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2015 Formula Hybrid Electrical System Form (ESF) Note: This ESF differs in many ways from FSAE-electric and other international competitions. However, this form was produced in cooperation with FSAE-electric and Formula Student Germany. Complete the following information: University Name: My College Team Name: My Team Car Number: 000 Main Team Contact for ESF related questions: Name: e-mail: Feel free to add team logo, car picture, and the like. Requirements: 1. This ESF must be accompanied by all the drawings required by Rule S4.4.11. 2. Read the document “How to pass ESF & FMEA” which can be found at: http://www.formulastudent.de/uploads/media/FSE2011_How_to_pass_ESF_FMEA_01.pdf 3. Maximum number of pages for the complete ESF is 100 pages! 4. Links to video or audio data are not permitted. 5. If you did not fill out the tables or if you changed the format of the ESF Template, your ESF will be rejected. 6. Every part and heading of the ESF Template must be filled with content. If the respective part is not relevant for your concept, describe shortly why not. 7. The table of contents must be hyperlinked. 8. The generated PDF must contain hyperlinked bookmarks. 9. Use internal reference links. For example when describing wiring and mentioning a figure in the text then link it to the figure. 10. Do not just copy all of your datasheets in the appendix, e.g. we do not need to know what you have to do to program your motor controller; we do not need the user’s manuals for your microcontrollers, etc. etc. 11. Single pages with figures and/or tables extracted from the complete datasheet that show the important parameters, etc. are usually sufficient, but the source/link to the complete datasheet must be provided. If the datasheet describes more than one type, clearly mark in the datasheet which type you are referring to. 1 Be sure to refer to the most recent revision of the Formula Hybrid rules. (Rev 3 as of February 26, 2015) 2015 Formula Hybrid ESF (Rev. 0) i 12. Datasheets should only be used as a reference. Please include the important data in your text by using tables, figures, etc. 13. If you refer to parts of a data sheet, then you should provide an internal document link from the text to the respective datasheet and another internal document link back from the datasheet to the text section. For example a link in the motor controller section “The datasheet can be found here (clickable)” and a link above the motor controller datasheet in the appendix “The section covering the motor controller can be found here (clickable)”. 14. If you do not understand the reviewer’s feedback, please e-mail and ask. 15. Parts of the ESF which are changed because of reviewer’s feedback must be marked in red. 16. When completed, this file must be saved as a pdf and submitted to: http://formula-hybrid.com/uploads/ Important: Many of the entry fields in this form are populated with sample data. This is provided to help illustrate the information that is required. You must overwrite all of the sample data with your own, or with an explanation of why it does not apply. Forms that are returned with fields still containing sample data may be rejected. 2015 Formula Hybrid ESF (Rev. 0) ii Table of Contents I List of Figures ............................................................................................................ vi II List of Tables ............................................................................................................. vii III List of Abbreviations ............................................................................................... viii Section 1 System Overview ........................................................................................... 1 Section 2 Electrical Systems ......................................................................................... 2 2.1 Shutdown Circuit ............................................................................................................... 2 2.1.1 2.1.2 2.1.3 2.2 IMD ................................................................................................................................... 3 2.2.1 2.2.2 2.3 Description ................................................................................................................. 4 Wiring, connectors, cables ......................................................................................... 4 Pre-Charge circuitry .......................................................................................................... 4 2.8.1 2.8.2 2.9 Description/circuitry .................................................................................................... 4 Wiring/cables/connectors ........................................................................................... 4 Tractive System Measurement Points (TSMP) .................................................................. 4 2.7.1 2.7.2 2.8 Description/circuitry .................................................................................................... 4 Wiring/cables/connectors ........................................................................................... 4 Tractive System Voltage Present light (TSVP) .................................................................. 4 2.6.1 2.6.2 2.7 Description/circuitry .................................................................................................... 3 Wiring/cables/connectors ........................................................................................... 