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Workshop 2011 – Bosch Engineering
FSE Rules 2012
Tobias Michaels
Agenda
Reasons for rule changes
Major rules changes and possible changes for the final
version
Global Electric Rules Development
Questions
Reasons for rule changes
Safety Issues that we have encountered prior, during and
after FSG2011
Clarifications to make the rules easier to understand
Balancing between concepts to keep it interesting
European Rules Harmonization & Global Rules
Development
Major rule changes & additions
3.7 Safety Responsible and Safety Advisor
Clarification: SR needs an HV-Certificate in any case, if not
an EE student
Safety Advisor: Professional Engineer with competence in the
respective area assists in developing the vehicle
Safety Advisor is a strong recommendation in 2012, but may
become mandatory in future rules sets
Major rule changes & additions
3.11 Testing and Work Safety
Nothing has changed
Always keep in mind work safety and common sense
The best is to always follow event rules (see the
EventHandbook 2011 for example)
Major rule changes & additions
4.3.1 Brake System Master cylinder actuation
The wording may change slightly
Removing 50% value to account for the fact that a stiff brake
pedal / brake system would only leave some mm of travel for
regenerative braking (if this rule is enforced)
Add another, similar criteria e.g. a maximum absolute brake
pedal travel to be used for regenerative braking
Major rule changes & additions
4.9 Firewall
Must be insulated
Must be fireproof according to UL94-V0 or equivalent
Must be puncture and scratch resistant
Must be well grounded, if a coated electrically conductive
material is used, see rule 7.9
Additional robustness requirements may be added
Major rule changes & additions
4.11.2 Power Limitation
85kW
Data of any violation will be made public
Further definition of a violation may be added
E.g. the 85kW limit must not be violated for more than 2% of the
official time for a particular run
Your Acc time: 3.81s
Maximum sum of violation duration: 76.2ms
Major rule changes & additions
4.11.4 Torque Encoder (throttle pedal position sensor)
Implausibility defined as 10% difference in pedal travel
Shutdown of the tractive system is now mandatory, if one
sensor fails (two sensor setup)
Major rule changes & additions
4.11.5 Torque Encoder Plausibility Check
Power to the motors has to be shutdown, if the torque
encoder signals more than 25% while the brake pedal is
actuated
Shutdown has to remain active until the torque encoder
signals less than 5% (hysteresis), no matter if the brake pedal
is still actuated or not
Major rule changes & additions
7.4 High-Voltage (HV) and Low-Voltage (LV)
Minimum spacing requirements may be added
7.5 Positioning of tractive-system parts
All parts belonging to the tractive-system must be contained
within the frame.
Outboard wheel motors need an interlock
The frame structure may be further specified
Major rule changes & additions
7.6 Grounding
300mOhm@1A for every possibly conducting part
Take grounding into account when designing / manufacturing
carbon fibre parts
The IMD is not the main cause for this rule.
Dangerous voltage levels from inductive and capacitive
coupling shall be prevented -> BMW KERS accident
Major rule changes & additions
7.13 Tractive-system-active light (TSAL)
The monitored voltage must directly control the TSAL (no
software control)
Driver helmet must not contact the TSAL in any position
Major rule changes & additions
7.16 Inertia Switch
Sensata or equivalent resettable crash sensor
Must interrupt the safety circuit in the event of an accident
May be reset by the driver
It must be possible to demount the device during
scrutineering to check it for proper operation
Major rule changes & additions
7.17 Safety Circuit
If the tractive system is shut down by BMS or IMD the tractive
system must remain disabled until being externally reset.
It must not be possible for the driver to re-activate the tractive
system from within the car in case of an BMS or IMD fault.
Motors must spin free, if the tractive system is de-activated
Major rule changes & additions
7.18 Activating the Tractive System
Only closing the Safety Circuit/AIRs must not set the car to
ready-to-drive mode
Additional actions are required by the driver to set the car to
ready-to-drive-mode e.g. pressing a dedicated start button
Being ready-to-drive and an active tractive system are not
same modes of operation!
