Hybrid-Electric Drive for the SAE Mini-Baja Car

Project PlanProject Number: May05-13

Client: Iowa State University, Society of Automotive Engineers

Faculty Advisor: Dr. Venkataramana Ajjarapu

Team Members:Daniel Robinson (Team Captain) MEJeremy Boon MEGodwin Itteera EEDouglas Milewsky CprENicholas Olson EERajdeep Wadhwa EE

Date: October 5, 2004

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Table of Contents Page Number

List of Figures iiList of Tables iiiList of Definitions iv

Introductory Material

Abstract 1Acknowledgement 1Problem Statement 1Operating Environment 2Intended Users and Intended Uses 2Assumptions and Limitations 2Expected End Product and Other Deliverables 3

Proposed Approach and Statement of Work

Proposed Approach 4Statement of Work 6

Estimated Resources and Schedules

Estimated Resource Requirement 7Schedules 8

Closure Material

Project Team Information 12Closing Summery 13References 13

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List of Figures Page Number

Figure 1: Mini-Baja Car Title page

Figure 2: Diagram of series set-up hybrid-electric drive iv

Figure 3: Gantt chart of tasks 16

Figure 4: Gantt chart of deliverables 17

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List of Tables Page Number

Table 1: Group Schedule 15

Table 2: Other Resources 17

Table 3: Financial Costs 18

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List of Definitions

Series Set-up- Configuration of a hybrid-electric car where the components are in series arrangement. A gas engine produces initial energy for the system which is converted to electrical power through a generator. The electrical current is managed by a controller to drive motors to power the wheels.

Figure 1: A diagram of the series setup of the electric motor and components

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Introductory Material

Abstract

The collegiate Society of Automotive Engineers (SAE) Mini-Baja team at Iowa State University (ISU) is seeking to develop innovative design components into their competition racecar. The ISU SAE Mini-Baja team participates in an annual design competition against other collegiate teams. Points are awarded based on design, cost, presentation, and performance. ISU SAE feels that a design including a hybrid-electric drive would gain their team a competitive advantage.

The May05-13 senior design team is tasked to develop and produce the design and methods for implementing such a drive into future ISU SAE Mini-Baja racecars. This is a two phase project split into two year-long segments. The first year represents the May05-13 team which will design the concept, simulate possible solutions through computer software, and create working drawings. Phase two will be composed of an entirely separate team who will build, test, and retrofit the hydro-electric drive into the ISU SAE racecar.

Acknowledgement

The ISU SAE Mini-Baja team will cover all costs outside of costs associated with the EE/CprE 491/492 class requirements (poster, report binding and printing etc.). Other costs will be covered by sponsorships obtained by the Mini-Baja team specifically aimed at the electric drive system.

Ethan Slattery will be providing assistance in the form of technical advice, and assistance in accessing any SAE products or workshop facilities.

Problem Statement

The Iowa State University Society of Automotive Engineers (ISU SAE) Mini-Baja team requests the design of a hybrid-electric drive for their Baja racecar. Design and implementation of project will occur over a two year period. Phase I, the design stage, is planned for the 2004-2005 academic year. Phase II, the implementation and testing stage, is planned for the 2005-2006 academic year. The Senior Design group will work as an independent entity from ISU SAE. Yet it is intended that close ties remain between the groups. The Senior Design group will have full access to ISU SAE shop facilities, previous designs, and working drawings. Any information provided by SAE remains property of ISU SAE.

The hybrid-electric drive system is to be powered by a 10 HP Briggs and Stratton engine. The senior design team will design a system to drive one or two electric motors that will in turn drive the car. The senior design team will also design controls for the system as well as a power generation system to be run by the Briggs and Stratton engine as previously stated. The senior design team will need to conform to all rules set forth by the SAE Mini-Baja Collegiate Design Series.

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Operating Environment

The hybrid-electric drive will be integrated into the design of a Baja race car. The car will be subjected to many extreme conditions including dust, dirt, mud, water, potentially high temperatures (>200°F), grease/oil (lubricant), high torque, shock loading, high stress loading, and potential collision with solid object, i.e. rocks. All components must be designed to withstand impact and shock loading from rough terrain. Critical components such as gear housing and electronics must be sealed from contaminants. Adequate cooling must be supplied to the electric motor yet the motor must also be protected from dust and water. Mechanical components must be designed for high cycle life. Electrical equipment must be protected from over currents and/or voltages that may result in electrical shock. Safety of the driver is critical. All components must integrate with the car so that no hazard, i.e. electrical shock, fire, mechanical failure threaten the safety of the driver or bystanders.

