2013 Electric Vehicle2013 Electric VehicleGrand Prix ChampionshipGrand Prix Championship

Washington DC

The Electric Vehicle The Electric Vehicle Association, Greater Association, Greater Washington Washington DCDC

Charlie GarlowUS EPA, EVADC

EVADC Sponsors EV racingEVADC Sponsors EV racing

EVADC Sponsors Solar EVADC Sponsors Solar EducationEducation

EVADC Supports modern EVsEVADC Supports modern EVs

Solar Decathlon and Solar Decathlon and California EV ChallengeCalifornia EV Challenge

Richard KingUS DOE

The Washington DC The Washington DC Electric Vehicle Grand Electric Vehicle Grand Prix Prix ChampionshipChampionship

Dr. Nabih BedewiGlobal EEE

Question?Question?

What do you get when you combine some of the latest technologies from

Formula 1 racing, satellites, and F-16 jets

with the most energetic and innovative minds in universities worldwide?

Answer? Solar Race CarsAnswer? Solar Race Cars

Aerodynamic body designs with thousands of hours of

wind tunnel testing and computer simulations

Aerodynamic body designs with thousands of hours of

wind tunnel testing and computer simulations

Most efficient terrestrial and space

grade solar cells

Most efficient terrestrial and space

grade solar cells

Advanced peak power trackers and

PV electronics

Advanced peak power trackers and

PV electronics

Latest encapsulation films for solar array

Latest encapsulation films for solar array

Most efficient LED technology for turn

signals & brake lights

Most efficient LED technology for turn

signals & brake lights

Advanced telemetry systems and

computer control

Advanced telemetry systems and

computer control

Most efficient custom wheel-

mounted electric motors on the planet

Most efficient custom wheel-

mounted electric motors on the planet

Lightweight and efficient custom wheels and low-

loss bearings

Lightweight and efficient custom wheels and low-

loss bearings

Advanced carbon-fiber composite chassis

fabrication

Advanced carbon-fiber composite chassis

fabrication

Advanced Kevlar and Nomex

fabrication for solar panel substructure

Advanced Kevlar and Nomex

fabrication for solar panel substructure

Lightest and most efficient Lithium based battery

technology

Lightest and most efficient Lithium based battery

technology

Sophisticated battery monitoring and management

system

Sophisticated battery monitoring and management

system

Sophisticated weather prediction and energy management/strategy systems and software

Sophisticated weather prediction and energy management/strategy systems and software

Lightweight and efficient low-scrub suspension and

steering

Lightweight and efficient low-scrub suspension and

steering

Advanced cockpit instrumentation and

control interface

Advanced cockpit instrumentation and

control interface

Lowest rolling resistance high

performance tyres

Lowest rolling resistance high

performance tyres

University ProjectsUniversity Projects

Engineering schools look for high Engineering schools look for high

school students with school students with

demonstrated involvement and demonstrated involvement and

hands-on experience with similar hands-on experience with similar

projectsprojects

Overview videoOverview video

New York State EV Competition

2013 EV Grand Prix in DC2013 EV Grand Prix in DC

Opportunity for high schools in DC, MD and VA to get Opportunity for high schools in DC, MD and VA to get

startedstarted

First year competition limited to “novice teams”First year competition limited to “novice teams”

Cap on cost – level playing fieldCap on cost – level playing field

Partnered with NuGen Mobility to create kitPartnered with NuGen Mobility to create kit

– Minimize risk and unknowns for school/teacherMinimize risk and unknowns for school/teacher

– Allow time to build program, know-how and track recordAllow time to build program, know-how and track record

– Add more capabilities (design, welding, etc) following Add more capabilities (design, welding, etc) following

yearsyears

– Plenty of room for technical creativity and innovationPlenty of room for technical creativity and innovation

Partnered with EVA/DC to support schools and eventPartnered with EVA/DC to support schools and event

Top finishers have opportunity to compete in Irvine, CATop finishers have opportunity to compete in Irvine, CA

Teams can participate in other competitions in the USTeams can participate in other competitions in the US

2013 EV Grand Prix in DC2013 EV Grand Prix in DC

Competition to be held in DC Metro Area (location TBD)Competition to be held in DC Metro Area (location TBD) F1 style closed track – 0.5 to 1 mileF1 style closed track – 0.5 to 1 mile

One day raceOne day race Run on battery onlyRun on battery only One hour heatsOne hour heats Longest distance winsLongest distance wins