3 Tractive system active light (TSAL) ................................................................................... 4 2.5.1 2.5.2 2.6 Description/circuitry .................................................................................................... 3 Wiring/cables/connectors ........................................................................................... 3 Shutdown System Interlocks ............................................................................................. 3 2.4.1 2.4.2 2.5 Description (type, operation parameters) ................................................................... 3 Wiring/cables/connectors/ .......................................................................................... 3 Reset / Latching for IMD and AMS .................................................................................... 3 2.3.1 2.3.2 2.4 Description/concept .................................................................................................... 2 Wiring / additional circuitry within the shutdown circuit ............................................... 2 Position in car ............................................................................................................ 3 Description ................................................................................................................. 4 Wiring, cables, current calculations, connectors ......................................................... 4 Discharge circuitry............................................................................................................. 5 2.9.1 Description ................................................................................................................. 5 2015 Formula Hybrid ESF (Rev. 0) iii 2.9.2 2.10 HV Disconnect (HVD)........................................................................................................ 6 2.10.1 2.10.2 2.11 Description, type, operating parameters ................................................................... 12 Wiring, cables, current calculations, connectors ....................................................... 12 Motor 2, 3, 4… ................................................................................................................ 12 Section 6 6.1 6.2 Motors ........................................................................................................... 12 Motor 1 ............................................................................................................................ 12 5.1.1 5.1.2 5.2 Description, type, operation parameters ................................................................... 11 Wiring, cables, current calculations, connectors ....................................................... 11 Motor Controller 2 ........................................................................................................... 11 Section 5 5.1 Motor Controller ........................................................................................... 11 Motor Controller 1 ........................................................................................................... 11 4.1.1 4.1.2 4.2 Overview / description / parameters ........................................................................... 7 Cell description .......................................................................................................... 7 Cell configuration ....................................................................................................... 8 Lithium-Ion Pouch Cells ............................................................................................. 8 Cell temperature monitoring ....................................................................................... 8 Accumulator Isolation relays ...................................................................................... 8 Fusing ........................................................................................................................ 9 Battery management system ...................................................................................... 9 Accumulator indicator ................................................................................................. 9 Accumulator wiring, cables, current calculations, connectors ..................................... 9 Charging .................................................................................................................. 10 Accumulator Container/Housing ............................................................................... 10 Accumulator pack 2 ......................................................................................................... 10 Section 4 4.1 Accumulator ................................................................................................... 7 Accumulator pack 1 ........................................................................................................... 7 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.2 Description ................................................................................................................. 6 HV-LV Separation ............................................................................................................. 6 Conduit ............................................................................................................................. 6 Section 3 3.1 Description ................................................................................................................. 