1. FLORIDA INSTITUTE OF TECHNOLOGY COLLEGE OF ENGINEERING
Design Presentation
Project: 2007 R.E.V. Team
Presented By:
Elizabeth Diaz Jason Miner Jared Doescher Josh Wales
Kathy Murray AJ Nick Dave Wickers Oliver Zimmerman

2. Project Scope: Design and Build an electric racing vehicle
Promote community awareness of electric vehicles
Electric Car designed to compete in SCCA Autocross
and Formula Hybrid competition
Will meet requirements for the 2007 Formula Hybrid
competition and NEDRA race competition
The Racing Electric Vehicle, or R.E.V., is an electric car designed to compete in the 2007 Formula Hybrid competition. This competition is for IEEE student members to redesign, modify, and compete with hybrid Formula SAE racing cars. The students are encouraged to make use of previous years Formula SAE cars so that the knowledge, creativity, and imagination of the students are challenged. The cars are built with a team effort over a period of about one year and are taken to the annual competition for judging and comparison with other modified Formula SAE vehicles from colleges and university throughout the United States. The end result is a great experience for aspiring engineers in a meaningful project as well as the opportunity of working in a dedicated team effort.
The R.E.V. team will design, manufacture, assemble, test, and present their electric car in the 2007 Formula Hybrid competition.

3. Formula Hybrid Competition:
Competition to design and build a Formula SAE hybrid vehicle
Competing as “Hybrid-in-Progress” vehicle for one year only
Electric Car designed to compete in Autocross, Acceleration and Endurance races
The Racing Electric Vehicle, or R.E.V., is an electric car designed to compete in the 2007 Formula Hybrid competition. This competition is for IEEE student members to redesign, modify, and compete with hybrid Formula SAE racing cars. The students are encouraged to make use of previous years Formula SAE cars so that the knowledge, creativity, and imagination of the students are challenged. The cars are built with a team effort over a period of about one year and are taken to the annual competition for judging and comparison with other modified Formula SAE vehicles from colleges and university throughout the United States. The end result is a great experience for aspiring engineers in a meaningful project as well as the opportunity of working in a dedicated team effort.
The R.E.V. team will design, manufacture, assemble, test, and present their electric car in the 2007 Formula Hybrid competition.

4. Driver Interface & Ergonomics
Team Organization:
Team Lead
Design Teams
Development Group
Procurement Group
Manufacturing Group
Integration Team
Chassis & Body
Chassis Redesign
Body Redesign
Mounting Points
Aeros/Ground Effects
Drive System
Motor
Drivetrain
Control System
Battery System
Cooling System
Shielding System
Electrical
Battery Management
Instrumentation
Data Transfer System
Power Management
Vehicle Dynamics
Suspension System
Steering System
Braking System
Driver Interface & Ergonomics
Cockpit Design
Safety Equipment
Driver Interface

5. Team Organization: REV Design Teams
Team Lead:
Elizabeth Diaz
Design Teams
Drive System Team:
Vehicle Dynamics Team:
Chassis & Body Team:
Josh Wales
AJ Nick
Kathy Murray
Jason Miner
AJ Nick
Elizabeth Diaz
Jason Miner
Dave Wickers Elizabeth Diaz
Jared Doescher
Kathy Murray
Electrical Team:
Driver Interface Team:
Matt Reedy
Kristi Harrell
Valerie Bastien
Audrey Moyers
Oliver Zimmerman
Elizabeth Diaz
Audrey Moyers

6. Engineering Objectives:
Acceleration from 0 to 60 mph in under 5 seconds
Top speed of 80 mph
Maximum power available between 20 and 40 mph
Lightweight (under 650lb with driver)
15 minute battery life for continuous draw

7. Florida Tech REV

8. Design Changes: Electrical
Lead Acid Batteries 174lbs, 10 usable Ah
12 cells, cost approx. $1000
Lithium Ion Batteries 90lbs, 28 usable Ah
550 cells, cost approx $ BMS
Odyssey Battery,
Model PC680

