconds
Typical times: 4-9 seconds

7. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

8. System Overview: Basic Functions
Store & discharge energy
Implement management and cell balancing
Control system states
Display information
Define and implement serial communication between subsystems
Provide safety measures

9. LFEV-ESCM: Overview
Two configurations
Discharge

10. LFEV-ESCM: Overview
Two configurations
Charge

11. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

12. Cell Packaging: Overview
Secures cells and BMS
Provides safety measures
Isolation relays & fusing
Initially developing and testing a three-cell pack
Later integrating full seven-cell pack

13. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

14. BMS: Overview Monitors the following (per cell): Communicates with:
Voltage
Temperature
Current
Communicates with:
SCADA
Pit Station
Controls bypass circuit

15. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

16. Pit Station: Overview Charge a pack Manage cells during charging
Enable/disable bypass
Log data
Display status to the user

17. Pit Station: Cell Balancing
Cell balancing brings cell’s charge levels into alignment
Used to:
Extend lifetime of cells
Improve health over lifetime
Increase accuracy of State of Charge calculations

18. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

19. Monitors and controls:
SCADA: Overview
Monitors and controls:
Cells (via BMS)
System states
Safety Loop
Load Controller Isolation Relays
Log system data

20. SCADA: Safety Functions
Decides when parameters are out of bounds
Cell over voltage threshold, temperature threshold, etc.
Controls final connection to the load
Sends a signal to close the Load Controller Isolation Relays (IRs) when user presses a button

21. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition
Safety Loop
Conclusion

22. Safety Loop: Overview Function How
Shut down the system in case of an emergency or malfunction
How
Accumulator Isolation Relays (AIRs) in the battery pack

23. Emergency Stop Buttons
Safety Loop: Overview
Safety Box
Safety Loop
Power
Emergency Stop Buttons
SCADA
Packs
Load Controller
AIRs
The Loop:
Starts at the Safety Box
3 Emergency Stop Buttons
Brake over-travel switch
SCADA
Packs
Load Controller
Cap to connect loop

24. Safety Loop: System Connections
Discharge

25. Presentation Outline Introduction System Overview Energy Storage
Cell Packaging
Battery Management System (BMS)
Control and Management
Pit Station
System Control and Data Acquisition (SCADA)
Safety Loop
Conclusion

26. Conclusion: LFEV-ESCM
System for storing and managing energy
Directed at EV applications
Important subsystems:
Battery pack
SCADA & Pit Station
Safety loop

27. Conclusion: LFEV-ESCM
The LFEV-ESCM team thanks you for your time!