More than one team per institution may participateMore than one team per institution may participate

Registration fee: $250Registration fee: $250 Includes membership in EA – can compete elsewhereIncludes membership in EA – can compete elsewhere Receive official car number and design/rules handbookReceive official car number and design/rules handbook Covers track liability insuranceCovers track liability insurance

AwardsAwards

Overall Grand Prix winner – longest distance in one Overall Grand Prix winner – longest distance in one

hourhour

Fastest 0.25 mile dashFastest 0.25 mile dash

Best overall graphics designBest overall graphics design

SportsmanshipSportsmanship

Best team photoBest team photo

Best team videoBest team video

Trophies, awards, cash prizesTrophies, awards, cash prizes

ScheduleSchedule

Registration deadline: January 5Registration deadline: January 5

Kit orders: February 1Kit orders: February 1

Shipping considerations/lead time: 30 daysShipping considerations/lead time: 30 days

Kit delivery: March 5Kit delivery: March 5

Construction time: March 5 to May 15Construction time: March 5 to May 15

Test/optimization/driver training: May 15 – Test/optimization/driver training: May 15 – June 15June 15

Race: week of June 15Race: week of June 15

Teacher and Student SupportTeacher and Student Support

Technical support available throughoutTechnical support available throughout

Assembly overview session when kits arriveAssembly overview session when kits arrive

Guidance session for F&M studentsGuidance session for F&M students

Help students develop strategy and action Help students develop strategy and action planplan

Assist with fundraising proposalsAssist with fundraising proposals

Critique “elevator pitch”Critique “elevator pitch”

Vehicle OptionsVehicle Options

The VehicleThe Vehicle

What is important?What is important?

EfficiencyEfficiency MotorMotor ControllerController Charger (in between events)Charger (in between events) ElectronicsElectronics TiresTires

Vehicle weightVehicle weight Driver weight not an issue – ballastedDriver weight not an issue – ballasted

Gear ratio selectionGear ratio selection

StrategyStrategy

DC Electric Vehicle DC Electric Vehicle Grand Prix Kit and Grand Prix Kit and ComponentsComponents

Eric TakamuraNuGen Mobility, Inc.

Key CategoriesKey Categories Chassis, Body & Wheels & TiresChassis, Body & Wheels & Tires

ReliableReliable

TestedTested

Easy to build / assembleEasy to build / assemble

Drive System: Motor, Controller, connection and mountingDrive System: Motor, Controller, connection and mounting

ReliableReliable

EfficientEfficient

Correct operational ZonesCorrect operational Zones

Safety & ElectricalSafety & Electrical

Five Point Seat beltFive Point Seat belt

All components to complete safe, functional and reliable circuitAll components to complete safe, functional and reliable circuit

Power & Energy: Batteries & Battery ChargerPower & Energy: Batteries & Battery Charger

Component SelectionComponent Selection Several suppliers existSeveral suppliers exist

Time and decisions to make Time and decisions to make choices and find suppliers choices and find suppliers could take weeks if not could take weeks if not monthsmonths

Quality/performance variesQuality/performance varies

Knowing what is requiredKnowing what is required

Cost: $4,500 - $5,500Cost: $4,500 - $5,500

Individual Shipping is highIndividual Shipping is high

Adds another $500+Adds another $500+

Result:Result: Logistic NightmareLogistic Nightmare

High risk High risk

Unknown CostsUnknown Costs

Key ObjectivesKey Objectives Hands On ExperienceHands On Experience

Students focus on assembly, learning & StrategyStudents focus on assembly, learning & Strategy

Don’t get bogged with logisticsDon’t get bogged with logistics

Affordable and level playing fieldAffordable and level playing field

Reduce effect that “$” winReduce effect that “$” win

Fun – Fun –

““Doable” : Doable” :

“ “Competitive”Competitive”

**** Safe !**** Safe !

Kit componentsKit components

As mentioned, first year parts are standardized into kitAs mentioned, first year parts are standardized into kit

Experience: most suitable chassis/outer body - Blue Sky Experience: most suitable chassis/outer body - Blue Sky

DesignDesign

– Costs $1950 plus shipping from west coast (Costs $1950 plus shipping from west coast ( $300) $300)

