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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.
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
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
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
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
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