6 Wiring, cables, current calculations, connectors ......................................................... 6 Ready-To-Drive-Sound (RTDS) ........................................................................................ 6 2.11.1 2.12 2.13 Wiring, cables, current calculations, connectors ......................................................... 5 Throttle Position Encoder ........................................................................... 13 Description/additional circuitry ......................................................................................... 13 Throttle position encoder plausibility check ..................................................................... 13 2015 Formula Hybrid ESF (Rev. 0) iv 6.3 Wiring .............................................................................................................................. 13 Section 7 7.1 LV part 1 ......................................................................................................................... 14 7.1.1 7.1.2 Section 8 8.1 8.2 8.3 Grounding .................................................................................................... 15 Firewall(s) ..................................................................................................... 16 Firewall 1......................................................................................................................... 16 9.1.1 9.1.2 9.2 Description ............................................................................................................... 14 Wiring, cables, ......................................................................................................... 14 Description of the Grounding ........................................................................................... 15 Carbon Fiber panels ........................................................................................................ 15 Grounding Measurements ............................................................................................... 15 Section 9 9.1 Additional LV-parts ...................................................................................... 14 Description/materials ................................................................................................ 16 Position in car .......................................................................................................... 16 Firewall 2......................................................................................................................... 16 Section 10 Wire Table ................................................................................................. 17 Section 11 Appendix ................................................................................................... 18 2015 Formula Hybrid ESF (Rev. 0) v I List of Figures Must be hyperlinked! 2015 Formula Hybrid vi List of Figures II List of Tables Table 1 General parameters ............................................................................................................ 1 Table 2 List of switches in the shutdown circuit ............................................................................... 2 Table 3 Wiring – Shutdown circuit ................................................................................................... 3 Table 4 Parameters of the IMD........................................................................................................ 3 Table 6 General data of the pre-charge resistor .............................................................................. 5 Table 7 General data of the pre-charge relay .................................................................................. 5 Table 8 General data of the discharge circuit. ................................................................................. 6 Table 9 Main accumulator parameters ............................................................................................ 7 Table 10 Main cell specification ....................................................................................................... 8 Table 11 Basic AIR data .................................................................................................................. 8 Table 12 Basic fuse data ................................................................................................................. 9 Table 14 General charger data ...................................................................................................... 10 Table 15 General motor controller data ......................................................................................... 11 Table 16 General motor data ......................................................................................................... 12 Table 17 Throttle Position encoder data ........................................................................................ 13 Table 18 Wire Table ...................................................................................................................... 17 Must be hyperlinked! 