2. Mechanical System Designer Electrical System Designer
Team Members
Project Manager
Mechanical System Designer
Frame & Body Designer
Electrical System Designer
Daulet Urkenbayev
Rajeev Bhattacharya
Paul
Orieukwu
Jonathon Fulbright
Advisors
Instructor Raresh Pascali Professor (University of Houston)
Faculty Advisor Marcus Gamino Engineer I (3Dent Technology)
Industry Advisor William Hesser Software Engineer (Lime Instruments, LLC)
Underclassman Matt Walsh MECT (University of Houston)
Alumni Ayazhan Zhakhan ELET (University of Houston)

3. Presentation Outline The Formula Hybrid Competition
Competition Summary
Competition Events
Team Objective and Goals
What is a Hybrid?
Types of Hybrid
UH Formula Hybrid Design
Frame
Traction
Energy Storage
Drivetrain
Control
Project Management
Work Breakdown Structure
Gannt Chart
Budget

4. The Competition The Future on Track Annual Student Design Competition
Part of the Society of Automotive Engineers’ Collegiate Design Series
Founded by the Thayer School of Engineering at Dartmouth University
Open to graduate and undergraduate university students from all over the world
Emphasizes drivetrain innovation and interdisciplinary collaboration

5. Competition Summary Competition Breakdown
April 27th 2015 at the New Hampshire Motor Speedway in Loudon
Teams of university students are challenged to design, fabricate, and race a formula-style hybrid racecar
The teams will compete in time trials and head-to-head races 35
Open
30 Registered
India
Pakistan
South Korea
Canada
USA
Turkey
Australia

6. Competition Events and Scoring
STATIC
DYNAMIC

7. Team Objective and Goals
Team Red Devils endeavors to promote the University of Houston and College of Technology on an international stage by competing competitively at the SAE’s Formula Hybrid Competition on April 27, 2015.
Goals
Register before slots fill
Implement mixed hybrid drive
Curb weight bellow 1200 lbs.
Implement data logging system
Complete 246 ft (75 m) acceleration run in 5.4 seconds or less
Complete final assembly by April 1

8. What is a Hybrid? Long Range Lower Efficiency Higher Emissions
Increased Efficiency
Lower Emissions
Limited Range

9. Types of Hybrid Parallel: Higher power, but less efficient Series:
Better efficiency, but less power

10. The Design Main Systems Frame Electric Traction
Internal Combustion Traction
Drivetrain
Control

11. The Mixed Hybrid
The Red Devils will implement a mixed hybrid design that combines the power of a parallel hybrid with the efficiency of a series hybrid

12. Low Driving Performance High Driving Performance
Mixed Hybrid Layout
Series Hybrid Mode
Parallel Hybrid Mode
High Efficiency
Low Efficiency
Low Driving Performance
High Driving Performance

13. Presentation Outline UH Formula Hybrid Design Material Frame
Suspension
Finite Elemental Analysis

14. The Frame – Material Factor (Importance) Score (1-5) Steel Aluminum
Yield Strength = 50,800psi
Modulus of elasticity = 29,700ksi
Density: 2.48lb/in3
Price: $44/ft
Yield Strength = 31,000psi
Modulus of elasticity = 10,000ksi
Density: lb/in3
Price: $20/ft
Yield Strength = 710,684psi
Modulus of elasticity = 33,000ksi
Density: .055g/in3
Price: $106.5/ft
Factor (Importance)
Score (1-5)
Steel
Aluminum
Carbon Fiber
Yield strength (5) 4 2 5
Weight (4) 3
Feasibility (3) 1
Cost (2)
Final Score 59 41 50

15. The Frame – Design Frame 1 Frame 2 Frame 3 Factor (Importance)
Score (1-5)
Frame 1
Frame 2
Frame 3
Safe (5) 2 5
Design (4) 3
Weight (3) 4
Feasibility (2)
Final Score 42 33 62

16. The Frame – Suspension Design
To Design an optimal frame for the competition the team needed to determine the best suspension geometry
Considerations:
Track Width
Camber
Roll Center
Center of Gravity
Rim Diameter
Chassis Dimension
Kingpin Angle
Ride Height

17. The Frame – FEA Von Mises (psi) Front Impact - 24 mph Von Mises (psi)
Side Impact - 15 mph

18. Presentation Outline UH Formula Hybrid Design Motors Controllers
Batteries
Battery Management System

19. Traction – Electric Perm PMG 132 AC 12 Type: Brushed DC Power: 19 HP
Max Torque: 15 ft-lb
Cost: Donated
AC 12
Type: AC Induction
Power: 44 HP
Max Torque: 100 ft-lb
Cost: Donated

20. Control Motor Control 1 per motor 1x AC Controller 2x DC Controller
Central Control
Controls Motor Controllers and IC Engine

21. Control – Motor Controllers
Front Motor Controller
Kelly KDZ12401
Type: DC
Regen: Yes
Price: $479
Rear Motor Controller
Curtis 1239E
Type: AC
Regen: Yes
Price: $1,562
(Donated)

