csu formula sae - walter scott, jr. college of...
TRANSCRIPT
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CSU Formula SAE
Ram Racing 2016
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Background/History
Colligate Electric Racecar design competition
Ram Racing was established in 1996
2nd iteration of Formula SAE Electric
Competition
Static events
Design Judging, Cost Report, Project Presentation, Technical Inspection
Dynamic events
Acceleration, Skid pad, Autocross, and Endurance
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Problem Statement
Design all systems independently
May have professional advice but all designs must be Student drafted
Acquire data for future teams
Battery temperature characteristics, discharge time, and charge time
Forces acting on the car and driver
Optimum gears ratios for each event
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Objectives and Constraints
All designs are acceptable according to Formula SAE requirements 2015-2016
http://students.sae.org/cds/formulaseries/rules/2015-16_fsae_rules.pdf
Pass technical inspection
System should lend itself to evolution design
Remain within budget
Fundraising, Donations, Sponsorships
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Design Summary
Design Control Circuits
Reliable, Simple, and easily maintained
Years after wont have to worry about these circuits
Design Battery
300VDC, Lithium Cobalt Oxide
10Ah at 15C discharge
Implement Real-time Microcontroller
CAN communication
Data allocation
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Mechanical Design Summery
Spaceframe chassis
EMRAX 207 motor connected to differential via chain
Interchangeable rear sprockets to vary gear ratios
Batteries cooled by forced airflow from sidepods and exhaust fans (if needed)
Key Improvements
Improved rear suspension
New battery case
New motor mount
Redesigned sidepods
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Design Decisions
Safety and Control Circuits
12VDC system, in series switches and relays controlled by parallel systems (IMD, BMS, etc…)
Ladder logic
Robust, reliable, simple, and proven
12 VDC coil, 10 A contact, small (15mm cubes), automotive grade
Real time Microcontroller
Atmel 32-bit AVR UC3 AT32UC3C0512 144 pin
5VDC-12VDC power input
Dual CAN Communications, Local Network Interfaces
One 4-channel PWM controller, one 16-channel ADC, two 12-bit DAC, 123 GPIO pins
Atmel studio IDE, C programming
http://www.rlocman.ru/i/Image/2011/03/16/AT32UC3C-EK.JPG
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Design Decisions
CAN Protocols Encoder protocols
Accelerator 10% Accuracy, voted output, pass to motor control
Brake plausibility Accelerator is not outputting while brakes are applied
Data logging Speeds
G-forces
Battery states
Motor states
Pedal positions
https://upload.wikimedia.org/wikipedia/commons/thumb/5/5e/CAN-Bus-frame_in_base_format_without_stuffbits.svg/709px-CAN-Bus-frame_in_base_format_without_stuffbits.svg.png
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Design Decisions
High voltage Controller
Rinehart PM-100DX
Used From 2014-’15
Future Evolutions May Not Use
100-360VDC IN, 300VAC OUT, 250ADC Continuous, 350ADC P-P
Not a Choice of the Present Team (Cost Consideration)
Motor
EMRAX 207 (208)
300VAC, 140 Nm (103 ft-lb), 160ARMS, Weight 20.7 lbs
Chosen for Cost, Size, Weight, Standardization
http://www.rinehartmotion.com/standard.html
http://estacars.com/wp-content/uploads/2014/11/emrax_228_oct_04.jpg
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Design Decisions
Battery cells Melasta SLPB9664155
3.7 VDC nominal, 10Ah
15C (150A) continuous discharge rate, 20C (200A) max.
72 series configuration for 300VDC
Battery Management System Orion controller
108 cell voltage sensors
Cell voltage balancing
Dual CAN Communications
Thermistor Expansion Module 80 temperature sensors
CAN bus communication
http://melastabattery.sell.everychina.com/
http://evolveelectrics.com/images/products/secondary/orion%20bms-1.png
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Budget• Predicted Initial Budget• Simplified Budget
• Total Raised: $7,500• Account balance: $1,300• Need to raise: $6,500
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At-risk Items and Mitigation Plan
Most At-Risk Components (Electrical)
Motor (Heating/Power), Battery(Heating), MSC (Component Failure)
Formula = (Rank/40)*R.O.O.* D
1, .6, .315 (Weighted Risk)
High Risk Due to High Occurrence
Not Indicative of Catastrophic Fault but working Limitations
Performance Impacted Mostly
ESA and FMEA have lead to realization of possible subsystem/battery failure
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Validation (Design Evaluation, Prototype Evaluation)
Electrical Validation Benchtop testing
Test-to-Validate Approach
Test integrated vehicle circuit before installation
Functional Testing in Vehicle
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Work-plan
Purchase the Orion Battery Management System
Bench-test circuits
Rolling chassis by 1/1
Assemble wiring harness on chassis
Battery complete by 2/1
Completed car for testing by 3/14
Test drive and collect data for future improvements
Complete tested car by E-days
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Questions?
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Logic Schematic and Diagram
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Electrical FMEA
Mechanical FMEA