Powertrain for
RIT EV Team TTZero Race Bike
R12900
Sean Harriman
5/20/2012
Updated Mission Statement
 To
design, bench test and implement an
electric drive system on a rolling chassis
provided by the Electric Vehicle Team
that operates at race speeds and has a
just enough range to finish the TT-Zero
around the Isle of Man Road Course while
maximizing the power of the electric
motor to the road through the use of a
traction controller.
Place of Innovation
 “the
Isle of Man TT, the toughest
motorcycle race in the world. The
technology at work is so advanced, so
unprecedented, that we may be looking
not just at the future of motorcycles, but
of all electric vehicles." From the article
"Inside Story Motoczysz E1PC Worlds Most
Advanced Electric Motorcycle"
 Electric Motorcycle Racing 3rd year
already approaching lap times of low end
1000cc Grand Prix Bikes
TT-Zero Race Details



"The technical concept is for motorcycles (two
wheeled) to be powered without the use of
carbon based fuels and have zero toxic/noxious
emissions." -REGULATIONS TT ZERO
£10,000 for the first entrant to exceed the
prestigious 100 mph (22 minutes and 38.388
seconds) average speed there are also awards for
the first ten teams to break the record
Top competing university which is offered a prize
of £5,000
Snaefell Mountain
Course
Length: 37.733 miles
200 Corners
60 Named Corners
TT-Zero: 1 Lap
Isle of Man TT: one of the most
prestigious motorcycle races in
the world
Constraints:




Race Date: May 28, 2013 (Assumed same date as
2012)
Race Electrical Safety Regulations
Input Charging Power: 240 V single phase 13 amp
max
Vehicle Total Weight: 100kg-300kg (220lbs-660lbs)




Powertrain Weight Allowance (exclude batteries/motor):
60lbs (Subject to change)
Course Length 37.75 miles
Qualifying time: 50 mins average course speed
45.3 mph
Must perform standing start on 18% incline
Changes in Design
Problem/Objective Needs








Essentially Same Design Problem: Push
Performance of Electric Vehicle Design
From reach spec of Range of 140 miles to easy
37.75 miles
From easy spec of operating speeds 45-55 mph to
reach spec of 150+ mph
Still high emphasis on fuel efficiency
No longer constrained to road registered vehicle
Still focus on powertrain
More defined scope, meet race safety regulations
and constraints
More integrated design with Traction Controller
Functional Decomposition:
Flow Diagram
Benchmarks
Motorcycles:
Honda CBR1000RR (Course Record)
MotoCzysz E1pc (2010/11 Winner)
MIT EV Team eSuperbike
Brammo Empulse R (1st time Competitor)
Honda Mugen EV (1st time Competitor)
Specifications Compared:
Motor: Style/output/operating Volts/amps
Controller Style
Battery Pack: Chemistry/volts/amps
Weight
Range/Top Speed/Course Average Speed
Transmission
Honda CBR1000RR

Motor : ICE 999cc
inline 4





178 hp/82.6 lb-ft
Wet Weight: 441 lbs
Top Speed: 184.6
mph(stock) 200+
mph (race)
Course Average:
131.6 mph 17’12.3
min’sec
Holds Course Record
MotoCzysz E1pc







Motor: DC perm magnet
‘D1g1tal Dr1ve’

100 hp / 250 lb-ft

500 V/ 125 Kwh
Battery: LiPo
Top Speed: 140 mph
Direct Drive
Course Average:
99.604 mph 22' 43.68
min'sec
Current EV course record,
winner 2010/11
Focused on developing
fastest bike with sufficient
capacity buffer. Finished
w/ 60% charge left
MIT eSuperbike