Intended Users

The design team’s electric drive is intended for the Mini-Baja team. The main user of this drive will be the individual who is driving the vehicle at the time. The design team will give an overview of this design to the whole Baja team. This is so each individual who directly works on the vehicle will know how the drive works and functions in case there is a problem. In thiscase, the Baja team should understand the available trouble shooting methods.

Intended Use

The use of this drive is intended for the Mini-Baja car and will be designed specifically for this vehicle. By using the drive, the Mini-Baja team hopes to improve the performance of some aspects of the car. The car is used in a nationwide test to see how well each vehicle is designed and performs. The drive will be powered by the already existing Briggs and Stratton motor. It will then deliver power to the wheels through some control.

Assumptions

Simplifications to aid design. Constant electrical output from generator Constant power from gasoline engine running at peak rpm’s Addition of hybrid-electric components does not affect center of gravity All power for electronics will be available from Baja car battery

Limitations

Rules, restrictions, and constraints for the design. Design must adhere to all rules defined by SAE Mini-Baja Collegiate Design Series No initial stored energy to power wheels. Weight considerations (Max weight limited by SAE rules) Size constraints from SAE

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Power available from 10hp Briggs and Stratton engine Wet and dry conditions Design to original performance of original car

Expected End Product and Other Deliverables

The next couple of sections describes the expectation of the senior design team.

Expected End Product (Delivery date: 5/5/2004):

The expected end product is a design for a system to drive the Mini-Baja car with electric motor(s). In the end our team would like to have a completed final design report for an electric drive system that would drive the Mini-Baja car. This report would include diagrams and schematics that will explain what devices will be used for the electric drive system. Also, included would be instructions for SAE on how to construct the system. Simulation and test results will be included with this report so SAE will know exactly what to expect from system once it is built.

Other Deliverables:

Bound Project Plan (Delivery date: 10/5/2004):

The Bound Project Plan contains many abstract ideas on how to approach the problem of developing an electric drive system for a Mini-Baja car. This plan addresses the issue of the many limitations that will be involved during the design process. This plan also has a schedule, and estimates of the many expenses involved in designing, simulating, and building an electric drive system.

Project Poster (Delivery date: 10/12/2004):

The Project Poster will be a large printed board that will be illustrating many aspects of the designing and implementing phases of the project. The information will be similar to the contents of the Project Plan; like the estimates of the number of hours of work required by each group member, along with the costs, and general information about the project.

Bound Design Report (Delivery date: 12/15/2004):

The Design Report will contain all of the specifications for the designing of the electric drive system. There will be diagrams, and specifics as to the type of parts that will be used and how the system will be connected. A preliminary block diagram is shown in figure 2.

Simulation Results (Delivery date: 5/5/2004):

The simulation results will contain the data that will be collected from the many computer simulations that will be run, after the design has been finalized. This data will be presented to SAE, providing evidence of the electric drive systems capabilities.

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Proposed ApproachThere are 12 major components to the approach. These components outline the approach taken to complete the project and to make sure consideration has been given to all necessary areas.

1. RequirementsList of functional requirements.

Vehicle must be drivable Driver will not be harmed Speed must be controllable by driver Wheels must only be powered by electric motor

2.Constraints considerationsPhysical limits and requirements.

Size: due to the min-Baja being a small vehicle Weight: rules outlined by SAE Power: 10HP engine to work max

3. TechnologyTechnology utilized for design.

Hybrid vehicle Motors (DC) Generators Control systems

4. Technical approachTechnical considerations for design team. Simulations Computer models Mechanical blueprints Electrical schematics

5. Testing requirementsLists two items of consideration on the testing level. Simulation of controller and motor response by means of computer software Quarter-scale mock-up

6. Security considerationsThe concept and implementation of a hybrid-electric drive for SAE competition car is exclusive and proprietary to ISU SAE. This document and the project discussed herein is owned by ISU SAE.

7. SafetySafety considerations for operator and by-standers.

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Hybrid-electric drive must pose not risk to driver or by-standers Electronics must be weatherproofed due to variable environment conditions Mechanical features should be designed against fatigue and failure modes

8. Intellectual propertyName owner of intellectual properties. Documents, concepts, renderings, schematics, diagrams, software code, results,

designs, and the like are property of the Iowa State University SAE Mini-Baja team. This knowledge is not to be shared to any party other than Iowa State University SAE

Mini-Baja team.

9. Commercialization considerationsCommercialization is not a consideration. There exists efficient, commercialized hybrid-electric vehicles. The purpose of this project is to introduce novel and innovative technologies into the design of a SAE Mini-Baja collegiate competition car.