2015 Formula Hybrid vii List of Tables III List of Abbreviations AIR AMS GLV TSV TSAL TSVP TSMP Accumulator Isolation Relay Accumulator Management System Grounded Low-Voltage Tractive System Voltage Tractive System Active Light Tractive System Voltage Present light Tractive System Measurement Point (Add more as needed) 2015 Formula Hybrid ESF viii List of Abbreviations Section 1 System Overview Person primarily responsible for this section: Name: e-mail: Short description of the system’s design Include all drawings required by Formula Hybrid rule S4.4.1 Include a block diagram showing all parts associated with the electrical systems and the tractive-system. (No detailed wiring) Additionally fill out the following table, replacing the values with your specifications: Item Data Max. Tractive System voltage(TSV) 150 VDC (typically this is during charging): Nominal Tractive System voltage: 120 VDC Control System voltage (GLV): 12 VDC Accumulator configuration: 3 parallel strings, each consisting of 200 cells in series Total Accumulator capacity: 200 Ah Number of motors: Total 4, one per wheel Table 1 General parameters 2015 Formula Hybrid ESF 1 System Overview Section 2 Electrical Systems Person primarily responsible for this section: Name: e-mail: 2.1 Shutdown Circuit 2.1.1 Description/concept Describe your shutdown circuit, including the master switches, shut down buttons, brake overtravel switch, etc. Additionally fill out the following table replacing the values with your specification and append additional switches from your setup: Part Function Main Switch (for control and tractive-system; Normally open CSMS, TSMS) Brake over-travel switch (BOTS) Normally closed Shutdown buttons (BRB) Normally closed Insulation Monitoring Device (IMD) Normally open Battery Management System (AMS) Normally open Interlocks Closed when circuits are connected Table 2 List of switches in the shutdown circuit 2.1.2 Wiring / additional circuitry within the shutdown circuit Describe wiring and additional circuitry, show extra schematics for example if additional transistors etc. are used, also describe the function of additional circuitry and make good use of figures. Additionally fill out and add information to the following table: Total Number of AIRs: 4 Coil holding current per AIR: 0.5 A Current drawn by other components wired in 2A parallel with the AIRs. 2015 Formula Hybrid ESF 2 Electrical Systems Total current: 7A Table 3 Wiring – Shutdown circuit 2.1.3 Position in car Provide CAD-renderings showing the relevant parts. Mark the parts in the renderings, if necessary. 2.2 IMD 2.2.1 Description (type, operation parameters) Describe the IMD used and use a table for the common operation parameters, like supply voltage, temperature, etc. Also describe how the IMD indicator light is wired, etc. Additionally fill out the following table replacing the values with your specification: 300 kΩ (500 Ω/Volt) Set response value: Table 4 Parameters of the IMD 2.2.2 Wiring/cables/connectors/ Describe IMD wiring, show schematics, describe connectors and cables used and show useful data regarding the wiring. 2.3 Reset / Latching for IMD and AMS 2.3.1 Description/circuitry Describe the functioning and circuitry of the latching/reset system for a tripped IMD or AMS. 2.3.2 Wiring/cables/connectors Describe wiring, show schematics, describe connectors and cables used and show useful data regarding the wiring. 2.4 Shutdown System Interlocks 2.4.1 Description/circuitry Describe the functioning and circuitry of the Shutdown System Interlocks. 2.4.2 Wiring/cables/connectors Describe wiring, show schematics, describe connectors and cables used and show useful data regarding the wiring. 2015 Formula Hybrid ESF 3 Electrical Systems 2.5 Tractive system active light (TSAL) 2.5.1 Description/circuitry Describe the tractive system active light operation and required circuitry. 2.5.2 Wiring/cables/connectors Describe wiring, show schematics, describe connectors and cables used and show useful data regarding the wiring. 2.6 Tractive System Voltage Present light (TSVP) 2.6.1 Description/circuitry Describe how the TSVP indicator functions. Include indicating voltage range and circuitry including method of galvanic isolation. 2.6.2 Wiring/cables/connectors Describe wiring, show schematics, describe connectors and cables used and show useful data regarding the wiring. 2.7 Tractive System Measurement Points (TSMP) 2.7.1 Description Describe the TSMP housing used and how it can be accessed, etc. 2.7.2 Wiring, connectors, cables Describe wiring, show schematics, and describe connectors and cables used and show useful data regarding the wiring. 2.8 Pre-Charge circuitry 2.8.1 Description Describe your design for the pre-charge circuitry. 2.8.2 Wiring, cables, current calculations, connectors Describe wiring, show schematics, describe connectors and cables used and show useful data regarding the wiring. Include a plot of “Percentage of Maximum Voltage” vs. time Include a plot of Current vs. time Additionally fill out the tables: 2015 Formula Hybrid ESF 4 Electrical Systems Resistor Type: ABC Resistor Resistance: 680 Ω Continuous power rating: 60 W Overload power rating: 200 W for 30 sec Voltage rating: 1500 V Table 5 General data of the pre-charge resistor Relay Type: DEF Relay Contact arrangement: SPDT Continuous DC contact current: 25 A Contact voltage rating 2000 VDC Table 6 General data of the pre-charge relay 2.9 Discharge circuitry 2.9.1 Description Describe your concept of the discharge circuitry. 2.9.2 Wiring, cables, current calculations, connectors Describe wiring, show schematics, describe connectors and cables used and show useful data regarding the wiring. Include a plot of “Voltage” vs. time Include a plot of “Discharge current” vs. time Additionally fill out the table: Resistor Type: ABC Resistor Resistance: 680 Ω Continuous power rating: 350 W Overload power rating: 600 W for 20 sec Voltage rating: 1500 V 2015 Formula Hybrid ESF 5 Electrical Systems Maximum expected current: 0.7 A Average current: 0.3 A Table 7 General data of the discharge circuit. 