Motor: 2x Lynch DC
Thin-Gab Axial Flux
Motors
Battery: A123
Automotive LiFePO4
Prismatic Modules
Top Speed: 100 mph
Direct Drive
Course Average
Speed: 79.163 mph 28'
35.81 min'sec
Metrics/Specifications
Metrics/Specifications 2
Metrics/Specifications 3
Metrics/Specifications 4
House of Quality
Measure of Performance
Marginal Value
Current trips on all electrical circuits
2 Emergency Disconnects
Wire exceeding x voltage sperate from onboard circuit
Electrical Equipment Protection
Insulation resistance under 300 V
Insulation resistance over 300 V
Normal Insulation test voltage
Target
Target
Up
Target
Target
Target
9
1
3
1
3
1
9
3
1
3
9
1
3
1
1
3
3
3
3
3
3
3
1
1
1
1
1
1
1
9
1
1
1
1
1
1
1
1
3
1
1
1
Discharge Rate
Target
b.8
9
1
17.0%
500 max
b.7
9
17.0%
KWh C rating Chemical Make Up
0
b.6
9
1
3
1
Nominal Value
b.5
9
1
Volts
b.4
Chemistry
MSD Project Scoping
b.3
9
3
9
9
3
1
1
3
17.0%
b.2
9
3
9
9
9
1
1
50.0%
b.1
1
9
3
3
1
9
1
Up
Co-Development with
Electric Vehicle Team
Meets All Race Safety Regulations
Range to just finish the race
Qualifies for the race
Operates at race speeds
Regenerative Capabilities
High Fuel Efficiency
Maximize power and torque to the road
Inform driver for optimal shifting
Operates consistently for entire race
Minimal recharge time
Easy Battery Swap out
Club members on MSD team
Club Advisor support
Space for senior design build in KGCOE and
Optimzed Race and Course Model
Fall Quarter MSD I Winter Quarter MSD II
Design small enough for senior design team
Powertrain budget
Energy Storage
Reliability/Ease of Use
1.1
1.2
1.3
1.4
1.5
1.6
2.1
2.2
2.3
2.4
2.5
3.1
3.2
3.3
3.4
4.1
4.2
4.3
Preferred Direction
Down
Race ready electric
drivesystem for a
motorcycle
CO # VOC - Customer Objectives
Battery Pack operating Voltage
VOC - Affinity Groups
Customer Weights
To design bench test and implement an electric drive system on a
rolling chassis provided by the Electric Vehicle Team that
operates at race speeds and has a just enough range to finish the
TT-Zero around the Isle of Man Road Course while maximizing the
power of the electric motor to the road through the use of a
traction controller.
a.4
Target
a.1
a.2
a.3
Engineering Metrics
Target
Spec
0
50 or
125
more
0 LiPo
LiFePO4
yes/no yes/no volts IP
kohms kohms volts/hz
vol
yes
yes
42
44
250
500 2000/50 400
yes
yes
42
55
250
500 2000/50 400
House of Quality
SD II
eam
Electrical Equipment Protection
Insulation resistance under 300 V
Customer
Weights
Insulation
resistance
over 300 V
NormalPack
Insulation
test Voltage
voltage
Battery
operating
Energy Storage
Reinforced Insulation Test Voltage
Discharge Rate
Light Insulation only on onboard circuit
Capacitors voltage fall below X volts w/ x sec
Chemistry
Motor/
Controller
Capability
Current
trips
on all electrical
circuits
2 Emergency Disconnects
Energy Required for Accessories
Wire exceeding x voltage sperate from onboard circuit
Electrical Equipment Protection
Insulation resistance under 300 V
Motor Style
Output
InsulationPower
resistance
over 300 V