22. Control – DC Motor Controllers
Kelly KDZ12401
Voltage: V
Current: 400 A
Price: $595
Kelly KDZ12400
Voltage: V
Current: 400 A
Price: $419
RoboteQ HDC2472
Voltage: =< 72 V
Current: 120 A / Ch
Price : $795
Factor (Importance)
Score (1-5)
Kelly KDZ12401
Kelly KDZ12400
RoboteQ HDC2472
Current (3) 4 2
Regen (5) 5
Cost (3) 3
Final Score 46 24 21

23. Control – Central Processor
Arduino Mega
I/O: 54
Software: Arduino IDE
Price: $30
Rasberry Pi B+
I/O: 40
Software: Python IDE
Price: $70
myRio
I/O: 40
Software: LabView
Price : $250
Factor (Importance)
Score (1-5)
Arduino
Raspberry Pi
myRio
I/O(3) 4 1 5
Software (2) 3 2
Cost (1)
Final Score 17 12 24

24. Energy Storage LiPo Pouch Specific Energy: 100-265 Wh/Kg
Discharge: 20C
Price: $5,000
Lead Acid
Specific Energy: Wh/Kg
Discharge: 1C
Price: $1,000
myRio
Specific Energy: Wh/Kg
Discharge: 10C
Price : $3,000
Factor (Importance)
Score (1-5)
Lithium Polymer
Lead Acid
LiFePO4
Specific Energy(4) 5 1 4
Discharge (4) 2
Cost (5) 3
Final Score 25 32 47

25. Energy Management Lithiumate Interface: CAN Output: Analog Orion BMS
Interface: Dual CAN
Output: Analog
Price: $890
Lithiumate
Interface: CAN
Output: Analog
Price: $795
Factor (Importance)
Score (1-5)
Orion BMS
Lithiumate
CAN Interface(3) 5
I/O (4)
Cost (5) 2 3
Final Score 45 50

26. Presentation Outline UH Formula Hybrid Design
Internal Combustion Engine
Calculations
Differential
Drivetrain Design

27. Traction – Internal Combustion
Subaru EX21
Power Output: 7 Hp
Price (New): $479.97
Lifan 250cc V-Twin Engine
Power Output: 16.5 Hp
Price (used): $625
Kawasaki Ninja 250R
Power Output: 37 Hp
Price (used): $450- $650
Factor (Importance)
Score (1-5)
Subaru EX21
Lifan V-Twin Engine
Kawasaki 250R
Torque (5) 2 3 5
Power (Output) (4)
Cost (3) 4
Final Score 33 42 57

28. Calculations to know how much force the differential will experience1 2
Final Drive Reduction

29. Drivetrain - Differential
Taylor Industries
Torsen Traction-JTEKT
Westgarage Engineering
Torque: 550 ft-lb
Weight: 10 lb
Cost: $2600
Torque: 380 ft-lb
Weight: 15 lb
Cost: $650
Torque: 450 ft-lb
Weight: 10 lb
Cost: $1000
Factor (Importance)
Score (1-5)
Taylor Industries
Torsen Traction
Westgarage Engineering
Torque (4) 5 3 4
Weight (5) 2
Cost (3)
Final Score 41 53

30. Drivetrain – UH Mixed Hybrid
Internal Combustion Engine
Electric Motor
Electric Clutch (ON/OFF) [PARALLEL/SERIES]
Differential
The internal combustion engine and the AC electric motor provide power to the differential in parallel mode. When in series mode the electric clutch disengages and the Internal Combustion Engine generates power through the AC 12.

31. Presentation Outline Project Management Project Completion
Work Breakdown Structure
Gantt Chart
Risk Matrix
Budget

32. Project Management Current Progress Phase 1 – 91% Phase 2 – 12%
Total – 26%
Projected Progress by Year’s End
Phase 1 – 100%
Phase 2 – 20%
Total – 30%

33. Work Breakdown Structure

34. Gannt Chart

35. Risk Matrix
Risk Matrix

36. Budget Components Low High Frame and Body Internal Combustion
$300
$2,500
Steel Tubing
$600
Fiberglass Shell
Donated
$400
Cost of Construction
$1,500
Internal Combustion
$630
$2,700
Engine
$450
$2,000
Upgrades and Modifications
Excluded
Hoses and Connections
$80
$100
Exhaust
Electrical System
$5,650
$16,200
DC Electric Motors
DC Electric Motor Controllers
$1,400
AC Induction Motor
$1,200
AC Induction Motor Controller
$3,000
Input/output Transducers
$800
Cables and Connections
$200
$500
Batteries and Battery Management System
$5,000
Central Controller
$250
Drivetrain and Suspension
$1,800
$7,200
Axels, Bearings, and CV Connections
Chains and Sprockets
Differential and Electric Clutch
$1,000
Wheels and Tires
$1,600
Travel Expenses $0
$4,400
Truck and Trailer Rental
Lodging and Food
Gas
Entry Fee
$2,150
Total
$10,530
$35,150

37. Questions?
Comments?

38. Mid-Project Movie