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Project Overview • Primary Goal –Design and build a working electric vehicle • Accelerated design cycle –Modification of previous designs Project Overview • 1st electric vehicle for Ram Racing – Create the platform for future years of Ram Racing to iterate on • Integration of electrical and mechanical engineers – Adds expertise of electrical systems which will allow addition of more complex systems like: • Regenerative braking • The use of high voltage systems Background • FSAE is the largest international competition involving engineering and automotive design • FSAE competition is comprised of 7 scored events Static Events include: Dynamic Events include: • Cost report • Design Judging • Presentation • • • • Acceleration Skidpad Autocross Endurance Background • Progression of cars Photo courtesy: Ram Racing Photo courtesy: Ram Racing 2013 CSU FSAE RR13 Photo courtesy: Ram Racing 2007 Ram Racing FSAE RR07 2011 CSU FSAE RR11 Photo courtesy: Ram Racing 2012 CSU FSAE RR12 Design Constraints Constraint Method of Measurement Limits Driving Factor Wheelbase Length in inches: from the centerline of front to rear tires >60in. FSAE Rule T2.3 Track Width Width in inches: from the centerline of side to side tires >75% front track to rear track FSAE Rule T2.4 Power Output Kilowatts: Drawn from high voltage battery <80kW FSAE Rule EV2.2 High Voltage Battery Pack Roll Plane Volts: overall voltage from any two points 300 V DC Max FSAE Rule EV1.1.2 Measured by tangent line between Main and Front Roll Hoops 2in, min clearance to driver helmet FSAE Rule T3.10.3 Suspension Inches of bounce and jounce 1in in both directions, min FSAE Rule T6.1 Battery Pack Pack must withstand external loading FSAE Rule AF4.8.2 Safety Determined by Electrical safety officers Determined by Technical Inspectors at FSAE For Car safety to prevent Serious injury or death 20g long. 20g lat 20g vert 0 FSAE Rules/ Team Driven Design Objectives Objective Priority Rating 5-Highest 1-Lowest Method of Measurement (Theoretical) Method of Measurement (Actual) Objective Direction Target Battery Pack Capacity 4 Hand calculations, lap simulations Endurance simulation at test site increase Battery Pack Mass 3 Spec Sheet with hand calculations Scale decrease Lap times: Autocross 1 Lap simulations Vehicle testing details TBD decrease +10% of endurance distance <140lbs Compared to other FSAE EV teams batteries < 1min 20sec from the Michigan 2013 track layout Endurance Completion 5 Lap simulations 22km endurance test increase Light Weight 1 Hand calculations Scale decrease +10% of endurance distance <700lbs w/out driver Design Summary • Due to the complications of integrating an electric drivetrain, the team has decided that getting the car done early is the biggest concern – Getting the car done earlier will allow for more testing time – The electrical system will be tuned primarily based off of driver feel Final Concept Image: Ram Racing • Function Final Concept – Main structure – Protects driver – Transmits loads • Feasibility – Modeling in CAD – Installed torsional stiffness test • DFX Image: Ram Racing – Manufacture – Packaging – Safety • Details – FEA stiffness: 998 lb-ft/deg – 17% correction factor (overestimate): 828 lb-ft/deg – Mass (est.): 90.7 lbs • Tubes: 83.7 lbs • Filler Rod: 2 lbs • Tabs: 5lbs Image: Ram Racing Units (Deg) Final Concept (FMEA) Potential Failure Mode Potential Effect(s) of Failure S E V Potential Cause(s)/Mechanism(s) of Failure O C C Current Design Controls D E T R P N Recommend Actions 1 Chassis Primary Structure Weld Failure Disabled Vehicle, Driver Injury, Loss of Control 10 Bad Weld Quality 6 Visual Inspection 4 240 100% Inspect All Chassis Welds 2 Chassis Secondary Structure Motor Support Failure Driver Injury, Damage to other systems 10 Bad Weld Quality, Incorrect Geometry 6 Visual Inspection 4 240 100% Inspect All Chassis Welds Tube Failure Loss of Stiffness, Damage to Other Systems 6 Undersize Wall Thickness in Tube 4 Manufacturer Certifications, Visual Inspection 7 168 100% Inpsect all Chassis Tubes Before Welding Tab Failure Damage to Other Systems, Loss of Control 7 Bad Weld Quality, Incorrect Geometry 6 Visual Inspection 4 168 100% Inspect All Chassis Welds 2 Visual Inspection, Manufacturer Certifications, Additional Battery Containment 5 100 100% Inspect All Chassis