– Steel ChassisSteel Chassis

– ABS outer body and FRP seat panABS outer body and FRP seat pan

– Acrylic tinted canopyAcrylic tinted canopy

– Wheels, brakes, steeringWheels, brakes, steering

Kit ComponentsKit Components

24V High Efficiency electric motor24V High Efficiency electric motor

24-48V, 300A controller24-48V, 300A controller

Reliable Sealed lead acid batteriesReliable Sealed lead acid batteries

Compatible Battery chargerCompatible Battery charger

Five point seat belt systemFive point seat belt system

Aluminum sprocket adaptor with freewheel and chain Aluminum sprocket adaptor with freewheel and chain guardsguards

Sprocket set (three, to allow different drive ratio's)Sprocket set (three, to allow different drive ratio's)

20” rear and 16” front high pressure tires and tubes20” rear and 16” front high pressure tires and tubes

All electrical components including sensors and All electrical components including sensors and display, battery power cable, copper connectors, 3 display, battery power cable, copper connectors, 3 stage master power switch, main power fuse, shunt stage master power switch, main power fuse, shunt resistor, potentiometer for accelerator, foot pedal, etcresistor, potentiometer for accelerator, foot pedal, etc

Estimated EffortEstimated Effort

Rolling Chassis Assembly: 5 hrsRolling Chassis Assembly: 5 hrs

Electrical & Drive System Integration: 10 hrsElectrical & Drive System Integration: 10 hrs

Outer body and canopy integration: 10 hrsOuter body and canopy integration: 10 hrs

Vehicle paint, decals, other finishes: 10 hrsVehicle paint, decals, other finishes: 10 hrs

Testing and adjustments: 15 hrsTesting and adjustments: 15 hrs

Some of these tasks run in parallel (total under Some of these tasks run in parallel (total under 50 hrs)50 hrs)

Group of 6-8 students can complete vehicle in 8 Group of 6-8 students can complete vehicle in 8 weeksweeks

Ordering ProceduresOrdering Procedures

Collect all orders at onceCollect all orders at once

Everything ships to NuGen facility near Dulles Everything ships to NuGen facility near Dulles AirportAirport

Overall shipping costs reducedOverall shipping costs reduced

Bring pickup or U-Haul to transport kits back to Bring pickup or U-Haul to transport kits back to schoolschool

NuGen personnel available for technical supportNuGen personnel available for technical support

Teacher session when kits arriveTeacher session when kits arrive

Kit price $4,500 + shippingKit price $4,500 + shipping

Project Management, Project Management, Marketing and Marketing and FundraisingFundraising

Charles GabrialDeloitte and Touche

Project ManagementProject Management

Project teaches leadership, team work, and Project teaches leadership, team work, and

managementmanagement

Create project organization chartCreate project organization chart

– Faculty AdviserFaculty Adviser

– Student Project LeaderStudent Project Leader

– Group leadersGroup leaders

o Chassis, steering, wheels, brakes & tires groupChassis, steering, wheels, brakes & tires group

o Outer body and canopy groupOuter body and canopy group

o Drive system and electrical groupDrive system and electrical group

o Graphics design and paint/decals groupGraphics design and paint/decals group

o Marketing and fundraising groupMarketing and fundraising group

o Logistics and testing groupLogistics and testing group

Project ManagementProject Management

Create and agree on project schedule and tasks Create and agree on project schedule and tasks

upfrontupfront

Meeting days and timesMeeting days and times

– After school M, W, F 3:00 PM – 5:00 PMAfter school M, W, F 3:00 PM – 5:00 PM

– Saturdays 9:00 AM – 3:00 PMSaturdays 9:00 AM – 3:00 PM

– Class timeClass time

All-hands team meeting at least once a week, not longAll-hands team meeting at least once a week, not long

Student Project Leader review schedule and make Student Project Leader review schedule and make

updatesupdates

Marketing/fundraising group activities importantMarketing/fundraising group activities important

Schedule testing and optimization phaseSchedule testing and optimization phase

MarketingMarketing

Important component of the projectImportant component of the project

– Dovetails with fundraisingDovetails with fundraising

Recruit creative students not interested in the scienceRecruit creative students not interested in the science

Create flyers, pamphlets, emailsCreate flyers, pamphlets, emails

Develop and maintain project web siteDevelop and maintain project web site

Use social media to rally the school communityUse social media to rally the school community

– Keep people informedKeep people informed

– Announce fundraising and sponsor eventsAnnounce fundraising and sponsor events

– Solicit ideas and feedback for fundraisingSolicit ideas and feedback for fundraising

