Raresh Pascali - Instructor

Marcus Gamino - Faculty Advisor

William Hesser - Industry Advisor

Matt Walsh -

Underclassman

Ayazhan Zhakhan - Alumni

Team Members

Daulet Urkenbaye

v

Paul Orieukwu

Jonathon Fulbright

Rajeev Bhattachary

a

Advisors

Project Manag

er

Mechanical System

Designer

Frame & Body

Designer

Electrical System

Designer

3

Outline

1. Competition Objective

2. Team Goals

3. What is a Hybrid Vehicle?

4. 3D Model of the Car

5. Frame Material

6. Frame Design

7. Finite Element Analysis

8. Aerodynamics Devices

9. Internal Combustion Components

10. Calculations

11. Electrical Components

12. Project Management

4

Competition Objective

To challenge teams of university students to design, fabricate and build a formula hybrid-powered vehicle and compete at the annual Competition in Loudon, New Hampshire on April 27, 2015

35 Open

24 Registere

d

19 Compete

d

12 Hybrid

7 Electric

Formula Hybrid 2014

Projection for Formula Hybrid 2015

35 Open

30 Registered

19USA

1Australia

1Turkey

1Pakistan

3Canada

4India

1South Korea

5

100

200

75

75150

400

Competition Scoring

Presentation

Engineering Design

Acceleration-Unrestricted

Acceleration-Electric

Autocross

Endurance

1000

Competition Events & Scoring

Presentation Engineering Design

Acceleration EnduranceAutocross

DYNAMICSTATIC

6

Team Goals

Register before slots fill.

Implement switchable hybrid drive.

Curb weight not to exceed 650 lbs.

Implement data logging system.

Complete unrestricted 246 ft acceleration run in 5.4 sec or less.

Complete the final assembly by April 1.

7

What is a Hybrid Vehicle?

Series Hybrid Layout Parallel Hybrid Layout

High Efficiency Low Efficiency

Low Driving Performance High Driving Performance

8

Illustration of the FH Car

To design system with the ability to switch between the series and parallel hybrid systems.

9

Frame and Body Outline

1. Frame Material

2. Frame Design

3. Finite Element Analysis

10

Frame Material

Steel

Carbon Fiber Aluminum

Yield Strength = 710,684psi

Modulus of elasticity =

33,000ksi

Density: .055g/in3

Price: $106.5/ft

Yield Strength = 31,000psi

Modulus of elasticity =

10,000ksi

Density: .0975 lb/in3

Price: $20/ft

Yield Strength = 50,800psi

Modulus of elasticity =

29,700ksi

Density: 2.48lb/in3

Price: $44/ft

11

Frame Design

Design #1

Design #2

Design #3

12

Finite Element Analysis (FEA)

Front Impact Results (Von Mises)(psi) Side Impact Results (Von Mises)(psi)

13

Aerodynamics Devices

All of the components should increase the downforce on the vehicle by manipulating the air flow.

Body DiffuserFront Wing

14

Mechanical Outline

1. Internal Combustion Engine

2. Calculations

3. Differential

15

Internal Combustion Engine

Specification:Engine: Four-Stroke, DOHC, Parallel TwinDisplacement: 249 ccCompression: 11.6 : 1Cooling: LiquidIgnition: ElectricalTransmission: Six SpeedFinal Drive: 14 in Chain SprocketCooling type: Liquid

Kawasaki Ninja 250RPower Output: 37 HpPrice (used): $450- $650

Subaru EX21 Power Output: 7 HpPrice (New): $479.97

Lifan 250cc V-Twin Engine Power Output: 16.5 HpPrice (used): $625

16

Calculations

17

Differential

Torsen Traction-JTEKT

Taylor Industries

Westgarage Engineering

Torque: 800 ft-lbWeight: 10 lbCost: $2600

Torque: 600 ft-lbWeight: 15 lbCost: $415

Torque: 680 ft-lbWeight: 10 lbCost: $1000

18

Electrical Outline

1. Electric Motors

2. Controllers

3. Batteries

4. BMS

5. CCU

19

Front Electric Motors

Specification:Type: PMDC Weight: 24.8 lbTorque Max: 28 ft-lb 

Perm PMG-132 PMDC Power Output: 19 HPPrice: Donated

ME0909 Brushed DC Power Output: 20 HPPrice (New): $385

Liquid Cooled BLDC MotorPower Output: 13 HPPrice (New): $918

20

Rear Electric Motor

Specification:Type: AC InductionWeight: 46 lbs. Torque Max: 100 ft-lb 

AC 12Power Output: 44 HPPrice: Donated

ME 1118 PMACPower Output: 19 HPPrice (New): $1895

ME0909 PMDCPower Output: 20 HPPrice (New): $385

21

Controllers

Kelly KDZ12401

Regen: YesPrice: $479

Curtis 1239E

Regen: YesPrice: $1,562

(Donated)

Front

Rear

22

Battery

Li PolymerSpecifications:Cell Capacity: 2.8 AhSize: 18650Cost: $3000

Lead AcidSpecifications:Cell Capacity: 12 AhSize: 6” x 2” x 3.7”Cost: $1000

LiFePO4Specifications:Cell Capacity: 8 AhSize: 38120Cost: $3000

23

Battery Management System (BMS)

MBS-EP128Price: $425

Orion BMSPrice: $890

LithiumatePrice: $795Specifications:• USB and RS232 Ports• CAN Bus Capable• Analog and Digital I/O

24

Central Control Unit (CCU)

Arduino MegaI/O: 54

Price: $30

Rasberry Pi B+

I/O: 40Price: $70

myRioSpecification: I/O: 40Analog out: 10 Analog in: 6Input power: 6-16 VClock speed: 667 MHzPrice : $250

25

Budget Components Low High

Frame and Body $300 $2,500Steel Tubing $300 $600Fiberglass Shell Donated $400Cost of Construction Donated $1,500

Internal Combustion $630 $2,700Engine $450 $2,000Upgrades and Modifications Excluded $300Hoses and Connections $80 $100Exhaust $100 $300

Electrical System $5,650 $16,200DC Electric Motors Donated $2,000DC Electric Motor Controllers $1,400 $2,000AC Induction Motor Donated $1,200AC Induction Motor Controller Donated $3,000Input/output Transducers $800 $2,000Cables and Connections $200 $500Batteries and Battery Management System $3,000 $5,000Central Controller $250 $500

Drivetrain and Suspension $1,800 $7,200Axels, Bearings, and CV Connections $500 $2,000Chains and Sprockets $300 $600Differential and Electric Clutch $1,000 $3,000Wheels and Tires Donated $1,600

Travel Expenses $0 $4,400Truck and Trailer Rental Donated $1,200Lodging and Food Donated $1,200Gas Donated $2,000

Entry Fee $2,150 $2,150Total $10,530 $35,150

26

Gantt Chart

27

Work Breakdown Structure

28

Risk Matrix

29

Questions?