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FSAE-Electric 2016 Problem Statement Develop a formula SAE electric racecar capable of passing technical inspection and obtain data for future generations of the EV car design. Overall Vehicle Goals • Incorporate an all-electric drivetrain into a competitive race design. • Redesign the EV1 electrical systems for increased reliability and serviceability. • Gather data to build profile for battery characteristics • Systems design approach that emphasizes safety. Concept Selection • Formula SAE rules and guidelines used to drive product requirements. • Functional requirements derived from competition scoring. • Concepts evaluated using decision matrices. Component Goals Electrical Suspension • Design safety circuits and reliable battery which meet specs given in rules and passes Technical inspection • Integrate a Automotive grade Microcontroller • Integrate motor controller and motor with battery and Microcontroller to pass technical inspection • Obtain battery performance data for next iteration • Redesign rockers and Antiroll • Improve ride height Cooling • Design an accumulator case that cools battery cells and can withstand impact forces • Design sidepods that effectively increase air flow to the battery cells Drivetrain • Mount the Emrax 208 motor • Utilize Ford Quaife Differential • Chain Drive with interchangeable sprockets for varied gear ratio Low Voltage Controls • Driver Controls – Brake sensor – Torque Encoders – Voted Encoder System (MCU Driven) – Driver Profiles • Safety – Shutdown Circuitry • • • • • Insulation Monitoring Device Crash Sensor E-Stop Buttons Brake plausibility device Brake-Over-Travel Tractive System • Battery Pack – Melasta Cell 10Ah • • • • • Max Voltage, 300 VDC Nominal Voltage, 266 VDC LiCoO2 cell chemistry 72 Series Configuration Motor Controller – RMS PM100DX • • • • • • Max power, 100 kW Max output current, 300 ARMS Pre-charge/ Discharge Circuit Rpm limiting Temp, Current and Voltage monitoring Full motor profile • Suspension Designed to Accommodate Hoosier 20.5x7.0 - 13 FSAE Race Tires – – • Carbon Fiber Unequal Length Double A-Arm – – – • Kinematics designed in Optimum K based on characteristics derived from tire data Roll and pitch rates designed to accommodate mass of electric drivetrain Unsprung mass: 27kg per corner Mathematical Modeling – – • Low degree of camber change through suspension travel. Adjustable Ackermann: +2 to -2 deg at average steer angle Iterative design process sought simultaneous compromises between many parameters Load transfer, steering, tire, and damper properties tracked through various cornering conditions RockShox Coil-Over Spring/Dampers – Tuned to damper force/speed curves obtained from dyno testing – Vehicle static ride height: 1” – Vehicle natural frequency: 3.1 Hz • CNC Machined Rockers – – Two piece rockers for easy manufacture and integrated spacers 1.1:1 and 1.4:1 motion ratio in front and rear respectively allows for full range of travel damper travel Cooling • Accumulator Case – Steel Case • Resists an impact load of 20 G’s – 72 battery cells – Large air vents to keep batteries below 60 C (140 F) • Aerodynamics – Nosecone – Aero fabric • Diverts air back into the sidepod – Sidepod • Airflow to the battery case • Fiberglass • Water Cooling – Radiator – Water Pump • Directs water to the Emrax 208 motor and HV Controller Drivetrain • Electric Motor – Emrax 208 Motor • Max power = 80 kW @ 300V • 140 Nm (103 ft-lb) peak torque • Chain Drive to Quaife Limited Slip Differential – Mid-engine rear wheel drive – 1 to 5 final drive ratio • Max Torque at wheels = 700 Nm (515 ft-lb) • Custom aluminum mount – Added support bearing – Built in chain adjustment Sponsors: G&N Construction Ault, Co. Special Thanks To: Dr. Mitchell Stansloski Dr. Troy Holland Dr. Donald Radford JR Garza Stephanie Rosso Bryan and Virginia Christensen The Houser family