2.10 HV Disconnect (HVD) 2.10.1 Description Describe your design for the HVD and how it is operated. 2.10.2 Wiring, cables, current calculations, connectors Describe wiring, show schematics, describe connectors and cables and show useful data regarding the wiring. 2.11 Ready-To-Drive-Sound (RTDS) 2.11.1 Description Describe your design for the RTDS activation, 2.12 HV-LV Separation Document separation of GLV and TSV wiring, Include photographs of wire spacing and describe how the spacings are maintained. Include information on your insulating materials and describe how they are mounted. Include photographs of team-built PCBs showing separation between TSV and GLV conductors 2.13 Conduit Describe conduit used for tractive system wiring outside of electrical enclosures, and how the conduit is anchored. 2015 Formula Hybrid ESF 6 Electrical Systems Section 3 Accumulator Person primarily responsible for this section: Name: e-mail: 3.1 Accumulator pack 1 3.1.1 Overview / description / parameters Describe design of accumulator pack, provide table with main parameters like number of cells, cell stacks separated by maintenance plugs, cell configuration, resulting voltages (minimum, maximum, nominal) currents, capacity etc. Fill out the following table: Maximum Voltage (during charging): 250 VDC Nominal Voltage: 200 VDC Total number of cells: 200 Total Capacity: 4.2 kWh Maximum Segment Capacity 5MJ Table 8 Main accumulator parameters 3.1.2 Cell description Describe the cell type used and the chemistry, provide table with main parameters. Fill out the following table: Cell Manufacturer and Type Cook-em XYZ Cell nominal capacity: 5.4 Ah Maximum Voltage: 4.2 V Nominal Voltage: 3.7 V Minimum Voltage: 2.8 V Maximum Cell Temperature (discharging) 65°C 2015 Formula Hybrid ESF 7 Accumulator Maximum Cell Temperature (charging) 55°C Cell chemistry: LiFePO4 Table 9 Main cell specification 3.1.3 Cell configuration Describe cell configuration, show schematics, cover additional parts like internal cell fuses etc. 3.1.4 Lithium-Ion Pouch Cells If your team has designed your accumulator system using individual Lithium-Ion pouch cells, include drawings, photographs and calculations demonstrating compliance with all sections of rule EV3.8. If your system has been issued a variance to EV3.8 by the Formula Hybrid rules committee, include the required documentation from the cell manufacturers. 3.1.5 Cell temperature monitoring Describe how the temperature of the cells is monitored, where the temperature sensors are placed, how many cells are monitored, etc. Show schematics, and a map of the physical layout. Include additional parts, etc. 3.1.6 Accumulator Isolation Relays (AIR) Describe the AIRs used and their main operation parameters. Use tables, etc. Additionally fill out the following table: Relay Type: ABC Relay Contact arraignment: SPST NO Continuous DC current rating: 100 A Overload DC current rating: 200 A for 10 sec Maximum operation voltage: 200 VDC Nominal coil voltage: 24 VDC Normal Load switching: Make and break up to 300 A Table 10 Basic AIR data 2015 Formula Hybrid ESF 8 Accumulator 3.1.7 Fusing Describe the fuses used and their main operation parameters use tables, etc. Additionally fill out the following table: Fuse type: MNO Fuse Continuous current rating: 150 A Max. operating voltage (specify AC or DC) 500 VDC Type of fuse: Fast Acting Interrupting Current (max. current at which the fuse can break the flow of current) 10000 A Table 11 Basic fuse data Create a table with components and wires protected by the fuse(s) and the continuous current rating of each component. Ensure that the rating of all of the components is greater than the rating of the fuse (such that none of the other components becomes the fuse). 3.1.8 Accumulator Management System (AMS) Describe the AMS used including at least the following: Sense wiring protection (fusing / fusible link wire used) At what upper and lower voltage does the AMS react at and how does it react? At what cell temperature does the AMS react at and how does it react? Include tables of operation parameters Describe how many cells are monitored by each AMS board, the configuration of the cells, the configuration of the boards and how AMS communications wiring is protected/isolated Describe how the AMS opens the AIRs if an error is detected Where in the AMS system is the isolation between TS and GLV? 3.1.9 Accumulator indicator Describe the indicator, including indicating voltage range. Show wiring, provide tables with operation etc. 3.1.10 Accumulator wiring, cables, current calculations, connectors Describe the internal wiring, show schematics, provide calculations for currents and voltages and show data regarding the cables and connectors used. Discuss maximum expected current, DC and AC how long will this be provided? Compare the maximum values to nominal currents Describe your maintenance plugs, provide pictures Reference the wires/cables to the list in Table 16 (Wire Table) 2015 Formula Hybrid ESF 9 Accumulator 3.1.11 Charging Describe how the accumulator will be charged. How will the charger be connected? How will the accumulator be supervised during charging? Show schematics, , etc., if needed. Additionally fill out the table: Charger Manufacturer and model: ABC Charger Maximum charging power: 3 kW Certification UL Maximum charging voltage: 250 V Maximum charging current: 20 A Interface with accumulator CAN-Bus, proprietary, serial. Input voltage: 230 VAC single phase Input current: 16 A Table 12 General charger data 3.1.12 Accumulator Container/Housing Describe the design of the accumulator container. Include the housing material specifications and construction methods. Include data sheets for insulating materials. Include information documenting compliance with UL94-V0, FAR25 or equivalent. Show how the cells are mounted, use CAD-Renderings, and include calculations showing compliance with rules EV3.4.2 and EV3.4.6 If the housing is made of conductive material, include information on how the poles of the accumulators are insulated and/or separated from the housing, and describe where and how the container is grounded to the chassis. Include additional photographs if required to comply with rule EV3.2.3 3.2 Accumulator pack 2 … If identical parts are used, just refer back to the corresponding sections, don’t copy and paste. 