Torque
Normal Insulation test voltage
Target
Target
Target
Down
Target
Up
Target
Target
Target
Target
Target
Target
Target
Target
Up
Target
Target
Up
Target
Up
Target
e.4 b.8
Up
e.3
b.7
Wire exceeding x voltage sperate from onboard circuit
b.6e.2
Target
b.5
2 Emergency Disconnects
b.3 e.1b.4
Target
d.1
b.2
Current trips on all electrical circuits
b.1
Target
c.1
Chemistry
a.4
b.10
Target
Customer Weights
a.1
b.7
b.8
a.2
a.3b.9
Engineering Metrics
9
9
9
9
93
9
9
9
1
1
3 9
9
9
3
1
1
3
19
9
1
9
3
3
1
9
1
9
9
9
99
3
3
CO # VOC - Customer Objectives
Race ready electric
50.0%
drivesystem for
a
motorcycle
3
9
9
9
1
1
d
OE and
b.6
9
ystem on a To design bench test and implement an electric drive system on a
at
rolling chassis provided by the Electric Vehicle Team that
finish the operates at race speeds and has a just enough range to finish the
mizing theTT-Zero around the Isle of Man Road Course while maximizing the
of a
power of the electric motor to the road through the use of a
traction controller.
VOC
Preferred
- Affinity
Direction
Groups
b.5
Discharge Rate
b.3 Spec
b.4
Up
b.2
Energy Storage
b.1
Down
a.4
Battery Pack operating Voltage
a.1
a.2
a.3
Engineering Metrics
Target
Spec
17.0%
Reliability/Ease
of Use
1
3
1
Co-Development with
17.0%
Electric Vehicle Team
1
MSD Project 17.0%
Scoping
Performance
KWh Measure
C rating of
Chemical
Make Up
Volts
0
500 max
1.13Meets All1 Race Safety Regulations
1
9
1.29Range to just finish the race
9
1.39Qualifies1for the race
3
1.43Operates3at race speeds
3
1.51Regenerative
1 Capabilities
1
1.61High Fuel3 Efficiency
9
2.13Maximize1 power and torque to the
1 road
2.2 Inform driver for optimal shifting
2.39Operates3consistently for entire race
3
3
2.43Minimal recharge
9
1
time
2.51Easy Battery
1 Swap out
1
3.1 Club members on MSD team
3.2 Club Advisor support
3.3 Space for senior design build in KGCOE1and
3.49Optimzed1 Race and Course Model
1
4.1 Fall Quarter MSD I Winter Quarter MSD II
4.2 Design small enough for senior design team
1
4.3 Powertrain budget
1
0Nominal0Value
LiPo
50 or
125Marginal LiFePO4
Value
more
Preferred Direction
50.0%
3
3
3
3 17.0%3
1
1
1
1
1
1
1
1
3
yes/no yes/no volts IP
1
17.0%
1
17.0%
1
kohms kohms Volts
volts/hz
yes
yes
42
44
250
yes
yes
42
55
250
1
3
1
3
1
31
3
1
9 3
3
1
33
9
1
3
1
1
1
1
9
1
1
3
1
1
1
1
9
9
3
3
13
3
1
1
1
volts/hz
KWh C rating
yes/no Chemical
volts/secMake
yes/no
Up
500 2000/50 0 4000/50
0 yes 0 LiPo
65/2
50 or
500 500
2000/50
max 4000/50
125 yes LiFePO4
65/5
more
3
3
33
3
3
9
9
3
9
9
9
9
9
9
3
9
9
3
9
9
3
9
9
3 3
3
3 9
3
3
9
3
9
1
9
1
1
1
1 3
9
31
9
3 1
9
31
1
1
1
1
11
3
1
3
1
3
3
1
yes/no volts
yes/no volts Motor
IP Style
kohms kohms
hp ft-lbs
volts/hzvoltsvol
no
yes
yes
1242
44
250 0 140
500 2000/50
250
400
yes
yes
yes
1242DC Brushless
55
250
180
500 2000/50
300 500400
ma
House of Quality
1
MSD
Project Scoping
1
3
no yes/no volts IP
1
1
kohms kohms volts/hz
1
Performance
volts/hzMeasure
yes/no ofvolts/sec
yes/no
volts
Motor Style
yes
42
44
250
500 2000/50 4000/50
Nominal
yes Value
