Presentation

Formula Hybrid

2. Needs Analysis

Design, build, and compete a small fully-electric vehicle

Categories:

Hybrid-in-Progress, Hybrid, Electric

Student conceived, designed and built

Agree and abide by rules

Good Engineering Practices - Safety

• Open Wheel, open cock pit
• Items under scrutiny for tech. inspec. must be visible
• Vehicle must complete a 75m run in < 10 seconds.
• The brakes must act on all four wheels and lock them.
• 50% of the brake travel may be used as regenerative braking.
• The brake pedal must be able to withstand 2000N of force.
• Brake over-travel switch will shut down engine, if brakes fail.
• Points capable of supporting vehicles weight in orange.

Driver/Cockpit Equipment

Cockpit Templates

In the Driver's Seat

• All drivers must use a 5,6, or 7 point restraint system, depending on seat inclination
• Restraint must be routed through seat, not around.

Driver Visibility

• When harnessed, Driver must have a minimum 200 degree field of vision with only turning their head.
• Mirrors can be set in place if drivers vision falls short of the limit adding additional weight to the car.

Vehicle Shutdown and Egress

• The driver must be able to activate and reset the driver’s shutdown button.
• Driver's must demonstrate shutdown activation in less than a second with obscured vision.

Powertrain

Transmission/Drivetrain

• No design limitations
• Any fluids used must be sealed to prevent leaks
• Scatter shields must be installed around chain drive components in case of failure

Transponders

6.4.4 Tire Traction – Limitations

Vehicles may not do “burnouts” before

competing in the acceleration event

6.6 Endurance Event

6.6.5 Endurance Course Specifications and Speeds

- Average speeds: 29.8 mph - 35.4 mph

- Top speed: ≥ 65.2 mph

- Time Limit: 60 minutes

- Course Length: 13.67 miles (22 km)

- All course specifications meet or exceed those

specifications of the Autocross event.

- No refueling/recharging is allowed

6.6.15.8 Inexperienced Driver

- All drivers at the competition must be experienced behind

the wheel of their car or they may be disqualified

7. Required Equipment

- All Required Equipment is located in Appendix H

in Section 10 of the Formula Hybrid 2012 Rules

document

- All required equipment must be kept with the car.

- All team members must know how to use the

equipment and where it is located.

8. Questions about the Formula Hybrid Rules

- General Questions: rules@formula-hybrid.org

- Mechanical Rules: mechanical@formula-hybrid.org

- Electrical Rules: electrical@formula-hybrid.org

4. Preliminary Test Plan

Formula Electric

2011-2012

Needs Analysis & Requirements Specification

By:

George Nimick

Scott Hill

Danny Covyeau

Stephen Kempinski

Tomas Bacci

Sam Risberg

Frame/Chassis and monocoque requirements

1inch diameter tubing and 2mm thickness for the main roll hoop

8in or larger in diameter

Rain tires must have 3/32 in

Steering free play must not exceed 7 degrees on the steering wheel

Roll hoops must be uncut members

Two shock absorbers for front and rear each and minimum of 2in of travel

Cockpit Opening Template

Helmet must meet the Snell, SFI and FIA requirements

• Will be inserted vertically into the vehicle

to ensure drivers have adequate room

to enter and exit the vehicle.

• Removable items

-Steering Wheel

-steering column

-driver's seat

-padding

Internal Cross Section

• Passed horizontally through the cockpit
• Area must be free of restrictions including

wires, hoses, tubes, etc.

• Removable items

-Steering Wheel

-Padding

60 in. wheelbase

Side impact tubing is also 1inch diameter and has a 1.2mm wall thickness.

• Smaller track must be no less than 75% of larger track. (Whether front or rear)
• Steering must affect at least 2 wheels

• All restraint systems must meet SFI Specification 16.1, SFI Specification 16.5, or FIA Specification 8853/98m, be adjustable and have single, metal, quick release latch.
• Must be replaced 2nd year after the date of manufacture

• Steering wheel with continuous perimeter; no concave sections
• Must have quick disconnect

Anchors must be 100mm apart

• Hole free, fire resistant gloves
• One piece fire resistant suit must be worn (no oil stains)

15W brake light required

200 degrees

• Vehicle must be equipped with 3 master shutdown switches.
• When pushed they must break the flow of current holding the accumulator isolation relays closed, shut down all power generation systems, and disconnect the LV systems from the LV battery.

placement

One on each side of the car just behind the driver's compartment at the level of the driver's head

near or on the instrument panel

Driver Egress

• Must be able to exit the vehicle with both feet on the ground within 5 seconds.
• The Driver will be fully suited with gloves and helmet.
• Must be able to removed the steering wheel and harness with gloves on.