10. Possible risks and risk managementPossible problem areas and how to deal with them. Moving mechanical components; guarding will be installed

o Nipo Pincho Shear

High current electronics; proper grounding and shielding

11. Project proposed milestones and evaluation criteriaTeam goals and how and measurement of effectiveness

Milestones Bound project plan Project poster Design report Simulation results Working model Complete component design, i.e. drawings, schematics, specifications

Evaluation, based on the scale of 1-7(1) exceeded, surpassed all expectations(2) attained, achieved expectations with excellence(3) met, achieved expectations with average performance(4) almost met, achieved most expectations(5) partially met, achieved some expectations(6) did not meet(7) did not attemptFor 6 and 7, an explanation will be required along with the milestone.

12. Project tracking proceduresWeekly reports will record individual contributions. End of semester evaluations to be administered by team-members and client.

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Statement of Work

1. Problem Definition

Task Objective:1a: Team shall receive information from client (SAE) to determine the scope of the project.

This will ensure delivery of expected design1b: Team shall identify the users and purpose of product

Task Approach: Team shall talk with its faculty advisor, client, discuss constraints with Baja-Team,

research items individually, and share the information with the rest of the team Task Expected Results: Team shall produce a detailed plan of what needs to be

accomplished over the next two semesters

2. Technology Consideration and Selection

Task Objective:2a: Team will, meaning we will try our best, to map power and efficiency through existing

drive2b: Team shall research components in an attempt to duplicate current machine’s efficiency.

Task Approach:Team shall make calculations and measurements to determine the existing power and efficiency of the drive. Team will also contact companies, professors, textbook, catalogs,journals, and perform online research to determine the drive design

Task Expected Results:Knowing the power of the existing drive will provide a benchmark of performance to compare the new system.

3. End Product Design

Task Objective:3a: Team shall select components based on efficiency, reliability, weight, and cost.3b: Team shall have a specific idea of what components will be in the drive and how they

will perform3c: Team shall document our design so progress can be easily and accurately retraced.

Task Approach:Team shall select the components and complete the conceptual design.

Task Expected Results:Team shall produce a clear, complete design that is ready for SAE to implement and put on the car.

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4. Project Reporting

Task Objective:4a: Team shall complete a project plan4b: Team shall make a poster 4c: Team shall document the design4d: Team shall communicate with advisors and professors on progress

Task Approach:Team shall split up the project plan among the group members and then put it together as a group. They will also work as a team to take the project plan and mold it into a poster. Individually, members are expected to keep good notes during the research and design. Team will email our advisor and professor when either needs to know about a meeting or could assist with a design problem.

Task Expected Results:Team shall provide a detailed project plan, poster, and documentation so that another group could make the same design.

Estimated Resources and SchedulesThe project would proceed while keeping the following requirements in mind:

Personnel effort requirements:As shown in Table 1, group members Daniel Robinson and Jeremy Boon will work an estimated 85 and 84 hours respectively. These hours are about half as much as the other members because they will only be working with the project for one semester instead of a full year. Group members Godwin Itteera, Doug Milewsky, Nicholas Olson, and Rajdeep Wadhwa will work an estimated 155, 159, 156, and 158 hours for the academic year.

Other resource requirements:The team will have access to the SAE shop (free of charge) if needed. They also may need simulation software to test and develop the drive system. There is free software available for download to accomplish this.

Financial requirements:As shown in Table 3, the estimated total cost of the project, including student labor is $8817.

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Personnel effort requirements

The project is divided into 9 different tasks:

Task 1 – Project Plan

Plan Project 9/6/2004-9/17/2004 12 daysRevise Project 9/20/2004-10/5/2004 11 days

Task 2 – Paper Work

Weekly Reports Every WeekUnbound Design Report 10/18/2004- 11/9/2004 18 daysStatus Report 10/18/2004-11/9/2004 18 daysRevised Design Report 11/15/2004 -12/15/2004 22 days

Task 3 – Motor design

Research 9/6/2004-10/4/2004 20 daysSet specification 9/27/2004-10/8/2004 10 daysSelect Components 10/25/2004-2/18/2005 65 days

Task 4 – Map power and efficiency thru drive

Block diagram 9/27/2004-10/8/2004 10 daysMathematical Diagram 10/4/2004-10/15/2004 10 days

Task 5 – Circuit diagram

Research 9/6/2004-10/4/2004 20 daysDefine system 9/27/2004-10/8/2004 10 daysDesign 10/25/2004-3/04/2005 85 daysError check and Compatibility 1/24/2005-3/04/2005 35 days

Task 6 – Battery selection/configuration

Research 9/6/2004-10/4/2004 20 daysSet Specification 9/27/2004-10/8/2004 10 daysSelect Components 10/25/2004-2/18/2005 65 days

Task 7 – Control System (program micro-controllers)

Research 9/6/2004-10/4/2004 20 daysDesign Control system 9/27/2004-10/22/2004 20 daysProgram 10/25/2004-3/04/2005 85 days

