Frame Designer - UH Red Devils

Report
Team Members:
Instructor: Raresh Pascali
Daulet Urkenbayev
(Project Manager)
Paul Orieukwu
(Frame Designer)
Jonathon Fulbright (Electrical System Designer)
Rajeev Bhattacharya (Mechanical System Designer)
Underclassman: Matt Walsh
Competition Objective

To challenge teams of university students to conceive,
design, fabricate, develop, and compete with small,
formula-style hybrid-powered cars.

The formula hybrid competition is intended as an
educational program requiring students to work across
disciplinary boundaries.

To allow teams to freely express design, engineering,
and imagination.

Teams are allowed eight to twelve month to design,
build, and test for the competition.
1
Competition Scoring
STATIC EVENTS
HYBRID
Presentation
100
Engineering Design
200
DYNAMIC EVENTS

Acceleration - Electric
75
Acceleration - Unrestricted
75
Autocross
150
Endurance
400
TOTAL POINTS
1000
Top three teams that score the highest points will
receive trophies and awards.
2
Team Goal

Register for competition before slots fill.

Successfully implement switchable hybrid drive.

Finished curb weight not to accede 650 pounds.

Successfully implement data logging system.

Complete unrestricted 75 meter (246 feet) acceleration
run in 5.4 seconds or less.

Complete the final assembly by April 1.
3
What is a Hybrid?
Parallel Hybrid System Layout
Energy flows in 2 parallel
paths from reservoirs to the
wheels.
Series Hybrid System Layout
Energy flows in one path from
reservoir, through all
components, and finally to
the wheels.
4
Design Outlook
Both Parallel and Series configuration have different
advantages and disadvantages. This is why we plan to
implement a design that has the ability to switch between
the two. In theory, this should achieve the best of both
worlds.
5
Material Market Research
Material Consideration

Weight

Feasibility

Strength

Cost
Carbon Fiber
Yield Strength = 710684psi
Modulus of elasticity = 33000ksi
Aluminum
Yield Strength = 31000psi
Modulus of elasticity = 10000ksi
Steel
Yield Strength = 50800psi
Modulus of elasticity = 29700ksi
6
Conceptual Frame Design
University of Idaho
SAE Frame

Lawrence Technology University
SAE Frame
University of Houston
SAE Frame
Must meet the 95th percentile male and 5th percentile female
template.
7
Aerodynamic Devices
Back Wing
Front Wing
Diffuser

All of these device are used to increase the downforce on the
vehicle by manipulating the air flow.
8
Conceptual Design of Body
(1) McMaster University
(2) University of Idaho
(3) Embry-Riddle Aeronautical University

These are the top three teams who scored the highest in the
design category.

Expectation for our project is for it to be unique and
marketable.
9
Internal Combustion Market
Research
Subaru EX21 4 stroke engine
211cc- $479.97 (New)-7Hp
Lifan 250cc V-Twin Engine
4 stroke Air Cooled- $625
(Used)– $1099 (New)- 16.5Hp
Specifications:
Shipping weight: 35pounds
Displacement Range: 121cc/240cc
Horsepower Range: 3.6– 7.9Hp
Compression: 8.3:1
Carburetor Type: Float
Ignition System: Electronic
Cooling System: Air
Specification:
Displacement: 248cc
Max Power Output: 16.5Hp/8000RPM
Max Torque: 13feet/pounds. @ 6000RPM
Compression: 10:1
Ignition: Electric and Kick Start
Weight: 95pounds
Cooling: Air
10
Internal Combustion Market
Research Continued…
Kawasaki Ninja 250r Engine
4 stroke Liquid Cooled$450- $650 (used)- 37Hp
Specification:
Engine: Four-Stroke, DOHC, Parallel
Twin
Displacement: 249cc
Compression: 11.6:1
Cooling: Liquid
Ignition: Electrical
Transmission: Six Speed
Final Drive: 14inch Chain Sprocket
Power Output: 37Hp
Differential Market Research
$415 by Torsen Traction JTEKT
$2,699 by Taylor Industries.
$1000 Westgarage
Engineering Chain drive
LSD
12
Electric Motors Market Research
12.9kW PMAC ME1118
5kW Brushless DC Motor
Liquid Cooled
3kW Brushless DC Motor
Hub Motor
13
Controller Market Research
5kW Brushless DC
Motor Controller
RoboteQ HDC2472
Dual Kelly KEB72801
14
Batteries Market Research
LiFePO4 3.2V 60Ah x24
SLA 6V 12Ah x60
Ultra High Energy LG Lithium 18650
3.7V 2800mAh x420
15
Budget
#
Components
Cost
1
Frame & Body
$5,000
2
Internal Combustion Engine
$4,000
3
Electrical System
$7,500
4
Suspension, Brakes, Steering System
$3,200
5
Differential, Wheels, Tires
$1,500
6
Travel Expenditure
$4,350
7
Entry Fee
$2,150
TOTAL
$27,700
16
GANTT CHART
DAYS
9-Sep
29-Sep
3D MODEL BODY &
ATTENTUATOR
3D MODEL DIFFERENTIAL
8-Nov
28-Nov
18-Dec
TASKS
ORDERING PARTS
27-Jan
16-Feb
8-Mar
28-Mar
17-Apr
18
14
9
149
PHASE 2
SPONSORSHIP CAMPAIGN
7-Jan
46
PHASE 1
3D MODEL FRAME 3
19-Oct
28
42
35
CHASIS TESTING
22
AERODYNAMIC BODY
18
FINAL CAR ASSEMBLY
PHASE 3
29
DRIVING TEST &
TROUBLESHOOTING
29
PHASE 4
3
TRIP TO LOUDON, NEW
HEMPSHIRE
3
Completed (days)
Remaining (days)
17
WBS
PHASE 1
PHASE 2
PHASE 3
PHASE 4
10/21/14
03/28/15
04/24/15
04/31/15
Market
Research
70%
Sponsorship
Campaign
Final Assembly
Preparation
3D Model
Frame
Ordering
Parts
Driving Test &
Troubleshooting
Travel
3D Model
Body &
Attenuator
Frame
Fine Tuning
Arrival
3D Model
Differential
Assembly &
Construction
FEA
Frame
Body
Sub-frame
Suspension
& Steering
18
Risk Matrix
4
Risk Element
Part lost in mail
2
Defective components
3
Weight of car
4
Safety inspection
5
Error Codes (Controller)
6
Wire shorts
Catastrophic
9,7
10
Severe
5
Severity
1
1
3
High
6,8
Medium
7
Communication between IC
and Electrical components
8
Defective IC
9
Slow reimbursement
10 Delayed shipping
2
Low
Definite
Very High
High
Possible
Low
Probability
19
Questions?
20

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