A custom monocoque can be used with the following limitations

3X

X

shields for chains

• made of 2.66mm steel
• width minimum is three times the width of the chain

Belt Scatter Shields

Belt Scatter Shields

• Must be made from at least 3mm (.120in) 6061-T6 Al
• Must be centered around belt and be the width of the belt plus 35%

X

0.35X

No sharp edges on the bodywork

A three point bending test will be performed on the monocoque to prove impact saftey_

Must prove SAE/AISI 1010 steel equivalency test

Team Assignments

• DC or rechargable
• Used to record lap times
• must be placed on the driver's right side

Front impact attenuator

must be 7.8inx3.9in

-foam or honeycomb

Suspension Design - Tomas Bacci & Stephen Kempinski

Chassis Design - Samuel Risberg and George Nimick

Battery Management - Scott Hill

Motor Design - Danny Covyeau

Bender

IR475LY

• All vehicles must be equipped with an on-board Ground Fault Detector (GFD)

• The output relay of this device must be wired in series with the shutdown buttons such that a ground fault will cause an immediate shutdown of all electrical systems.

• Components and cables capable of movement must be positively restrained to maintain spacings.

Ground Fault Detector Test

• All controls, indicators and data acquisition connections must be isolated using optical isolation, transformers or the equivalent.

• The ground fault detector will be tested during technical inspection, by connecting, a known resistance below the trip threshold between points on the HV circuit and the grounded frame with the HV systems at full charge.

Cable Braces

Optical Isolators

4. Electrical Requirements

• A High Voltage (HV) test connector must be installed in the vehicle and easily accessible by the inspectors during technical inspection.

HV Test Connecter Pinouts

Circuit Spacing

• No HV connections may be exposed. Non-conductive covers must prevent inadvertent human contact.

• When high and low voltages are present within an enclosure they must be separated by insulating barriers made of moisture resistant; UL recognized insulating materials rated for 150 C or higher.

HV Test Connecter Specs

• A 10 cm long, 0.6 cm diameter (4 x ¼ inch) insulated test probe must not be able to touch a HV connection.

HV Connector

• All HV wiring must be done to professional standards

Wire Insulation

• Insulated wires must be commercially marked with a wire gauge, temperature rating and insulation voltage rating.

Electrical Constraints

• There must be no connection between the frame of the vehicle and any part of any HV circuits.

• HV and low-voltage circuits must be physically segregated and may not run through the same conduit

Wire Insulation

Accumulator Type and Size

• The maximum potential between any 2 points in the electrical systems may not exceed 300 V. Special cases can be made per the rules committee.
• Teams must state, as accurately as possible, their accumulator capacity.

HV Conduit

Fuse Rating

• All electrical systems (both low and high voltage) must be appropriately fused.

Fusing (Referred to as 4.4.1)

• The continuous current rating of a fuse must not be greater than the continuous current rating of the smallest wire it protects

• All fuses must be rated for the highest voltage in the systems they protect.

Series and Parallel Fusing

Accumulator Monitoring

• In single-series string configurations, a series fuse is required.
• In parallel-string configurations, each string of batteries or capacitors must be individually fused.
• In parallel-cell configurations, each cell must be individually fused.

High Voltage Component Location

• The accumulator monitoring system must disable the HV system by opening energy storage contactors if a hazardous condition is detected.
• The system must remain disabled until manually reset.

Fuse

• All parts containing high voltage must be positioned within the surface defined by the top of the roll bar and the outside edges of the four tires.

• In side view no high voltage component can be below the lower surface of the frame or monocoque.

Electrical Configuration

• Accumulator monitoring system, and other high-voltage sense wires must be fused with ratings complying with the previous slide

• All energy storage must be in closed container that cannot be accessed when the HV system is energized

• The accumulator enclosure must remain closed during charging

Grounding

Energy Storage Container Configuration

• All exposed conductive parts on the vehicle must be well grounded.

Accumulator Monitoring System Sense Wires

• Low-voltage circuits must be grounded to the frame of the car.

Energy Storage Container Cockpit Barrier

• The accumulator enclosure and mounting must be designed to withstand:

• A fireproof barrier must be provided between energy storage containers and the cockpit

Mechanical Configuration

• Monitoring fuses may be soldered or otherwise connected in-line and covered with heat shrink tubing.

• 20g static load in both the for/aft and side to side directions
• 8g static force in the vertical direction

3. Requirements Specifications

1. Overview of the Design Team

Section 5 Static Events

The finished car must pass a four-part technical inspection before being able to participate in competition events.