Welds # Item and Function 3 4 5 Chassis Primary Structure Chassis Secondary Structure Chassis Tertiary Structure Battery Support Failure Driver Injury, Diasbled Vehicle 10 Bad Weld Quality, Improper Support Final Concept (Budget) Chassis Budget Cost Source Donation? Chassis Tubes and Profiling $2,900 Cartesian VR3 No Remachining Fixture Plates $500 Woodward Yes Fixturing Stock $400 McMaster No Fasteners $100 Suburban Bolt No Welding Filler $100 Arc-Zone No Tab Stock $100 Online Metals No Total: $6,600 Cost After Donations: $3,600 Final Concept • Function – Keep tires in contact with pavement – Keep tires in condition for optimum accelerations • • – Manufacture – Reliability – Performance Feasibility – Modeling in CAD/FEA – Optimum Kinematics Analysis Image: Ram Racing Creo Solid Model DFX • Accelerated Design Cycle – Adaptation of design features from last 3 years Image: Ram Racing Optimum K Kinematics Model Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure S E V Potential Cause(s)/Mechanism(s) of Failure O C C Current Design Controls D E T R P N Recommend Actions 1 Outer Suspension Ends Stress Concentration in Bending Damage to other systems, Loss of control 10 Manufacturing Error 1 Visual Inspection 2 20 Inspection by recipiant 2 Uprights Stress Concentration in Bending Damage to other systems, Loss of control 8 Manufacturing Error 2 Visual Inspection 7 112 Inspection by recipiant Panel Delamination Damage to other systems, Loss of control 8 Manufacturing Error 1 Visual Inspection 6 48 None 10 Incorrect Geometry 1 Pre-testing Visual Inspection 5 50 Pre and PostTesting Inspection 10 Improper Bonding Procedure, Insifficient Bonding Area 4 Visual Inspection 7 280 Tighter Control of layup process 3 Rockers 4 Carbon Tubes Buckling/Bending Damage to other systems, Loss of control 5 Pull/Push Rod Tubes & Aarm Tubes Adhesive Failure in Shear Damage to other systems, Loss of control Final Concept (Budget) Suspension Budget Brake Discs Brake Pads Brake Calipers Bearings (spindle) Bearings (rod ends) Carbon tubes Cost $200 $75 $150 $150 $400 $200 Source In house In house In house SKF Aurora In house Donation? No No No No No No Stock Tires Dampers $200 $170 x 4 $1,720 Metal Distributor Hoosier In house No No No Springs $250 In house No Total: $9,025 Cost After Donations: $1,430 Final Concept • Function: – Transfers Torque to rear wheels – Accelerates car • Feasability: – Modeling in CAD – FEA analysis • DFX: – Efficiency – Reliability – Packaging Image: Ram Racing • Details: – – – – Torque: 210 Nm Chain pull 6700N 4:1 gear ratio Up to 80% Torque bias to one wheel: 624 NM Image: Ram Racing Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure S E V Potential Cause(s)/Mechanism(s) of Failure O C C Current Design Controls D E T R P N Recommend Actions 1 Half Shaft Torsional Shear Disabled Vehicle 8 Poor design, Machining Imperfections 4 FEA, Previous cars' Performance 9 288 FEA, Stronger Spares 2 Chain Elongation, Break Disabled Vehicle 8 Improper Maintenance/tensioning 2 Professional Help, Math 6 96 Spare Sprockets, Spare Chain 3 Differential Mounts Fatigue, Bending, Shear Disabled Vehicle 8 Poor design, Machining Imperfections 3 FEA 7 168 Spare Mounts, Material Evaluation 4 Motor Mounts Fatigue, Shear Disabled Vehicle, Driver Injury 10 Poor design, Machining Imperfections 3 FEA 7 210 Spare Mounts, Material Evaluation Oil Starvation Disabled vehicle, Motor Failure 2 Specialty Pumps, Professional Help 32 Monitor Pumps Closely, Safety Shutoff 5 Motor Cooling 8 Improper Flow Rate, Pump Failure 2 Final Concept (Budget) Drivetrain Budget Cost Source Donation? Motor $9,000.00 Remy, Inc Yes Differential Inboard Tripod Carriers $1,000.00 HPF Performance No $370.00 RCV No Tripods $140.00 RCV No Cooling Pumps $1,000 Meziere Yes Half Shaft Stock $300.00 Metal Distributors No Aluminum Mount Stock $200.00 Metal Distributors No Chain $60.00 Ebay No Sprockets $120.00 Sprocket Specialists No Total $12,190.00 Cost After Donations $2,190.00 Final Concept • Function -Drivetrain power • Feasibility – Modeling in CAD – Circuit schematics • DFX Image: Ram Racing – Packaging – Safety • Details – 72S2P battery back – 300Vdc max, 266Vdc nom. – Capable of 375Adc continuous – Safe under failure – Weight: Est 104 lbs – 7.5kW hrs Image: Ram Racing Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure S E V Potential Cause(s)/Mechanism(s) of