Hybrid-Electric Drive for the SAE Mini-Baja Car
Project Plan
Project Number: May05-13
Client: Iowa State University, Society of Automotive Engineers
Faculty Advisor: Dr. Venkataramana Ajjarapu
Team Members: Daniel Robinson (Team Captain) Jeremy Boon Godwin Itteera Douglas Milewsky Nicholas Olson Rajdeep Wadhwa
ME ME EE CprE EE EE
Date: October 5, 2004
Table of Contents
List of Figures List of Tables List of Definitions
Page Number ii iii iv
Introductory Material
Abstract Acknowledgement Problem Statement Operating Environment Intended Users and Intended Uses Assumptions and Limitations Expected End Product and Other Deliverables 1 1 1 2 2 2 3
Proposed Approach and Statement of Work
Proposed Approach Statement of Work 4 6
Estimated Resources and Schedules
Estimated Resource Requirement Schedules 7 8
Closure Material
Project Team Information Closing Summery References 12 13 13
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List of Figures
Figure 1: Mini-Baja Car Figure 2: Diagram of series set-up hybrid-electric drive Figure 3: Gantt chart of tasks Figure 4: Gantt chart of deliverables
Page Number Title page iv 16 17
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List of Tables
Table 1: Group Schedule Table 2: Other Resources Table 3: Financial Costs
Page Number 15 17 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 this case, 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 Approach
There 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. Requirements List 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 considerations Physical 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. Technology Technology utilized for design. Hybrid vehicle Motors (DC) Generators Control systems
4. Technical approach Technical considerations for design team. Simulations Computer models Mechanical blueprints Electrical schematics 5. Testing requirements Lists 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 considerations The 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. Safety Safety 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 property Name 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 considerations Commercialization is not a consideration. There exists efficient, commercialized hybridelectric 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 management Possible problem areas and how to deal with them. Moving mechanical components; guarding will be installed o Nip o Pinch o Shear High current electronics; proper grounding and shielding 11. Project proposed milestones and evaluation criteria Team 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 attempt For 6 and 7, an explanation will be required along with the milestone. 12. Project tracking procedures Weekly reports will record individual contributions. End of semester evaluations to be administered by team-members and client. -5-
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 design 1b: 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 drive 2b: 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 perform 3c: 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 plan 4b: Team shall make a poster 4c: Team shall document the design 4d: 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 Schedules
The 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 Revise Project Task 2 – Paper Work Weekly Reports Every Week Unbound Design Report Status Report Revised Design Report Task 3 – Motor design Research Set specification Select Components
9/6/2004-9/17/2004 9/20/2004-10/5/2004
12 days 11 days
10/18/2004- 11/9/2004 10/18/2004-11/9/2004 11/15/2004 -12/15/2004
18 days 18 days 22 days
9/6/2004-10/4/2004 9/27/2004-10/8/2004 10/25/2004-2/18/2005
20 days 10 days 65 days
Task 4 – Map power and efficiency thru drive Block diagram 9/27/2004-10/8/2004 Mathematical Diagram 10/4/2004-10/15/2004 Task 5 – Circuit diagram Research Define system Design Error check and Compatibility
10 days 10 days
9/6/2004-10/4/2004 9/27/2004-10/8/2004 10/25/2004-3/04/2005 1/24/2005-3/04/2005
20 days 10 days 85 days 35 days
Task 6 – Battery selection/configuration Research 9/6/2004-10/4/2004 Set Specification 9/27/2004-10/8/2004 Select Components 10/25/2004-2/18/2005 Task 7 – Control System (program micro-controllers) Research 9/6/2004-10/4/2004 Design Control system 9/27/2004-10/22/2004 Program 10/25/2004-3/04/2005 Task 8 – Simulation Develop model Test specifications Task 9 – Design poster Design poster
20 days 10 days 65 days
20 days 20 days 85 days
10/18/2004-11/5/2004 11/9/2004-11/19/2004
15 days 10 days
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 Godwin Itteera Doug Milewsky Nick Olson Jeremy Boon Daniel Robinson Rajdeep Wadhwa Total Hrs
Task Task Task Task Task Task Task Task Task Total 1 2 3 4 5 6 7 8 9 10 10 11 9 20 14 66 20 20 20 20 20 11 111 40 20 0 0 0 0 60 0 0 0 25 20 0 45 40 0 100 0 0 40 180 20 0 0 0 0 0 20 0 104 0 0 0 68 172 5 5 5 5 5 5 30 20 0 20 25 20 20 105 155 159 156 84 85 158 797
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 utilized
Item Poster Power lab Baja Shop Totals
Team hours 12 40 35 87
Other hours 0 0 0 0
Cost $50 0 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 labor
Item Parts and Materials Poster Motors ( two) Briggs and Stratton engine Rectifier unit Alternator Subtotal Labor at & 10.50/hr Godwin Itteera Doug Milewsky Nick Olson Jeremy Boon Daniel Robinson RajdeepWadhwa Subtotal
W/o labor $50 $418 Donated $40 $25 $533
With labor $50 $418 Donated $40 $25 $533
$1627.50 $1669.50 $1638.00 $882.00 $808.00 $1659.00 $8284.00
Totals
$533
$8817.00
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Project Team Information
Acting client: Ethan Slattery Project Manager 2004-2005 ISU SAE Mini-Baja 1306 Iowa Cir Ames, IA 50014 Cell: (641) 821-0202 ejslap@iastate.edu
Jeremy Boon Mechanical Engineering 2820 Lincoln Way #2 Ames, IA 50014 Cell: (515) 291-3220 jerboon@iastate.edu Godwin Itteera Electrical Engineering 4290 Birch Lange Ames, IA 50013 Home: (515) 572-3559 gitteera@iastate.edu Douglas Milewsky Computer Engineering 3218 Lincoln Way Ames, IA 50014 Home: (515) 268-1569 dmilewsk@iastate.edu Nicholas Olson Electrical Engineering 4138 Fredericksen Ct Ames, IA 50010 Home: (515) 572-7880 nolson1@iastate.edu Rajdeep Wadhwa Electrical Engineering 4112 Lincoln Swing #216 Ames, IA 50014 Home: (515) 441-0284 rajdeep@iastate.edu
Faculty advisor:
Dr. Venkataramana Ajjarapu Office: 1122 Coover Ames, IA 50011 Home: 2704 Valley View Rd Ames, IA 50014 Office: (515) 294-7687 Home: (515) 292-3887 Fax: (515) 294-4263 vajjarap@iastate.edu
Team members:
Daniel Robinson (Team Captain) Mechanical Engineering 151 University Village, Apt C Ames, IA 50010 Cell: (515) 460-1819 drobins@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/
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