2015 Formula Hybrid ESF 10 Accumulator Section 4 Motor Controller Person primarily responsible for this section: Name: e-mail: 4.1 Motor Controller 1 4.1.1 Description, type, operation parameters Describe important functions; provide table with main parameters like resulting voltages>minimum, maximum, nominal, currents etc. Fill out the following table: Motor controller type: ABC Controller Maximum Input voltage: 300 VDC Output voltage: 250 VAC Isolation voltage between GLV and TS connections 2500 V Table 13 General motor controller data 4.1.2 Wiring, cables, current calculations, connectors Describe the wiring, show schematics, provide calculations for currents and voltages and show data regarding the cables and connectors used. 4.2 Motor Controller 2 … If identical parts are used, just refer to the corresponding sections, don’t copy and paste. . 2015 Formula Hybrid ESF 11 Motor Controller Section 5 Motors Person primarily responsible for this section: Name: e-mail: 5.1 Motor 1 5.1.1 Description, type, operating parameters Describe the motor used, provide table with main parameters like resulting voltages->minimum, maximum, nominal, currents, resulting motor power, use figures to show important characteristics. Additionally fill out table: Manufacturer and Model: ABC Motor Motor type Asynchronous, permanently excited Table 14 General motor data 5.1.2 Wiring, cables, current calculations, connectors Describe the wiring, show schematics, provide calculations for currents and voltages and show data regarding the cables and connectors used. 5.2 Motor 2, 3, 4… … If identical parts are used, just refer to the corresponding sections, don’t copy and paste. 2015 Formula Hybrid ESF 12 Motors Section 6 Throttle Position Encoder Person primarily responsible for this section: Name: e-mail: 6.1 Description/additional circuitry Describe the type of the throttle position encoder(s) used, provide tables with main operation parameters, and describe additional circuitry used to check or manipulate the signal going to the motor controller. Describe how the system reacts if an implausibility or error (e.g. short circuit or open circuit or equivalent) is detected. Encoder manufacturer and model: ABC Encoder Encoder principle: Potentiometer Output: 0-5 V Table 15 Throttle Position encoder data 6.2 Throttle position encoder plausibility check Describe circuitry used to check or manipulate the signal going to the motor controller. Describe how failures (e.g. Implausibility, short circuit, open circuit etc.) are detected and how the system reacts if an implausibility or error is detected. 6.3 Wiring Describe the wiring, show schematics, show data regarding the cables and connectors used. 2015 Formula Hybrid ESF 13 Throttle Position Encoder Section 7 Additional LV-parts Person primarily responsible for this section: Name: e-mail: 7.1 LV part 1 Describe those parts here which can influence the tractive system, for example a controlling unit that measures wheel speeds and steering angle and calculates a target torque for each motor or a DC/DC-Converter providing power for the LV-system from the HV-system, etc. 7.1.1 Description Describe the parts used and their circuitry, and provide main operation parameters, use tables or figures, etc. 7.1.2 Wiring, cables, Describe the wiring, show schematics, etc. 2015 Formula Hybrid ESF 14 Additional LV-parts Section 8 Grounding Person primarily responsible for this section: Name: e-mail: 8.1 Description of the Grounding Describe how you intend to keep the resistances between components below the required levels as defined in EV4.3. 8.2 Carbon Fiber panels If you have incorporated carbon fiber panels describe your fabrication methods to ensure point to point resistances that comply with EV4.3 8.3 Grounding Measurements Describe how resistance measurements were performed to check compliance with EV4.3 2015 Formula Hybrid ESF 15 Grounding Section 9 Firewall(s) Person primarily responsible for this section: Name: e-mail: 9.1 Firewall 1 9.1.1 Description/materials Describe the concept, layer structure and the materials used for the firewalls. Show how the low resistance connection to chassis ground is achieved. 9.1.2 Position in car Provide CAD-rendering or photographs showing the location of the firewall 9.2 Firewall 2 2015 Formula Hybrid ESF 16 Section 10 Wire Table List all wires used. (Wires in the GLV system that are protected by a fuse of 1 A or less may be omitted.) Mfg. Part Number Size AWG/mm2 (Circle one) Insulation Type Voltage Rating Temp. Rating Where Used (Describe or refer to section numbers above) Table 16 Wire Table 2015 Formula Hybrid ESF 17 Wire Table Section 11 Appendix Number appendices according to the relevant chapter. i.e. A datasheet for motor controller one should be numbered: 4.1.n 2015 Formula Hybrid ESF 18 Appendix