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Newsletter - Illini Hybrid Racing

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					Official newsletter of the University of Illinois at Urbana-Champaign Formula Hybrid Team




October 2010                                                                                                       Newsletter
Motorola Awards 2010 Innovation                                                                                    Record Student
                                                                                                                   Involvement
Generation Grant                                                                                                       This year’s Quad Day and E-Night
                                                                                                                   were both great successes for the team.
                                                                                                                   Quad Day is a campus wide event permit-
                                                          students regardless of their formal degree program.
                                                                                                                   ting University of Illinois student organi-
                                                          The team works to create opportunities for stu-
                                                                                                                   zations to share their programs with the
                                                          dents from both engineering and non-engineering
                                                                                                                   entire student body. Located on the main
                                                          fields of study to cooperatively collaborate on engi-
                                                                                                                   quad on August 22nd, the event encour-
                                                          neering and science aimed at the construction of an
                                                                                                                   ages students to get involved, helping
                                                          open-wheeled formula hybrid racecar. The Formula
                                                                                                                   advance both their educational and so-
                                                          Hybrid Team is a primarily extra-curricular student
                                                                                                                   cial skills. E-Night, a similar event hosted
   The University of Illinois Formula Hybrid Team         activity funded through corporate, private and edu-
                                                                                                                   August 30th by the Engineering Council,
is the proud recipient of a 2010 Innovation Gen-          cational donations.
                                                                                                                   is a place for all students to come out,
eration Grant awarded by the Motorola Foundation.             The Motorola Foundation grant of $30,200 will
                                                                                                                   learn about, and get involved in engineer-
The grant targets organizations inspiring students        cover nearly one-third of the teams 2010-2011 fis-
                                                                                                                   ing oriented student organizations. Be-
to learn about and pursue careers in science and          cal needs. The team expresses our sincerest grati-
                                                                                                                   tween Quad-Day and E-Night, over 250
technology.                                               tude to the Motorola Foundation for supporting us
                                                                                                                   students expressed interest in joining the
   The Formula Hybrid Team is a registered student        and believing in the educational value of this extra-
                                                                                                                   team, signing up to receive regular team
organization at the University of Illinois open to all    curricular activity.
                                                                                                                   emails. The team has record participa-
                                                                                                                   tion and continually expands its organiza-
                                                                                                                   tion and goals to provide ample opportu-
                                                                                                                   nities for all interested students.




                                                                                                                     Interested students speak to team
                                                                                                                      members at the annual Quad Day
                 The 2010 chassis; powercoating services provided complements of

                                                                                                                      In this issue
                                Advanced Powder Technology, Inc


Off to a Strong Start                                                                                              Engineering the 2011 Racecar
                                                                                                                   and Looking Towards 2012
Team hard at work over summer and fall
                                                                                                                   Students Attend Motorola
   The University of Illinois For-    of Dieterich, Illinois. The team            The ECE Machine Shop, lo-        Innovation Generation
mula Hybrid Team is off to a          could not be happier with the bril-     cated on campus, modified the        Network Conference
strong start preparing for the        liant job, friendly service, and rock   motor shaft and motor housing
2011 Formula Hybrid Interna-          solid surface provided by APT.          to permit the encoder to be rigid-   2009-2010 Season in Review
tional Competition in Loudon,             With the car stripped, the team     ly attached to the rear of the mo-   Team Member Profile: Joseph
NH beginning May 1st. Over the        took the opportunity to modify          tor casing. This created a more
                                                                                                                   Paquette
summer members of the team            the drive motor and mount the           compact and robust package
stripped the 2010 chassis down        drive motor and generator to a          than the timing belt layout used     Plascore Donates Impact
to its bare frame, making way to      dynamometer for testing. In or-         last season. With the encoder        Attenuation Honeycomb
powdercoat the chassis and be-        der to get the best possible per-       installed and the motor mount-




                                                                                                                      7
gin design of the 2011 vehicle.       formance out of our AO Smith            ed in the University of Illinois
   Powdercoating services were
provided complements of Ad-
                                      E317 motor and Yaskawa A1000
                                      motor drive, we mounted an en-
                                                                              Grainger Power Lab, the team is
                                                                              ready to begin testing and tuning.              months until
vanced Powder Technology, Inc.        coder directly to the motor shaft.                                                      competition day!