Major rule changes & additions
7.19 Ready-To-Drive-Sound
Maximum duration of 3seconds
Ready-to-drive and tractive system active are not equal!
7.20 Fusing
Each wire must be fused lower than the continuous current
which it is able to carry
May be further specified
Major rule changes & additions
7.22.1 Accumulator Container->General
Building one big accumulator container out of several
interconnected accumulator containers may be prohibited in
the next release
Major rule changes & additions
7.22.2 Accumulator Container->Electrical Configuration
Maintenance plugs to separate the accumulator in stacks
carrying below 120VDC
Plugs have to be removed whenever accumulator container is
opened
REMOVED: Indicator has to be visible in ready-to-race
condition
Indicator must again be directly controlled (no software)
Major rule changes & additions
7.22.3 Accumulator Container->Mechanical Configuration
Accumulator container must not enter the driver’s cell area
during a deceleration of 20g in the respective direction
Must be able to withstand 10g deceleration in any other
direction
Calculations/tests proving this must be part of the SES
The used material must be fireproof according to UL94-V0
7.22.3 Accumulator Container->Mechanical Configuration
Cell stacks must be separated by an insulating and fire
resistant (according to UL94-V0 or equivalent) barrier in a
way, that no single cell stack contains more than 5MJ energy,
if fully charged.
Major rule changes & additions
7.22.3 Accumulator Container->Mechanical Configuration
Accumulator Container Top View
Major rule changes & additions
Stack1< 5MJ
AIRsetc.
Stack2< 5MJ
Stack3< 5MJ
7.25 HV Disconnect (HVD)
It must be possible to remove the HVD within 10 seconds in
ready-to-race condition.
The team will have to demonstrate this during E-
Scrutineering.
Major rule changes & additions
7.26 Battery Management System (BMS)
30% of the cell temperatures have to be monitored, if no
intrinsically safe cell chemistries are being used
7.27 Wiring of the tractive system supply
No further energy storages except for reasonably sized
intermediate circuit capacitors are allowed beyond this point.
Major rule changes & additions
7.28 Energy Meter
Energy flowing from the motor(s) to the accumulator(s) will be
multiplied with a factor of 0.9 and subtracted from the used
energy.
Cost Rules
Additional cost tables will be provided
Major rule changes & additions
FSAE Article B11.4.5 (Battery Chemistries)
Is not applicable for FSE cars
Will explicitly be excluded in the next release
Major rule changes & additions
FS UK and FSG have been working together to unify the
electric rule sets
You may have noticed the additions in both rule sets which
should allow building a car for both competitions without
headaches
Small differences are remaining
For example the EnergyMeters will remain different due to
different concepts in their purpose
Global Electric Rules Development
FSG leads the development of a global electric rules set
It is planned to include this rules set in the FSAE 2013 rules
A draft will be released in spring 2012
This rules set will look very similar to the current FSE rules
The voltage limit is still under discussion
Global Electric Rules Development
Events accepting cars complying with FSE rules:
Formula Student Germany
Formula Student Austria
Formula Electric and Hybrid Italy
Formula Student Spain
Global Electric Rules Development
Events accepting electric cars (modifications may be needed):
Formula Student Uk (minor differences)
FSAE Australasia (minor differences)
Formula Hybrid (bigger differences, but still possible)
Global Electric Rules Development
Events which plan to accept electric cars in the future:
FSAE West in 2013 (Lincoln, Nebraska)
FSAE Japan in 2013
Global Electric Rules Development
Rules Questions can always be send to FSE-
[email protected] (please keep FSE Rule 3.2 in
mind regarding the format)
We are not a hotline. If you have questions which may delay
your design process, make sure to ask early
I will be around the whole day, just ask, if you have specific
questions
Jürgen Falb, Head of E-Scrutineering will also be around
Questions?
See you at Hockenheim
01. – 05. August 2012