Task 8 – Simulation

Develop model 10/18/2004-11/5/2004 15 daysTest specifications 11/9/2004-11/19/2004 10 days

Task 9 – Design poster

Design poster 11/15/2004-12/15/2004 18 days

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Table 1: Group Schedule. Breakdown of hours by team-member by task

Group member

Task1

Task 2

Task 3

Task 4

Task 5

Task 6

Task7

Task8

Task 9

Total

Godwin Itteera 10 20 40 0 40 20 0 5 20 155

Doug Milewsky 10 20 20 0 0 0 104 5 0 159

NickOlson 11 20 0 0 100 0 0 5 20 156

Jeremy Boon 9 20 0 25 0 0 0 5 25 84

Daniel Robinson 20 20 0 20 0 0 0 5 20 85

Rajdeep Wadhwa 14 11 0 0 40 0 68 5 20 158

Total Hrs 66 111 60 45 180 20 172 30 105 797

As shown in Figure 2, there are several tasks designated throughout the year. This chart shows which activities overlap and which activities must be completed before the start of another activity. It is a visual representation of the necessary order of work.

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Figure 2: Gantt Chart. The chart above shows the necessary order of operation graphically

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Other resource requirements

Upon completion of the design phase, the design team will be required to do some simulation/testing of the electric drive. Some simulation would also be required during the design phase itself. The power lab, as indicated in Table 2, which is a part of the electrical engineering department, has 3 hp motors that could be used for simulation and testing purposes. The Baja team is also willing to let the senior design team use their shop facilities.

Table 2: Other Resources. This table shows other resources that will be utilizedItem Team hours Other hours Cost

Poster 12 0 $50Power lab 40 0 0Baja Shop 35 0 0

Totals 87 0 $50

Financial Requirements

The financial budget has been presented in Table 3. The SAE Mini Baja team is funding a major part of the project. The costs for the poster will be taken care of by the electrical and computer engineering department. The design team’s advisor, Dr. Ajjarapu will be providing some reference materials. If any other reference material is required, the group members would pay for it and could keep it.

Table 3: Costs. The table shows all costs of the project by parts, material, and laborItem W/o labor With labor

Parts and MaterialsPoster $50 $50

Motors ( two) $418 $418Briggs and Stratton engine Donated Donated

Rectifier unit $40 $40Alternator $25 $25

Subtotal $533 $533

Labor at & 10.50/hrGodwin Itteera $1627.50Doug Milewsky $1669.50

Nick Olson $1638.00Jeremy Boon $882.00

Daniel Robinson $808.00RajdeepWadhwa $1659.00

Subtotal $8284.00

Totals $533 $8817.00

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Project Team Information

Acting client:

Ethan SlatteryProject Manager 2004-2005ISU SAE Mini-Baja1306 Iowa CirAmes, IA 50014Cell: (641) 821-0202ejslap@iastate.edu

Faculty advisor:

Dr. Venkataramana AjjarapuOffice: 1122 CooverAmes, IA 50011Home: 2704 Valley View RdAmes, IA 50014Office: (515) 294-7687Home: (515) 292-3887Fax: (515) 294-4263vajjarap@iastate.edu

Team members:

Daniel Robinson (Team Captain)Mechanical Engineering151 University Village, Apt CAmes, IA 50010Cell: (515) 460-1819drobins@iastate.edu

Jeremy BoonMechanical Engineering2820 Lincoln Way #2Ames, IA 50014Cell: (515) 291-3220jerboon@iastate.edu

Godwin ItteeraElectrical Engineering4290 Birch LangeAmes, IA 50013Home: (515) 572-3559gitteera@iastate.edu

Douglas MilewskyComputer Engineering3218 Lincoln WayAmes, IA 50014Home: (515) 268-1569dmilewsk@iastate.edu

Nicholas OlsonElectrical Engineering4138 Fredericksen CtAmes, IA 50010Home: (515) 572-7880nolson1@iastate.edu

Rajdeep WadhwaElectrical Engineering4112 Lincoln Swing #216Ames, IA 50014Home: (515) 441-0284rajdeep@iastate.edu

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Closing Summary

The challenge of this project is to determine a way to design an electric drive using a supplied 10 hp Briggs and Stratton motor. It must be determined how the drive will be tested and how it will be setup.

Many different requirements and considerations will have to be looked at to make sure the design is feasible, functional, within SAE rules, safe and has not infringed on any patents or intellectual property.

The expected solution would be a full design of how the electric drive will be implemented into the Baja car’s existing setup. This design should include a list of all the components needed and documentation of where these components came from and why they are needed.

References

http://www.public.iastate.edu/~isusae/Baja/