Instructor: Raresh Pascali Underclassman : Matt Walsh

Instructor: Raresh Pascali

Underclassman: Matt Walsh

Team Members:

Daulet Urkenbayev (Project Manager)

Paul Orieukwu (Frame Designer)

Jonathon Fulbright (Electrical System Designer)

Rajeev Bhattacharya (Mechanical System Designer) 

:

Competition Objective

To challenge teams of university students to conceive, design, fabricate, develop, and compete with small, formula-style hybrid-powered cars.

The formula hybrid competition is intended as an educational program requiring students to work across disciplinary boundaries.

To allow teams to freely express design, engineering, and imagination.

Teams are allowed eight to twelve month to design, build, and test for the competition.

1

Competition Scoring

STATIC EVENTS HYBRID

Presentation 100

Engineering Design 200

DYNAMIC EVENTS  

Acceleration - Electric 75

Acceleration - Unrestricted 75

Autocross 150

Endurance 400

TOTAL POINTS 1000

2

Top three teams that score the highest points will receive trophies and awards.

Team Goal

Register for competition before slots fill.

Successfully implement switchable hybrid drive.

Finished curb weight not to accede 650 pounds.

Successfully implement data logging system.

Complete unrestricted 75 meter (246 feet)

acceleration run in 5.4 seconds or less.

Complete the final assembly by April 1.

3

What is a Hybrid?

4

Series Hybrid System Layout

Parallel Hybrid System Layout

Energy flows in 2 parallel paths from reservoirs to the wheels.

Energy flows in one path from reservoir, through all components, and finally to the wheels.

Design Outlook

5

Both Parallel and Series configuration have different advantages and disadvantages. This is why we plan to implement a design that has the ability to switch between the two. In theory, this should achieve the

best of both worlds.

Material Market Research Material Consideration

Weight

Feasibility

Strength

Cost

6

Steel

Carbon Fiber

Aluminum

Yield Strength = 710684psiModulus of elasticity = 33000ksi

Yield Strength = 31000psiModulus of elasticity = 10000ksi

Yield Strength = 50800psiModulus of elasticity = 29700ksi

Conceptual Frame Design

Must meet the 95th percentile male and 5th percentile female template.

7

University of Idaho SAE Frame

University of Houston SAE Frame

Lawrence Technology University SAE Frame

Aerodynamic Devices

8

Front Wing

Back Wing

Diffuser

All of these device are used to increase the downforce on the vehicle by manipulating the air flow.

Conceptual Design of Body

These are the top three teams who scored the highest in the design category.

Expectation for our project is for it to be unique and marketable.

9

(1) McMaster University

(3) Embry-Riddle Aeronautical University

(2) University of Idaho

Internal Combustion Market Research

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Subaru EX21 4 stroke engine 211cc- $479.97 (New)-7Hp

Lifan 250cc V-Twin Engine 4 stroke Air Cooled- $625 (Used)– $1099 (New)- 16.5Hp

Specifications:Shipping weight: 35poundsDisplacement Range: 121cc/240ccHorsepower Range: 3.6– 7.9HpCompression: 8.3:1Carburetor Type: FloatIgnition System: ElectronicCooling System: Air 

Specification:Displacement: 248ccMax Power Output: 16.5Hp/8000RPMMax Torque: 13feet/pounds. @ 6000RPMCompression: 10:1Ignition: Electric and Kick StartWeight: 95poundsCooling: Air

Internal Combustion Market Research Continued…

Specification:Engine: Four-Stroke, DOHC, Parallel TwinDisplacement: 249ccCompression: 11.6:1Cooling: LiquidIgnition: ElectricalTransmission: Six SpeedFinal Drive: 14inch Chain SprocketPower Output: 37Hp

Kawasaki Ninja 250r Engine 4 stroke Liquid Cooled- $450- $650 (used)- 37Hp

Differential Market Research

12

$415 by Torsen Traction - JTEKT

$2,699 by Taylor Industries.

$1000 Westgarage Engineering Chain drive LSD

Electric Motors Market Research

13

5kW Brushless DC Motor Liquid Cooled

12.9kW PMAC ME1118

3kW Brushless DC Motor Hub Motor

Controller Market Research

14

RoboteQ HDC2472

Dual Kelly KEB72801

5kW Brushless DC Motor Controller

Batteries Market Research

15

SLA 6V 12Ah x60

Ultra High Energy LG Lithium 18650 3.7V 2800mAh x420

LiFePO4 3.2V 60Ah x24

Budget

# Components Cost

1 Frame & Body $5,000

2 Internal Combustion Engine $4,000

3 Electrical System $7,500

4 Suspension, Brakes, Steering System $3,200

5 Differential, Wheels, Tires $1,500

6 Travel Expenditure $4,350

7 Entry Fee $2,150

  TOTAL $27,700

16

GANTT CHART

3

46

18

14

9

149

28

42

35

22

18

29

29

3

3

9-Sep 29-Sep 19-Oct 8-Nov 28-Nov 18-Dec 7-Jan 27-Jan 16-Feb 8-Mar 28-Mar 17-Apr

PHA SE 1

3 D MODE L FR A ME

3 D MODE L B ODY & A T T E N T UATOR

3 D MODE L DI FFE R E N T I AL

PHA SE 2

SPON SOR SHI P C A MPA I G N

OR DER I N G PA R T S

C HA SI S T E ST I N G

A ER ODY N A MI C B ODY

FI N A L C A R A SSE MB L Y

PHA SE 3

DR I VI N G T E ST & T R OUB LE SHOOT I NG

PHA SE 4

T R I P T O LOU DON , N E W HE MPSHI R E

DAYS

TASK

S

Completed (days) Remaining (days)

17

WBS

18

PHASE 1

10/21/14

PHASE 2

03/28/15

PHASE 3

04/24/15

PHASE 4

04/31/15Market

Research 70%

3D Model Frame

3D Model Body &

Attenuator

3D Model Differential

FEA

Sponsorship

Campaign

Ordering Parts

Frame

Assembly & Constructio

n

Final Assembly

Driving Test & Troubleshooti

ng

Fine Tuning

Preparation

Travel

Arrival

Body

Sub-frame

Frame

Suspension &

Steering

Risk Matrix

19

Catastrophic

    4 1  

Severe

  9,7   10  

High

 5   3    

Medium

      6,8  

Low

      2  

Definite

Very High

High

Possible

Low

  Risk Element

1 Part lost in mail

2 Defective components

3 Weight of car

4 Safety inspection

5 Error Codes (Controller)

6 Wire shorts

7 Communication between IC and Electrical components

8 Defective IC

9 Slow reimbursement

10 Delayed shipping

Sev

erit

y

Probability

Questions?

20