University of Illinois at Urbana-Champaign Formula Hybrid Team
Visit our team website at www.illinihybridracing.com
Visit the Formula Hybrid International Competition Website at www.formula-hybrid.org
Illini Hybrid Racing                                                                                                                     October 2010


Engineering the 2011 Racecar
and Looking Towards 2012
    Due to a number of 2011 competition rule          begin design of the 2012 car. Due to the consid-
changes (especially one that limits the battery       erable complexity of a hybrid vehicle compared
pack voltage to 300V rather than 400V as in           to the standard Formula SAE all combustion sys-
2010) the team has decided to re-engineer the         tem, the team is moving to a two year design
2010 Formula Hybrid car over the course of the        cycle with a single vehicle completed each year.
Fall semester and bring it to the 2011 compe-         In other words, two vehicles will always be in de-
tition. Notable projects include modular battery      velopment, but staged one year apart. The first
pack design, cell-by-cell battery management          year targets a complete system design, followed
system development, chassis torsional rigid-          by manufacturing and assembly of all mechanical
                                                                                                                AO Smith E317 motor with shaft coupled
ity testing, dynamometer powertrain testing and       systems. The second year focuses on the man-
                                                                                                               encoder mounted for dynamometer testing
tuning, suspension simulation, open to limited        ufacture and integration of all electrical compo-
slip differential conversion, control strategy ad-    nents as well as final system testing and tuning.     Engineering Development, Design Validation,
vancement and optimization, repackaging of a              To help with documentation and to prevent         Production Validation, and Continued Compli-
200V motor drive, addition of a servomotor drive      propagation of errors from year to year, the team     ance Testing. Each component has a specific set
for improved power generation capabilities and        is implementing a design process modeled off of       of tasks that must be completed in order to pass
elimination of the engine starter motor, and com-     those used in the automotive industry. The pro-       to the next phase. Additionally, a 7-step method
plete redesign of the braking system.                 cess requires component owners to hold design         for problem solving will be utilized for resolving
    Also during the Fall semester, the team will      reviews that graduate the components through          failure issues.




Students Attend Motorola Innovation Generation Network Conference
   On July 12th, three formula hybrid team            by Sally Ride (first female astronaut), and a hand-   and Mathematics (STEM). The three team mem-
members, Dylan Erb (undergraduate general             ful of other group activities. The primary focus      bers found the event educational and returned
engineering), Emma Corley (undergraduate me-          of the event was the sharing of best practices        with a number of ideas on how to improve the
chanical engineering), and Gabriel Benavides                                                                effectiveness of the University of Illinois Formula
(Ph.D. aerospace engineering) attended the            “By bringing Formula Hybrid                           Hybrid Team as a collaborative and inspirational
2010 Motorola Innovation Generation Confer-                                                                 program. For example, the team now plans to
ence in Schaumburg, IL. The team gave a short         to K-12 students, the team                            integrate five K-12 educational events into the
presentation on the second day of the event in
a breakout session titled, “Innovation Genera-
                                                      hopes to help inspire the next                        teams 2010-2011 program. By bringing Formula
                                                                                                            Hybrid to K-12 students, the team hopes to help
tion University.” Additionally, during the day and    generation of young engineers”                        inspire the next generation of young engineers
a half event, the team members participated in                                                              that will eventually continue the legacy of great
networking sessions, panel discussions, pro-          geared towards inspiring young minds to seek          engineering at the University of Illinois, and more
gram demonstrations, a keynote address given          careers in Science, Technology, Engineering,          specifically, Illini Hybrid Racing.




2009-2010 Season
In Review
    The team officially became a University of Il-    cessfully raised ap-
linois Registered Student Organization (RSO)          proximately $32,000
in September of 2009 with just a handful of           in cash and in-kind
ambitious students with their sights set on at-       commitments        and
tending competition in May of 2011. How-              developed an ambi-
ever, before development could take place             tious plan to convert
on the car itself, substantial work had to be         the 2008 FSAE car
done to gain workspace and sponsors, lo-              to a hybrid system
cate a faculty advisor, recruit a wider member        in one semester.
base, and acquire tooling and raw materials.             After     reviewing
    The first challenge was gaining the support of    the teams revised
the U of I Engineering Design Council. The coun-      proposal, the En-            The team at the 2010 Formula Hybrid International Competition held at
cil not only offers matched funding, but work-        gineering        Design            New Hampshire Motor Speedway, Loudon, NH in May 2010
space in the Engineering Student Project Lab          Council granted the
(ESPL). In other words, the support of the Design     team $7,000 in matched funding in November           porters, the Illini Hybrid Race team completed
Council was essential for the start-up and long-      and space in the Engineering Student Project         an incredibly successful first season. Ultimately,
term success of the U of I Formula Hybrid Team.       Lab (ESPL) in late December of 2009. This left after a furious semester, the team raised over
However, while our initial two-year design-build      barely four months for the team to outfit the        $60,000 in cash and in-kind donations, assem-
plan provided sufficient time to effectively bring    shop, increase membership, redesign the FSAE bled its first proto-type, and brought the vehicle
our first car to competition, the council was clear   vehicle as a hybrid, locate sufficient sponsor- to competition in May 2010. While the first sea-
on the fact that they neither “provide seed fund-     ship, attain components, manufacture the ve- son was extremely hectic, it was also amazingly
ing” nor supported “two-year programs.” They          hicle, test, and finally travel to New Hampshire.    educational and rewarding for all the students in-
gave us one week to submit a revised proposal,        Though the task was clearly ambitious, the stu- volved. In the end, fifteen members of the team
with both proof of substantial sponsorship, and       dents were committed to meeting the challenge.       traveled to Loudon, New Hampshire, and tire-
a one-year design-build plan. Through the hard           Thanks to a team of dedicated students, en- lessly participated in the three day event, working
work of our founding members, the team suc-           thusiastic sponsors, and countless other sup-                                     continued overleaf