65/2
no
12
yes
42
55
250
500 2000/50 4000/50
Marginal
yes Value
65/5
yes
12 DC Brushless
1
1
3
Prevent
Excess
Wheel
Spinonboard circuit
Wire exceeding
x voltage
sperate
from
Limit
power
right before
wheel lift
Electrical
Equipment
Protection
Insulation resistance under 300 V
Power to the road optimization
Insulation
over 300 V
Maintain
RPMresistance
in Peak Efficiency
Range
Integration with controller
Normal Insulation test voltage
Target
Target
Target
Up
Target
Down
Target
Target
Target
Target
9
9
9
3
9
3
9
3
3
1
1
9
3
9
33
9
1
9
3
3
1
9
1
3
1
1
3
9
9
3
9
9
3
3
1
3
9
9
9
3
3
3
3
3
9
1
33
9
1
3
9
9
3
9
9
9
9
9
3 3
3
3
9
1
3
3
3
3
1
17.0%
3
3
3
1
1
1
1
1
1 1
11
1
9
9
9 1
9
1
1
9
9
9
9
3
317.0%3
3
3
3
9
3 1
1
31
3
3
9
9
9 1
1
31
3
1 1
11
1
%charge
hp Volts
ft-lbs voltsKWh C
% rating
lbs-ftChemical
at
yes/no
wheel Make
yes/noUp# yes/no
hp/ft-lbs
yes/noyes/no
volts units
IP
kohms kohms
±% volts/hz
yes/no yes/n
vol
after race
0 140 250 0
0
0 177
0 LiPo
yes
yes
yes
0
yes
86.8 no 42 no 44
250 30 500
25 2000/50
no
no400
50 or
180 500300
max
500 max
125 90 61.6LiFePO4
yes
yes
maxyes
6
133.3
yes yes 42 yes 55
250 15 500
10 2000/50
yes
yes
400
more
3
1
3
9
1
max output power/torque
2 Emergency Disconnects
91
3
1
target
Target
3
3
3
3
19
3
1
3
1
Current trips on all electrical circuits
3
3
3
3
9
3
9
1
g.6
b.8
Target
3
9
9
1
1
9
3
3
19
3
1
3
3
9
9
9
3
1
b.6g.4 b.7
g.5
Chemistry
3
93
9
39
13
1
31
3
3
9
9
50.0%
9
9
9
9
3
9
3
9
917.0%3
g.3
b.5
optimize # of gears
Manual Shifting
target
9
3
3
g.2
b.4
down
Strength to handle max input power/torque from motor
target
3
3 9
9 9
9 9
1
3 1
9
9
3 1
3
1
Preferred Direction
g.1b.3
Target
Discharge Rate
Min race power required for standing start at 18% grade
Up
Target
1
1
Peak Efficiency
1
1
1
Energy Storage
Operating
Voltage
1
Up
1
Co-Development with
1
1 Vehicle
1
1
Electric
Team
3
Down
Up
3
3
3
Reliability/Ease
of3 Use
9 All Race
9
Meets
Safety9 Regulations
9
Range to just finish the race
Qualifies for the race
Operates at race speeds
9
Regenerative Capabilities
9
High Fuel Efficiency
Maximize power and torque to the road 3
3
Inform driver for optimal shifting
3
3
3for entire race
1
Operates
consistently
3
Minimal recharge time
Easy Battery Swap out
Club members on MSD team
Club Advisor support
1 for senior
1
1 build in KGCOE and
Space
design
9
Optimzed Race and Course Model
Fall Quarter MSD I Winter Quarter MSD II
3
Design small enough for senior design team
1
1budget 1
Powertrain
Torque
Battery Pack operating Voltage
3
3
1.1
1.2
1.3
1.4
1.5
1.6
2.1
2.2
2.3
2.4
2.5
3.1
3.2
3.3
3.4
4.1
4.2
4.3
Up
Target
Energy Required for Accessories
Target
Race ready electric
drivesystem for a
motorcycle
f.3 b.1 f.4 b.2
Customer
Weights
Power Output
Motor/ Controller Capability
Target
9
f.2
Up
Capacitors voltage fall below X volts w/ x sec
Target
9
9
CO # VOC - Customer Objectives
a.1
e.3
e.4 a.2
a.3
e.5 e.6 a.4
f.1
Engineering Metrics
Motor Style
Light Insulation only on onboard circuit
Target
9
VOC - Affinity Groups
e.2
Target
