SAE Formula Car

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					 SAE Formula Car
   EE Senior Design

Project Proposal – Part II

    January 17, 2002
       Dr. Leiffer

    Aaron Roepke
      Matt Lyles
      Steve Ruse
   Nathan Brown (Jr)
   Paul Hummel (Jr)
1.0 Introduction:

          The Formula SAE competition is a competition in which SAE student members

conceive, design, fabricate, and compete with small formula-style race cars. Universities

and Colleges from around the world create cars to compete in this competition. The cars

compete in several different competitions, including straight-line acceleration, autocross

racing, skid-pad performance, fuel economy, and endurance events.

          To produce the most desirable car possible, some amount of electronics needs to

be used to optimize the entire system. Foremost, an engine control system is needed. This

control system must be capable of running the engine in the most efficient way possible.

Fuel injection and ignition techniques will be employed, allowing the engine to produce

the maximum power while using a minimum amount of fuel. To accomplish this, many

aspects of engine operation & driver input must be monitored, and calculations made to

keep the engine operating in an optimal manner.

          Also desired is a data acquisition system for the car. The optimal system would

give vital information such as engine RPM to the driver, while transmitting a much wider

variety of data back to a pit crew. The data received by the pit crew will give a large

amount of information on the performance of both the car and the driver. This data will

be analyzed both in real time and after practice runs, and modifications will be made to

the car and the driving style to help gain the maximum performance from the car &


          Certain safety requirements prescribed by SAE dictate that other basic electrical

work will be needed on the car as well.
2.0 Requirements:


   -     Engines researched regarding fuel injection (FI) possibilities
   -     Engines selected to purchase and get engine running with FI system whether it be
         factory installed or FI kit.
   -     Data acquisition system used to collect sensor information.
   -     Dashboard driving instruments selected and calibrated with respective sensors.
   -     Consulting/assistance with electrical related work on the car.


   -     Engines to be researched:
              o Honda F1
              o Honda F2
              o Honda F3
              o Honda F4
              o Honda F4i (factory FI system)
              o Honda GSX (factory FI system)
   -     Fuel Injection system to be a kit system if not factory installed.
   -     Fuel Injection system/Engine to be running as soon as possible.
   -     Data acquisition system is to transmit data real-time to a “pit computer.”
   -     Pit computer should display information from sensors as well as log the data to a
   -     Data transmission rate should be 5-10Hz.
   -     Data acquisition system should collect the following data:
              o RPM
              o Speed
              o Engine temperature
              o Oil pressure
              o Fuel level
              o Acceleration (3 axis)
              o Steering angle
              o Gear position
              o Throttle position
              o Vibration levels (in specified areas)
              o Oxygen sensor in intake
              o Fuel flow rate
              o Exhaust composition
   -     Dashboard should have the following displayed (format):
              o RPM (analog)
              o Speed (analog or digital)
              o Engine temperature (digital)
              o Fuel level (digital)
              o Oil pressure (digital)
           o Shift light (Boolean)
           o Acceleration (digital)
   -   Dashboard instruments should be easy to see from different angles and light
   -   Dashboard instruments should be easy to read even during vibrations caused by
       race driving conditions.
   -   Consulting/assistance work may include, but is not limited to, wiring of brake
       lights, safety switches, paddle shifting, and active suspension.
   -   The main electronics should be packaged in such a way that they can be mounted
       outside the driver compartment.
   -   The electrical systems must be powered off a 12VDC 10A battery.
   -   The electronics should be of minimal weight.

Systems Block Diagram:


   Various Vehicle            Onboard                Dashboard
      Sensors              Microcontroller          Instruments

                                                                         Radio Receiver

                                                                           Pit Computer

3.0 Technical Approach:

Engine Controls:

              We have chosen to use the Honda F4i engine. The engine has a built-in

       fuel injection system. Software is readily available to interface with the ECM and
       to tune the engine for the restricted air intake. Honda engines are the standard

       among formula teams from last year’s competition. The engine will be tuned, by

       the EE group, for peak horsepower output on a dynamometer.

Data Transmitter:

              We have chosen to use standard analog sensors to collect the required

       data, because of the ease of acquiring such sensors and their simple interface.

       Several data streams will be tapped from the F4i’s onboard computer system.

       These data streams are sent to our microcontroller. The PIC16F77

       microcontroller has 8 analog inputs with analog to digital converters. The 8-bit

       precision will provide sufficient accuracy and precision for the required

       measurements. A second PIC16F77 will be used in tandem with the first in order

       to acquire the necessary number of analog signals. The microcontroller sends the

       data to its onboard serial module, which transmits at 9600 baud TTL logic to a

       TTL-to-RS232 converter and then to a 56.6K wireless modem via a standard

       serial port. The modem transmits the data at 900Mhz and 9600 baud to the

       wireless modem connected to the laptop. The transmission packet consists of a

       “data-type number” which specifies what sensor the data is coming from, and the

       data itself. The transmission size is two bytes (16 bits) per sensor. Our software

       system collects, displays, and will log all data in real time. Cost was a limiting

       factor, resulting in more manual programming and setup as compared to an off the

       shelf product. The connection speeds are more than sufficient to send and collect

       10 points per second for each of the sensors.