University of Illinois at Urbana-Champaign Formula Hybrid Team
Illini Hybrid Racing                                                                                                                   October 2010
2009-2010 Season In Review (continued from previous page)
with judges to meet every qualification of the me-    performed admirably in the static events. Thanks      first season has surely provided a solid founda-
chanical and electrical inspections. Though with      to the great sportsmanship of fellow competitors,     tion that shall make the 2011 season an even
some disappointment a fusing complication pre-        attention to detail provided by the judging staff,    greater success. Season One yielded 16th place.
vented participation in dynamic events, the team      and gracious support of countless sponsors, the       Season Two we aim for 1st.



Plascore Donates Impact Attenuation Honeycomb
   The impact attenuators for both the 2010 and 2011          curately determine its crush behavior due to its unique
Formula Hybrid cars feature an aluminum honeycomb             property of a constant deformation force throughout the
impact structure donated by Plascore Inc. This is an im-      stroke of the material. An aluminum honeycomb with
portant safety component as it slows the car down reli-       crush strength of 245 psi quasi-static nominal was se-
ably in case of a collision.                                  lected because it provided a sufficiently small attenuator
   The competition rules require that the attenuator stop     size to allow for convenient packaging in the front of the
the competition car, traveling at 7 m/s with an average       car.
deceleration of less than 20 g. The aluminum honey-              We would like to thank Plascore Inc. for their donation
comb was ideal for our purposes as it allows us to ac-        and valued support!



Team member profile                                                                      Joseph Paquette
Name: Joseph Paquette                                         Team position: Chief Mechanical Officer
Subsystem position: Chassis                                   Major: Undergraduate Mechanical Engineering
Graduation Date: May 2011                                     Hometown: Chicago, Illinois
   Joe Paquette, otherwise known as Joey “add more            his job, or working on classes, he likes to spend his time
heat” Paquette, is one of only a handful of leaders on        working on his own car or motorcycle. Noticing a trend?
the Illini Hybrid Racing Team. Joey is currently the chief    He is a classic achiever with a “need for speed”. From
mechanical officer for the 2010-2011 academic year as         changing timing belts on his car, to building fiberglass
well as the chassis team leader. Joey is a committed          panels for his restored café racer bike, he is always find-
student who also spends considerable hours working in         ing new ways to improve his toys.
the shop. You’ll find him testing the previous car, design-      Joey is a critical asset to our team and is devoted to
ing the new chassis, or just welding two random pieces        building the best car possible. He will show up at the
of metal together. He is one of the more experienced          shop at anytime of day or night, and is not afraid to learn
welders on the team and keeps himself busy by sharing         something new. Keep up the great work Joey, and when
his knowledge with fellow teammates.                          in doubt just “Add more heat!”
   When Joey isn’t working on the Hybrid car, working at                                                                    Joseph Paquette


                                                Why you should support Formula Hybrid
                                                   The automotive industry has sought after students partici-
                                                pating in Formula SAE since its conception in 1978. Qualifying
                                                for an internship at Ford Motor Company and Honda Motor
                      GOAL                      Company specifically requires Formula SAE involvement. The
                                                competition has acknowledged educational value.
                      $110,000                     With an annual budget in excess of $100,000, the Illini Hy-
                                                brid Racing Team at the University of Illinois seeks out funding

                      Current                   from a variety of resources in order to keep the team rolling.
                                                Monetary and in-kind donations made by our corporate spon-
                                                sors are often matched by either the University of Illinois Col-
                      $30,200                   lege of Engineering or College of Engineering departments. The
                                                donations that our sponsors provide are essential to the team’s
                                                success. The team expresses deep gratitude to our sponsors
                                                for making the whole project possible.


                      ➨                               2011 Team Sponsors                                              Interested? Contact us
                                                                                                                      today for more information
                                                                                                                      Postal address:
                                                                                                                      Gabriel Benavides
                                                                                                                      University of Illinois at
                                                                                                                      Urbana-Champaign
                                                                                                                      Department of Aerospace Engineering
                                                                                                                      306 Talbot Lab
                                                                                                                      104 South Wright Street
                                                                                                                      Urbana, IL 61801
                                                                                                                      Email:
                                   Your company could be here.                                                        Gabriel Benavides
                                                                                                                      benavids@illinois.edu
                                   ALL DONATIONS ARE FULLY TAX DEDUCTIBLE

Special thanks to the University of Illinois at Urbana-Champaign Formula SAE
and Baja SAE teams for their invaluable contributions to Illini Hybrid Racing

				
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posted:7/9/2011
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