Part 2:

Scruteneering- Electrical

Part 1:

Scruteneering- Mechanical

Part 3:

Tilt Table Test

Part 4:

Noise, Master Switch, and Brake Tests

• Mechanical components of the vehicle are inspected
• Blindfold driver test of emergency shutdown system
• Driver Egress time taken
• Weight sticker placed

• Electrical components inspected

• SAE Standard J1673 “High Voltage Automotive Wiring Assembly Design” used as a guideline for proper wiring techniques

• The car must undergo a pair of tilt tests to demonstrate its safety.
• The 45 ° fuel and 60° stability tilt tests described in section 3 are performed in this part of the inspection.

• Max sound from the engine is not to exceed 110 dBA
• Master Switches (red buttons) operation tested.
• Break funcionality tested last by specified method (3.2)

If vehicle passes inspection, a sticker is placed on its front nose for recognition purposes.

Vehicles may be reinspected at any time.

Sample tilt test from 2010 competition

• Technical Inspection

• Presentation Event

• Design Event

One or more team members will give a presentation about their design

• Max 10 minutes
• Team members who do not present can still answer questions from judges provided they are in the "presentation group"
• Best presentation, regardless of design, wins the presentation event

The team with the best engineering ideas to meet design goals will win the design event.

The team must submit the following documents:

1. Design Report

2.Design Spec Sheet

• Excel form to be filled out
• Available on website
• Contains various parameters and dimensions of vehicle

• Document explaining engineering concepts of the car (new for repeat cars).
• Max 8 pages, and 3 should be vehicle drawings.
• Content will decide design group
• "Résumé" of the car

6. Dynamic Events,

7. Required Equipment,

& 8. Questions about Formula Hybrid

6. Dynamic Events

6.2Weather Conditions

6.2.1Running in Rain

A vehicle must be Rain Certified to operate in wet

conditions. This means that it must have rain tires

and must pass the 60 second water spray.

6.4 Acceleration Event

6.5 Autocross Event

6.5.3 Autocross Course Specifications and Speeds

- Average speed: ≥ 25 to 30 mph

- The Vehicle should be able to tackle the following track specifications with ease:

- 200 foot straights with hairpins at either end

- 150 foot straights with wide turns on either end

- Constant turns that are 75 to 148 feet in diameter

- Hairpin turns that are a minimum of 29.5 feet in diameter

- Slaloms with 25 to 40 foot spacing between cones

- Be able to drive on a track with a minimum width of 11.5 feet

6.10.7 Safety Glasses

- Safety glasses must be worn when working on the

vehicle or by anyone within 10 feet of the vehicle while

it’s being worked on.

• Insulated Gloves
• Safety Glasses
• MSDS Sheets

• Fire Extinguishers
• Chemical Spill Absorbent
• Cable Cutters

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formula-hybrid.org

Google Product Search

5. References

http://www.qrbiz.com/buy_Awg-Wire-Sizes - Wire mount Picture

http://www.optical-products.com/optical-isolator.html

http://www.kaf-tech.com/products/lt/lt_typea.html

safetyglassesreview.com

http://www.autointheknow.com/wp-content/uploads/2011/03/Kansas-City-Ford-Dealers.jpg

http://www.hotrod.com/techarticles/general/hrdp_1110_your_first_autocross/

http://reviews.carreview.com/wp-content/uploads/2008/08/2009_chevrolet_corvette_zr1_burnout1.jpg

http://www.simpsonraceproducts.com/wp-content/uploads/big_up6pt.gif

http://www.flickr.com/photos/thayerschool/sets/72157623887303883/detail/?page=3

http://www.robbinssports.com/pe-equipment-boundary-markers-c-207_248.html

http://www.stritch.luc.edu/lumen/meded/softchalkhdht/residency_interview_final_07_2011/residency_interview_final_07_2011_print.html

http://www.europeancarweb.com/firstlook/epcp_0808_2009_porsche_911_carrera_4_4s/photo_07.html

Overview of the Project

Driver Selection

Statement of the Problem

• will determine the drivers for the competition
• Also serve as test and tune

"non-professional weekend autocross competitior."

Prototype for manufacturing plant

Intended sales group:

Preferences/Goals:

200 degrees

timed testing preperation

• emergency shut down: under 1 second
• driver egress: under 5 seconds
• Acceleration: 75meters under 10 seconds

Strengths in acceleration, braking, and handling

Low cost, easy to maintain, and reliable Aesthetically pleasing, comfortable, accomodating

Use of common parts, reproducible

60 degree tilt test

• will measure the Center of Gravity
• 1.7 G equivalent
• Performed with the tallest driver in the normal driving position

Brake Test

• All 4 wheels must be able to lock completely
• Must stop in a straight line