Frame Design - UH Red Devils

```Team Members
Project
Manager
Mechanical System
Designer
Frame &amp; Body
Designer
Electrical System
Designer
Daulet
Urkenbayev
Rajeev
Bhattacharya
Paul
Orieukwu
Jonathon
Fulbright
Raresh Pascali
- Instructor
Marcus Gamino
William Hesser
Matt Walsh
- Underclassman
Ayazhan Zhakhan
- Alumni
Outline
1.
Competition Objective
2.
Team Goals
3.
What is a Hybrid Vehicle?
4.
3D Model of the Car
5.
Frame Material
6.
Frame Design
7.
Finite Element Analysis
8.
Aerodynamics Devices
9.
Internal Combustion Components
10.
Calculations
11.
Electrical Components
12.
Project Management
3
Competition Objective

To challenge teams of university students to design, fabricate and
build a formula hybrid-powered vehicle and compete at the annual
Competition in Loudon, New Hampshire on April 27, 2015
Formula Hybrid 2014
35
Open
24
Registered
12
Hybrid
19
Competed
7
Electric
Projection for Formula Hybrid 2015
1
South Korea
35
Open
4
India
19
USA
3
30
Registered
1
Australia
1
Pakistan
1
Turkey
4
Competition Events &amp; Scoring
DYNAMIC
STATIC
Presentation
Acceleration
Engineering Design
Autocross
Endurance
Competition Scoring
Presentation
100
400
Engineering Design
200
1000
Acceleration-Electric
75
150
Acceleration-Unrestricted
75
Autocross
Endurance
5
Team Goals

Register before slots fill.

Implement switchable hybrid drive.

Curb weight not to exceed 650 lbs.

Implement data logging system.

Complete unrestricted 246 ft acceleration run in 5.4 sec or less.

Complete the final assembly by April 1.
6
What is a Hybrid Vehicle?
Series Hybrid Layout
Parallel Hybrid Layout
High Efficiency
Low Efficiency
Low Driving Performance
High Driving Performance
7
Illustration of the FH Car
To design system with the ability to switch between the
series and parallel hybrid systems.
8
Frame and Body Outline
1.
Frame Material
2.
Frame Design
3.
Finite Element Analysis
9
Frame Material
Aluminum
Carbon Fiber
Yield Strength = 710,684psi
Yield Strength = 31,000psi
Modulus of elasticity = 33,000ksi
Modulus of elasticity = 10,000ksi
Density: .055g/in3
Density: .0975 lb/in3
Price: \$106.5/ft
Price: \$20/ft
Steel
Yield Strength = 50,800psi
Modulus of elasticity = 29,700ksi
Density: 2.48lb/in3
Price: \$44/ft
10
Frame Design
Design #1
Design #2
Design #3
11
Finite Element Analysis (FEA)
Front Impact
Results (Von Mises)(psi)
Side Impact
Results (Von Mises)(psi)
12
Aerodynamics Devices

All of the components should increase the downforce on
the vehicle by manipulating the air flow.
Front Wing
Body
Diffuser
13
Mechanical Outline
1.
Internal Combustion Engine
2.
Calculations
3.
Differential
14
Internal Combustion Engine
Subaru EX21
Lifan 250cc V-Twin Engine
Power Output: 7 Hp
Price (New): \$479.97
Power Output: 16.5 Hp
Price (used): \$625
Kawasaki Ninja 250R
Power Output: 37 Hp
Price (used): \$450- \$650
Specification:
Engine: Four-Stroke, DOHC, Parallel
Twin
Displacement: 249 cc
Compression: 11.6 : 1
Cooling: Liquid
Ignition: Electrical
Transmission: Six Speed
Final Drive: 14 in Chain Sprocket
Cooling type: Liquid
15
Calculations
16
Differential
Torque: 800 ft-lb
Weight: 10 lb
Cost: \$2600
Taylor Industries
Torque: 600 ft-lb
Weight: 15 lb
Cost: \$415
Torsen Traction-JTEKT
Torque: 680 ft-lb
Weight: 10 lb
Cost:
\$1000
Westgarage Engineering
17
Electrical Outline
1.
Electric Motors
2.
Controllers
3.
Batteries
4.
BMS
5.
CCU
18
Front Electric Motors
ME0909 Brushed DC
Power Output: 20 HP
Price (New): \$385
Liquid Cooled BLDC Motor
Power Output: 13 HP
Price (New): \$918
Specification:
Type: PMDC
Weight: 24.8 lb
Torque Max: 28 ft-lb
Perm PMG-132 PMDC
Power Output: 19 HP
Price: Donated
19
Rear Electric Motor
ME 1118 PMAC
Power Output: 19 HP
Price (New): \$1895
ME0909 PMDC
Power Output: 20 HP
Price (New): \$385
Specification:
Type: AC Induction
Weight: 46 lbs.
Torque Max: 100 ft-lb
AC 12
Power Output: 44 HP
Price: Donated
20
Controllers
Front
Kelly KDZ12401
Regen: Yes
Price: \$479
Rear
Curtis 1239E
Regen: Yes
Price: \$1,562
(Donated)
21
Battery
Li Polymer
Specifications:
Specifications:
Cell Capacity: 2.8 Ah
Size: 18650
Cost: \$3000
Cell Capacity: 12 Ah
Size: 6” x 2” x 3.7”
Cost: \$1000
LiFePO4
Specifications:
Cell Capacity: 8 Ah
Size: 38120
Cost: \$3000
22
Battery Management System (BMS)
MBS-EP128
Price: \$425
Orion BMS
Price: \$890
Lithiumate
Price: \$795
Specifications:
• USB and RS232 Ports
• CAN Bus Capable
• Analog and Digital I/O
23
Central Control Unit (CCU)
Arduino Mega
I/O: 54
Price: \$30
Rasberry Pi B+
I/O: 40
Price: \$70
myRio
Specification:
I/O:
Analog out:
Input power:
Clock speed:
Price :
40
10
6
6-16 V
667 MHz
\$250
24
Budget
Components
Frame and Body
Low
High
\$300
Steel Tubing
Fiberglass Shell
Cost of Construction
Internal Combustion
Engine
Hoses and Connections
Exhaust
Electrical System
DC Electric Motors
DC Electric Motor Controllers
AC Induction Motor
AC Induction Motor Controller
Input/output Transducers
Cables and Connections
Batteries and Battery Management System
Central Controller
Drivetrain and Suspension
Axels, Bearings, and CV Connections
Chains and Sprockets
Differential and Electric Clutch
Wheels and Tires
Travel Expenses
Truck and Trailer Rental
Lodging and Food
Gas
Entry Fee
Total
\$2,500
\$300
\$600
Donated
\$400
Donated
\$1,500
\$630
\$2,700
\$450
\$2,000
Excluded
\$300
\$80
\$100
\$100
\$300
\$5,650
\$16,200
Donated
\$2,000
\$1,400
\$2,000
Donated
\$1,200
Donated
\$3,000
\$800
\$2,000
\$200
\$500
\$3,000
\$5,000
\$250
\$500
\$1,800
\$7,200
\$500
\$2,000
\$300
\$600
\$1,000
\$3,000
Donated
\$1,600
\$0
\$4,400
Donated
\$1,200
Donated
\$1,200
Donated
\$2,000
\$2,150
\$2,150
\$10,530
\$35,150
25
Gantt Chart
26
Work Breakdown Structure
27
Risk Matrix
28
Questions?
29
```