Failure O C C Current Design Controls D E T R P N Recommend Actions 1 Battery Cell for energy storage Single cell failure Higher chance of failure in parallel cell counterpart 2 Neglect, exceeding rated specifications, poor cell construction 3 Battery management system monitoring 2 12 Handle with care, operate within specifications 2 Battery Management System for monitoring cells Voltage, Current, or Temperature sensing failure of 25% of cells Fire, cell abuse, Estimation of sensed parameters (done automatically by BMS) 10 Exceed lifetime, bad soldering, extreme vibration 2 Visual inspection, isolate cell boards from vibration along with cells 7 140 Inspect all solder work 3 High voltage controller for controlling the motor Control system failure Vehicle shutdown 8 Misuse/neglect 1 Care is to be taken with the controller 2 16 Handle with care, operate within specifications 4 Battery Cell for energy storage Two parallel cell failure Sudden loss of all power 8 Neglect, exceeding rated specifications, poor cell construction 2 Battery management system monitoring 2 32 Handle with care, operate within specifications 5 High voltage controller for controlling the motor HV cable disconnection Driver injury, total loss of power, fire 10 Improper torque for connection 2 Check all torque specifications 120 Check torque applied to connection point 6 Final Concept •Function – – – Technical Inspection Safety shutdown circuitry Power various sensors •Feasibility – Circuit schematics simulations – Test and retest circuits for faults •DFX – – Build/wire circuits Safety Image: Ram Racing Final Concept (FMEA) # Item and Function Potential Failure Mode Potential Effect(s) of Failure S E V Potential Cause(s)/Mechanism(s) of Failure O C C Current Design Controls D E T R P N Recommend Actions 1 Torque Encoder Accelerometer Sensor Failure Loss of Control 6 Sensor mounting error, loose wire/connections 4 Visual Inspection, Sensor fault test 3 90 Tighten connections, test with multimeter 2 Brake Encoder Brake Sensor Failure Loss of Control, 6 Sensor mounting error, loose wire/connections 4 Visual Inspection, Sensor fault test 3 90 Tighten connections, test with multimeter 3 Arduino Mega Microcontrolle r for low voltage controls Programming/ Power Failure Loss of Control, Signal error to motor controller 5 Visual Inspection, Inspection of programming code, 144 Tighten connections, test with multimeter, review program for errors 4 Sensata Crash Sensor Sensor Failure Driver Injury, due to improper shut down of tractive system 5 Visual Inspection, Sensor fault test 150 Shake the sensor to see if it opens the circuit 5 Bender Isometer Insulation Monitoring Device Tractive and Grounded low voltage system desegregation/ Sensor fault 6 Visual Inspection, Manufacturer Certifications, Sensor fault test 360 Check with multimeter to see if tractive and grounded low voltage systems are isolated Driver Injury, Potential shock 6 Loose connections, lose of power 10 Impact upon crash does not activate sensor 10 No seperation between tractive and grounded low voltage systems 4 3 6 Final Concept (Budget) Controls Budget Cost Source Donation? HV Cables $400 Yes HV Controller $5,250 Champlain Cable Rinehart Motion Systems Batteries $12,500 Part Sponser Bus Bar Batter Management System Torque/Brake Encoder Arduino Mega 2560n M3 $250 Melasta Storm Power Components $1,624 Elithion No $229 x 3 XT Racing No $28 Ardunio Yes Misc. Components $500 Various Mix Total $21,239 Cost After Donations $20,311 No No Validation Plan •Majority of parts for final assembly or testing have been ordered or are currently on hand •Assembly ongoing through winter break Image: Ram Racing Image: Ram Racing Validation Plan • Evaluation – CAD – Hand Calculations – Modified Ram Racing Designs – Road Testing – Simulation • – Image: Ram Racing Safety Circuit Specific Component Testing • Impact Attenuator • Battery Cell Image: Ram Racing Term II Work-Plan • Main Goals – Finish manufacturing and assembly of vehicle – Begin testing and data collection of vehicle • Secondary Goals and Contingency – Refine and fix any design flaws – Rework on systems that fail, break, or do not work as intended • [1] SAE International. (2014, September 1). 2015 Formula SAE® Rules [Online]. Available:http://www.fsaeonline.com/content/201516%20FSAE%20Rules%20revision%20in%20progress%20kz%208 3114.pdf