1. 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

2. Outline Overview Hybrid Design Frame & Suspension Design
Component Selection
Project Management

3. Overview
Objective
Goals
Competition
Acceleration Analysis

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

5. 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

6. 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

7. 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= 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

8. Hybrid Design Hybrid Systems Series/Parallel Design Wiring Diagram

9. 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

10. 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)

11. Series/Parallel Design
Type: AGM
Voltage: 12 V
Power: 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)
Engine: Ninja 250R
Description: Parallel twin, four-stroke, liquid cooled, DOHC
Displacement: 249cc
Weight: 90 lbs.
Power Output: 25Hp
Torque: ft-lb
Cost: $650 (Donated)
Generator: Mecc Alte S15W
Power: 1200 W
Power: 30 hp
Weight: 18 lbs.
Cost: $200
Power Split Device

12. Wiring Diagram

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

14. Material Selection Selection Matrix Aluminum Carbon Fiber Steel
Tensile Strength: psi
Density:101.5 lb/in3
Cost: $6.50/ft
Tensile Strength: psi
Density: 56.7 lb/in3
Cost: $47.00/ft
Tensile Strength: psi
Density: 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

15. 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

16. 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

17. 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
Rotor
Wheel Spacer
Upright
Upper Control Arm
Bearing
Wheel Hub
Wheel
Shock Absorber
Lower Control Arm
Suspension Mounts

18. 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”

19. Upright Design Considerations
First
Second
Third

20. 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

21. Component Selection Generator Accumulator Selection
Programmable Controller

22. Generator Motor: Manta Voltage: 48 V Efficiency: 94 % Power: 10 hp
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

23. Accumulator Selection
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

24. https://beagleboard.org/black
Programmable Controller Selection
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

25. Project Management Budget Project Timeline Work Breakdown Structure
Work Packages
Risk Matrix

26. 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

27. Timeline

28. 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

29. Work Packages

30. 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

31. QUESTIONS?