Reinforced Insulation Test Voltage
9
2 Emergency Disconnects
9
To design bench test and implement an electric drive system on a
rolling chassis provided by the Electric Vehicle Team that
operates at race speeds and has a just enough range to finish the
TT-Zero around the Isle of Man Road Course while maximizing the
power of the electric motor to the road through the use of a
traction controller.
Target
9
Current trips on all electrical circuits
Target
Spec
e.1
Normal Insulation test voltage
d.1
Target
c.1
Insulation resistance over 300 V
b.10
Target
b.9
Insulation resistance under 300 V
b.8
Target
b.7
Electrical Equipment Protection
b.6
Up
b.5
Wire exceeding x voltage sperate from onboard circuit
b.4
Target
b.3
Target
b.2
House of Quality
9
9
9
3
3
MSD Project3 Scoping
3
1
volts
Motor Style
12
12 DC Brushless
Gear Position Sensor
Discharge Rate
Throttle Position Sensor
Motor RPM Sensor
Suspension
Travel Sensor
Chemistry
Gyro
Sensor
Current trips
on all
electrical circuits
Accelerometer
2 Emergency
Disconnects
Wire exceeding
voltage sperate from
onboard circuit
Shift xIndicator/Instrument
Panel
Electrical Top
Equipment
Speed Protection
Insulation
underUse
300 V
Rangeresistance
Under Heavy
Drivetrain weight allowance
Insulation resistance over 300 V
Normal Insulation test voltage
Target
Target
Target
Target
Target
Target
Target
Target
Target
Target
Up
Target
Target
Target
Target
Target
Target
b.8
Target
Up
b.7
Integration with controls system
Energy Storage
b.6
i.3
Target
Down
b.5
i.2
Integration with controller
Battery Pack operating Voltage
b.4
i.1
3
9
9
9
3 1
3 1
9
1
1
3
1
3
1
3
9
9
3
1
1
93
3
39
3
1
1
1
9
3
3
1
9
91
9
3
1
1
9
9
9
9
9
9
9
9
3
9
9
9
Preferred Direction
3
3
9
1
3
h.7
b.3
Target
Target
3
h.6
b.2
Maintain Customer
RPM in Peak
Efficiency Range
Weights
Prevent Excess Wheel Spin
Target
Meets All9 Race Safety Regulations
3 to just finish
3 the race3
3
Range
1
9for the race
9
3
9
9
Qualifies
3
9
3
9
9
Operates
at race speeds
3
1
3
Regenerative
Capabilities
9 Fuel Efficiency
1
9
3
High
9
9 torque
3 to the 9road
3
Maximize
power and
9 driver for optimal
3
9
9
3
Inform
shifting
3
3 for entire
1
3
Operates
consistently
race
1
Minimal
recharge time
Easy Battery Swap out
3
Club members on1MSD team
3 Advisor support
1
1
Club
3
3
Space for senior design
build in KGCOE
and
Optimzed Race and Course Model9
Fall Quarter MSD I Winter Quarter MSD II
3 enough
3 for senior
9 design
3 team
Design small
9
9
Powertrain budget9
h.5
b.1
Target
max output power/torque
target
Torque
Up
9
1.1
3
1.2
3
1.3
9
1.4
9
1.5
3
1.6
1
2.1
1
2.2
2.3
1
2.4
2.5
3.1
3.2
3.3
1
3.4
4.1
4.2
4.3
h.4
Power to the road optimization
optimize # of gears
down
Power Output
Up
Co-Development with
3
3Team3
Electric Vehicle
CO # VOC - Customer Objectives
g.5
a.1
g.6 a.2 h.1a.3 h.2 a.4 h.3
Engineering Metrics
Down
Manual Shifting
target
Motor Style
Target
VOC - Affinity Groups
g.4
Limit power right before wheel lift
Strength to handle max input power/torque from motor
Spec
g.2 g.3
target
g.1