9. Design: Electrical Integration
Warp 9” motor, 70hp, 127ftlbs
12 Odyssey PC680s, 14.5lbs ea.
550amps, 144volts from Zilla 1K-HV
2 min run time, 4.2s 0-60,
Top Speed 6000 rpm
Pic to PLC to LCD

10. Design Changes: Side Pod
Using Odyssey Lead-acid batteries, PC680
Diagonal Support tube thickness increased to .095”
Battery Layout
- Strapped together then
strapped to supports
- Plexiglas to cover connections

11. Design Changes: Chassis Revised Engineering Specifications
Static deflection – 0.009in
Torsional Rigidity – no change
Dynamic Loading - insignificant change

12. Analysis Changes: Chassis
Deflection Analysis

13. Analysis Changes: Chassis Static Stress Analysis

14. Design: Rear Suspension
COILOVER ACTUATION DESIGN
COILOVER ACTUATION BUILD

15. Design: Rear Suspension

16. Design: Front Suspension
BELLCRANK POSITION CHANGE FOR CLEARANCE ISSUES

17. Design: Suspension Spring Rates
FRONT SPRING RATE ≈ 280 LB/IN REAR SPRING RATE ≈ 310 LB/IN

18. Design: Differential

19. Analysis: Differential Mount
Tensile Yield Stress of Aluminum: 47000 psi
3/8” thick aluminum
Max Von Mises stress: psi
Not within our factor of safety
Total Weight: 1 lbs

20. Analysis: Differential Mount
Tensile Yield Stress of Aluminum: 47000 psi
1/2” thick aluminum
Max Von Mises stress: psi
Within our factor of safety
Total Weight: 1.34 lbs
Adds 0.68 lbs to the chassis

21. Design Changes: Differential Mount
Added support to reduce vibrations

22. Design Changes: Acceleration Pedal
Parts arrived to finalize design
Redesign to incorporate ergonomics

23. Design Changes: Acceleration Pedal Ergonomics of Acceleration Pedal
Foot has a natural downward motion
Pedal mounted upside down incorporates
natural downward motion

24. Design Changes: Steering Wheel
Previous Design
Design Criteria
Must be able to hold the touch screen
Comply with SAE rules
Designed to be as light as possible while remaining rigid enough to protect touch screen
Designed for driver’s comfort
Alterations in Design
Changed because of the method of mounting provided from manufacturer
Will create new wheel to be fully closed loop IAW SAE rules
Current Design

25. Design Changes: Body Current Design Future Changes Fiberglass body
Using nose cone from previous Formula SAE car
Future Changes
Aluminum sheeting rather then fiberglass because of time constraints
Alterations to the nose cone due to intersections with the suspension

26. Major Challenges Complete the car Suspension
Mechanical/Electrical Integration
Create/Integrate Lithium-Ion pack
Resources and connections are in place
More publicity
Autocross racing
More EV events
Local advertising
Funding

27. Suspension: Plans Set ride heights Tune adjustable dampers
Determine new spring rates if need be
Anti-roll bars?
Data Logging?

28. Electrical Integration: Plans
To Do:
Obtain and Install new Controller
Build Battery Management System
Check and Adjust Differential Mounting
Test Real World Motor Performance
Locate Li-Ion/Li-Polymer Sponsor
Evaluate BMS (Battery
Management Systems) options

29. Milestones and Deadlines
Battery Beach Burnout, January 27th
Finish build & start testing, February 12th
Racing Opportunity at Moroso Speedway, March 1st **
Complete testing, April 1st
Design Showcase, April 13th
EV Autocross Event, April 25th**
Formula Hybrid Competition, May 1st – 3rd
** Dates are tentative

30. Gantt Chart: Mechanical Design

31. Gantt Chart: Electrical Design

32. Budget: Preliminary
With a Preliminary Budget, we can get a vehicle running for less money and use that product to raise funds for future enhancements

33. Budget: Secondary

34. Questions?!?