       The dashboard system will consist of the standard gauges for the Honda

       motorcycle, as well as an additional LED panel to display other necessary

       information. This method of dashboard instrumentation was significantly more

       cost effective than the use of an LCD panel.

Misc. Wiring:

                Other miscellaneous wiring on the car, i.e. brake lights, ignition system,

       safety fuel kill switch, etc will be preformed by the FormulaEE team.

4.0 Management Plan:

       The SAE formula team is made up of 22 members. The team is broken down into

five groups: Electrical/Controls, Powertrain/Drivetrain, Steering/Suspension,

Chassis/Body, and Brochure/Fundraising. Andy Dettmer is the overall project leader.

       The SAE formulaEE (Electrical/Controls) team is made up of 5 members. The

three seniors engineering students on the team include: Aaron Roepke (project leader),

Matt Lyles, and Steve Ruse. There are two junior engineering students on the team

assisting with the work specifically related to programming, Nathan Brown (EE) and

Paul Hummel (CSE). Each of the five groups reports to Andy Dettmer, the project

manager, at least once a week. Much of the assignments and communication will be

done through email and an online forum that has been setup for the formula team. The

entire formula team has a meeting once a week to discuss progress.

       The team will be using the senior design space and equipment in Engineering 3.

The team may also travel to UT Tyler to use their dynamometer. The responsibilities for

the spring semester are broken down as follows:

       Engine: Steve Ruse
       Onboard Computer: Aaron Roepke

       Sensors: Matt Lyles

       Pit Computer program: Nathan Brown, Paul Hummel

       Dashboard: Matt Lyles, Steve Ruse, Aaron Roepke

       Documentation: EE Team

       Packaging System: EE Team

5.0 Statement of Work:

       There are two main sections of work to be done on the FormulaEE project for the

spring semester: complete the main systems and wrap up the project.

       Completing the main systems consists of bringing the major sections of the

project, the engine, onboard computer, sensors, and pit computer program from the

preliminary prototype stage to full functionality. The engine must be started and tuned

on a dynamometer. The onboard computer system must be able to handle 16 analog

inputs instead of the current 8 sensors. This upgrade will include the use of a second

PIC16F77. The engine and vehicle sensors that are not included on the engine must be

purchased and formulas determined to relate the input stimulus to the 0-5VDC output.

Some sensors must be custom made to fit the formula team’s particular applications. The

sensors must be mounted on the car and tested. The pit computer program is functioning,

but still needs data saving capabilities added to it. Some minor problems exist in the pit

computer program that need to be worked through before the competition of the project.

       Some wrap-up type tasks need to be completed this semester also. The entire data

acquisition system needs to be packaged in a suitable enclosure. Final tests need to be

run the entire system after it is mounted in the car. Documentation needs to be written
for the entire system, including users manuals and technical specifications. Finally, the

car is taken to SAE competition in May.
6.0 Schedule:

                                    WBS     Duration
Complete Systems                    6
Engine                              6.1
Install new ECM                     6.1.1   1 day
Start engine                        6.1.2   7 days
Find dyno to use                    6.1.3   14 days
Tune Engine on dyno                 6.1.4   21 days
Onboard Computer                    6.2
Develop 2 PIC system                6.2.1   7 days
Program Master and Slave PICs       6.2.2   14 days
Test onboard computer system        6.2.3   14 days
Pit Computer                        6.3
Finish GUI                          6.3.1   35 days
Save data to file                   6.3.2   35 days
Sensors                             6.4
Determine linear equations          6.4.1   21 days
Construct custom sensors            6.4.2   21 days
Attach custom sensors to engine/car 6.4.3   14 days
Wrap-up Project                     7
Package Data Acquisistion System    7.1     14 days
Final Field Tests                   7.2     14 days
Documentation                       7.3     21 days
Instruction Manuals                 7.4     21 days
Final Demonstration                 8       1 day
SAE Competition                     9       1 day
7.0 Proposed Costs:

                                  Formula EE Budget
                                 Device              Est. Price    Actual Cost
 Dash Board Budget Standard Gauges               $          300.00 $    150.00
                   LED panel
    Radio Device   Transmitter/Receiver          $         150.00 $      63.86
  Data Acq Sensors Other sensors for DA          $         400.00
  Microprocessors PIC(s)                         $         100.00   Usage donated by Steve Ruse
                   programming board             $         200.00      $100.00
                   Final circuit board           $          20.00
                   Packaging/Chasis              $          25.00
                   Total                         $       1,195.00 $     313.86

8.0 Deliverables:

       By the completion of the project in May, our team will deliver an engine that is

functioning with a fuel injection system. The engine will be tuned to run with the air

intake restrictor plate that is defined by the SAE rules.

       The data from the full complement of sensors of the data acquisition system will

be relayed to the pit computer program that will display and save all data for later use.

The dashboard will be completed with all required information displayed for the driver.

Assistance and advice will be given to the mechanical engineering students in whatever

car wiring is necessary.

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