Min race power required for standing start at 18% grade
f.4
Target
f.3
Peak Efficiency
f.2
Target
9
9
3
3
1
3
f.1
To design bench test and implement an electric drive system on a
rolling chassis provided by the Electric Vehicle Team that
operates at race speeds and has a just enough range to finish the
TT-Zero around the Isle of Man Road Course while maximizing the
power of the electric motor to the road through the use of a
traction controller.
9
3 Race ready electric
3
3
3
3
9
9
9
drivesystem9 for 9a
9
motorcycle 9
9
3
3
9
3
9
3
9
9
3 Reliability/Ease
9
3 Use
3
of
3
3
9
e.5 e.6
Up
e.4
Operating Voltage
e.3
Up
e.2
Energy Required for Accessories
e.1
Target
d.1
9
1
3
9
9
3
3
3
3
9
3
3
3
50.0%
9
1
9
1
9
9
9
3
9
9
317.0%
3
3
3
17.0%
1
1
9
9
3
317.0%
1
1
1
3
1
3 3
9 1
9
3
9
1
9
9
9
9
9
9
9
3
3
9
9
3
9
9
3
3
9
9
33
3
1
19
3 1
3
3
31
1
3
1
3
1
3
1
3
3
3
3
9
1
91
1
31
1
19
9
39
3
3
1
1
9
3
13
9
3
3
1
9
9
39
9
19
9
91
9
1
%charge
Measure
of
Performance
hp ft-lbs volts
%
lbs-ft at
yes/no
wheel
yes/no #
hp/ft-lbs yes/no units
±% yes/no
Volts yes/no
KWhyes/no
C rating
yes/no
Chemical
yes/no
Make
yes/no
Up yes/no
yes/no yes/no
yes/no yes/no
volts IP
mph kohms
mi
kohms
lbs
volts/hz vol
after race
0 140 250
0 Nominal
0 177Value
yes
yes
0
86.8 no
no
30 25 no
no0
no
0
yes
0 LiPo yes
no
no
yes
no
yes
yes 42 140
44 37.75
250
60
500 2000/50 400
50 or
180 300 500 max Marginal
90 61.6 Value
yes
yes
max 6
133.3 yes
yes
15 10 yes
500 maxyes 125
yes
yes LiFePO4
yes
yes
yes
yes
yes
yes
yes 42 200
55 37.75
250
60
500 2000/50 400
more
Staffing Ideal Scope
Discipline
How
Many?
Anticipated Skills Needed
2
EE1: Main Circuit Design, onboard/accessory circuit design and assembly
EE2: Power system optimization, battery management, controls system design
ME
3
ME1: CAD Drawing, Interfacing w/ Traction Controller, Physical mounting
ME2: Transmission Modification/Optimization, Final Drive Design
ME3: Machining/Assembly Experience/Test Design
CE
1
CE1: Embedded real time system, fuzzy logic control algorithm. Device
programming. Signals Processing
EE
Feedback From Electric
Vehicle Team

Scoping
 Ideal Situation: Top Speeds 200 mph Course
average 131.6 mph 17'12.30 min'sec Goal: Beat
Course record
 Powertrain Budget: $15,000
 Medium Scope: Top Speeds 140 mph Course
average 100 mph 22'38.33 min'sec

Powertrain Budget: $7,500
Smallest Scope: Bench Test scaled components and
have Course Simulation of Ideal Scope
 Powertrain Budget:$500 MSD Funding


Goal: Beat 100 mph EV course record win 10,000
pounds prize and top competing university win 5,000
pounds prize
Feedback From Electric
Vehicle Team

Specifications:
 The Electric Vehicle Team will Develop a
Course/Race Model over summer



Provide MSD I with more specific and optimized
specification values
Battery/Motor selection
Staffing:
 Sean Harriman Electric Vehicle Team Powertrain
Project Manager: Lead Engineer-ME1 MSD Team
 Dan Brownlee Electric Vehicle Team Vice President:
ME2 MSD Team
 Andrew Robison Course/Race Model Developer:
ME3 MSD Team
Questions?