Welcome to Project 22

Power train Development for Formula Electric Vehicle

1 Project Overview

Oregon State University (OSU) has participated in combustion engine Formula SAE racing for many years. However, in 2011 it plans to participate in international racing using electric vehicles in the Formula Student Electric (FSE) class. The development of the race vehicle will be in collaboration with a German team. The consortium is referred to as GFR – Global Formula Racing. This group will deal with design of what is referred to as the “Tractive System” in the 2010 “Formula Student Electric Rules”.
The scope the project could be described as starting with wiring connecting to the Accumulator Isolation Relays and ending at the the electric motor. Also the scope includes Tractive System Master Switch and three emergency shutdown switches input to the Accumulator Isolation Relays. The requirements of the wiring is described later.
Because of the competitive needs of the vehicle, only a commercially built tractive control and motor are considered. The OSU SAE officers Bill Murray, Jeff Delany and Chris Patton are pursuing a donation of these items from industry. It is not known when these items will be chosen or acquired. Also, the actual vehicle chassis will be assembled in Germany and not available to us. Therefore, the design of the tractive system surrounding these key items must be flexible.
Project requirements are driven by the FSE rules and are listed below:
The tractive system must be completely insulated from the chassis or any other conductive parts of the car. A failure causing the control system to shut down must deactivate the tractive system.
The tractive system must have the ability for an insulation monitoring device (IMD) to be installed in the tractive system. This must be a Bender A-ISOMETER ® iso-F1 IR155, IR486, IR475LY3 or an FSE approved equivalent. In case of an insulation failure, the output of the IMD must break the holding current flow of the accumulator insulation relays to shut down the tractive system. The status of the IMD has to be shown to the driver by a red indicator light.
High voltage is defined as a circuit in normal operation carrying over 40 VDC or 25 VAC RMS.
All parts, especially live wires, contacts, etc., in the tractive system need to be isolated by nonconductive material or covers to be protected from being touched even with small tools.
Two tractive system voltage measuring points must be installed next to each other. These measuring points must be circular and must have a minimum diameter of 6mm. The measuring points must be made of conductive material and must be sealed in a housing that can easily be removed. They must be connected to the positive and negative Tractive Control supply lines.
All wires and terminals used in the tractive system must be reasonably sized and the wires must be marked with wire gauge, temperature rating and insulation voltage rating. Alternatively a serial number or a norm printed on the wire is sufficient if this serial number or norm is clearly bound to the wire characteristics for example by a data sheet.
All HV wires that are not protected by housings or enclosures must run in orange non-conductive cable channels.
Whenever the accumulator insulation relay is closed, or the voltage outside the accumulator containers exceeds 40V DC or 25V AC RMS, a light that can be seen in daylight must come on.
The tractive system must be appropriately fused. Any wiring of the tractive system must be fused with a smaller fuse value than the maximum rated constant current value for the used wiring.
2 Background Research
3 System Requirements and Desired Features
4 Design Solutions
5 Top Level Block Design

5.1 Motor Controller
5.2 Tractive System Active Light
5.3 Insulation Monitoring Device
5.4 Switches
5.5 Battery Simulator

6 Testing
7 Project Timeline
8 Test Evidence
9 Expo Materials
Team members from Left to right
Mohammed alarfaj Email: alarfajm@REMOVEengr.orst.edu
Jon Modrey Email: modreyj@REMOVEengr.orst.edu
Brian Barraugh Email: barraugb@REMOVEengr.orst.edu
Ahmad alhajji Email: alhajjia@REMOVEengr.orst.edu

Final Presentation Video
Click Here for the presentation

Mentors
DR.Robert K. Paasch paasch@REMOVEengr.orst.edu

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Useful webpage:
Motocysz
GFR

Documents:
Responsibility

Links:
Formula Student Electric Rules 2011
Planned Rules Changes
General Rules