Integrate with school PR to reach out to parents and Integrate with school PR to reach out to parents and

alumsalums

MarketingMarketing

Work with graphics design and paint/decals groupWork with graphics design and paint/decals group

Hold student competitionHold student competition

– Team/car nameTeam/car name

– Car and helmet colors and graphic designCar and helmet colors and graphic design

– Team uniform (T-shirt design)Team uniform (T-shirt design)

Develop plan for sponsor logo space and size on carDevelop plan for sponsor logo space and size on car

– Size proportional to sponsorshipSize proportional to sponsorship

– Integrate throughout web site, T-shirts, pamphletsIntegrate throughout web site, T-shirts, pamphlets

FundraisingFundraising

Set realistic expectations for amounts and scheduleSet realistic expectations for amounts and schedule

Understand school rules and guidelines for fundraisingUnderstand school rules and guidelines for fundraising

May need commitment from school for front fundingMay need commitment from school for front funding

Invite teachers, students, and staff to brainstorming Invite teachers, students, and staff to brainstorming

sessionsession

o Target corporate sponsors (car dealerships, stores in Target corporate sponsors (car dealerships, stores in

vicinity, etc)vicinity, etc)

o T-shirt sales on campusT-shirt sales on campus

o Car/team appearances at athletic events, sponsor Car/team appearances at athletic events, sponsor

locationslocations

o $1 drive around the parking$1 drive around the parking

Grants: corporate/family foundations – Grants: corporate/family foundations – www.foundationcenter.orgwww.foundationcenter.org

Create action plan, student elevator pitch – rehearseCreate action plan, student elevator pitch – rehearse

SafetySafety

Dr. Tarek OmarFRA R&D - DOT

OverviewOverview

Safety is critical to the success of any student Safety is critical to the success of any student

competitioncompetition

Address it with the students early on in the projectAddress it with the students early on in the project

Make it a culture of the projectMake it a culture of the project

– When making any decision - is it safe?When making any decision - is it safe?

– No shame in asking for help or getting instructionsNo shame in asking for help or getting instructions

– Always work in pairs, watch out for your buddyAlways work in pairs, watch out for your buddy

Two aspects to safetyTwo aspects to safety

– Phase leading up to competition (tools, lab, testing, etc)Phase leading up to competition (tools, lab, testing, etc)

– Vehicle safety and the competitionVehicle safety and the competition

Construction PhaseConstruction Phase

Use tools properly especially drills, saws, knives, etc.Use tools properly especially drills, saws, knives, etc.

Exercise care around electrical systems and magnetsExercise care around electrical systems and magnets

Wear goggles and mask when cutting fiberglassWear goggles and mask when cutting fiberglass

Insure proper ventilationInsure proper ventilation

Use common senseUse common sense

Testing PhaseTesting Phase

Supervised testing of the vehicle on campus or parking Supervised testing of the vehicle on campus or parking

lotlot

DO NOT drive the car on public roadsDO NOT drive the car on public roads

Initial testing at low speedInitial testing at low speed

Adequate communication with driver (radios or vocal)Adequate communication with driver (radios or vocal)

Team members surround test area with flagsTeam members surround test area with flags

Area well litArea well lit

Use common senseUse common sense

Car Design SafetyCar Design Safety

Race rules specific about safety requirementsRace rules specific about safety requirements– Chassis, roll bar, bumperChassis, roll bar, bumper

– Outer body protectionOuter body protection

– Five-point seat beltFive-point seat belt

– DOT certified helmetDOT certified helmet

– Stopping distanceStopping distance

– Head behind knees seatingHead behind knees seating

– Rearview mirrorRearview mirror

– Electrical disconnect and labelingElectrical disconnect and labeling

– Driver egressDriver egress

Cars will be inspected prior to, and during raceCars will be inspected prior to, and during race

Any changes made to kits need to be reported and Any changes made to kits need to be reported and

inspectedinspected

Drive TopologyDrive Topology

Race SafetyRace Safety

Race safety rules will be published in advanceRace safety rules will be published in advance

Learn meaning of flag colors (slow down, do not pass, Learn meaning of flag colors (slow down, do not pass,

etc)etc)

Driver/teacher meeting prior to the raceDriver/teacher meeting prior to the race

Stewards will issue warnings and disqualify driversStewards will issue warnings and disqualify drivers

It’s a race against the clock, not other carsIt’s a race against the clock, not other cars

Use common sense -- Have fun!Use common sense -- Have fun!