FLORIDA INSTITUTE OF TECHNOLOGY COLLEGE OF ENGINEERING

1. FLORIDA INSTITUTE OF TECHNOLOGY COLLEGE OF ENGINEERING Design Presentation Project: 2007 R.E.V. Team Presented By: Elizabeth Diaz Jason Miner Jared Doescher Josh Wales Kathy Murray AJ Nick Dave Wickers Oliver Zimmerman

2. Project Presentation Outline: • Project Scope • Team Organization • Engineering Objectives • Design • Cost Estimations • Time Estimations • Milestones • Resource Requirements • Conclusion

3. Project Scope: • Design and Build an electric racing vehicle • Promote community awareness of electric vehicles • Electric Car designed to compete in SCCA Autocross • Will meet requirements for the 2007 Formula Hybrid competition and NEDRA race competition

4. Team Organization: Team Lead Manufacturing Group Development Group Procurement Group Integration Team Design Teams Drive System Electrical Chassis & Body Vehicle Dynamics Driver Interface & Ergonomics • Battery Management • Instrumentation • Data Transfer System • Power Management • Suspension System • Steering System • Braking System • Motor • Drivetrain • Control System • Battery System • Cooling System • Shielding System • Chassis Redesign • Body Redesign • Mounting Points • Aeros/Ground Effects • Cockpit Design • Safety Equipment • Driver Interface

5. Team Organization: 2007 R.E.V. Design Teams Team Lead: Elizabeth Diaz Design Teams Drive System Team: Vehicle Dynamics Team: Chassis & Body Team: Josh Wales AJ Nick Kathy Murray Jason Miner AJ Nick Elizabeth Diaz Jason Miner Dave Wickers Elizabeth Diaz Jared Doescher Kathy Murray Electrical Team: Driver Interface Team: Matt Reedy Kristi Harrell Valerie Bastien Audrey Moyers Jason McSwain Oliver Zimmerman Elizabeth Diaz Audrey Moyers

6. Engineering Objectives: • Acceleration from 0 to 60 mph in under 5 seconds • Top speed of 80 mph • Maximum power available between 20 and 40 mph • Lightweight (under 650lb with driver) • 15 minute battery life for continuous draw

7. Design: Chassis Engineering Specifications • Static deflection – 0” (ideally) • Torsional Rigidity – between 1000-2000 ft-lbs/deg • Wheelbase – between 60” and 70” • Designed to fit 95 percentile person • Withstand stresses under dynamic and static loading

8. Design: Chassis Chassis Revisions

9. Design: Chassis Material Study • Options: Aluminum, Chromoly, Carbon Fiber • Decision Factors: Machinability, Weldability, Manufacturability, Strength, Cost, Availability • AISI 4130, Chromoly Tubing • 1-inch tubing with wall thicknesses of .095”, .065”, .049”

10. Design: Chassis Engineering Analysis Torsional Rigidity: 1100.78 ft-lbs/deg Static Deflection = .0056” (based on significantly weighted components) Chromoly Yield Strength = 63100 PSI

11. Design: Chassis Lane Change Video

12. Design: Side Pods • Battery Packs hold approximately 315 batteries • Battery packs compressed with 3-cell quick remove ability • Side pods designed for torsional rigidity • Each side pod supports weight of approximately 50 lbs of batteries

13. Design: Front Suspension

14. Design: Rear Suspension

15. Design: Electrical Batteries Lithium Ion Batteries A123 Systems Part Number: ANR26650M1 Nominal capacity and voltage: 2.3 Ah, 3.3 V Max continuous discharge: 70 A Operating temperature range: -30˚C to +60˚C Weight: 0.154 lbs (70g) Motor WarP 9 Motor 00-08219 Weight: 156.0 lbs Input Voltage: 96-144V Current Max:700 amps 32.3 HP – Continuous Rating 72.5 HP – Peak Rating Motor Controller Zilla Controller-Z1K-LV Weight: 15.5 lbs Max. Motor Amps: 1000 A Nom. Battery Voltage: 72 – 156 V Peak Power: 156,000 Watts System Diagram PLC EZPLC-D-96E: Voltage- 24V 96 I/O Max CPU Processor 32 Bit, 40 MHz Memory Available: 64 K Words Total Registers 8192 16Bit • Wireless Interface • 512 Ram • 1462 m Range • Small C – freeware with limited assembler User Interface EZ Monitor 5.7” Screen Displays vital system information from PLC

16. Design: Electrical Tachometer Analog display of the speed. Left side of main battery Displays the average voltage level of the batteries located on the left side. Changes color when any cell temperature is too high. Right side of main battery Displays the average voltage level of the batteries located on the right side. Changes color when any cell temperature is too high. User Interface Odometer Digital display of distance traveled. Main Screen RPM Displays revolutions per minute. Voltage Displays system main voltage. Current Displays system current. Timer Timer starts when “gas” pedal is initially pressed. Auxiliary battery Displays the voltage level of the auxiliary battery. Changes color when any cell temperature is too high.

17. Design: Electrical Individual Cells Displays the voltage level of the cell. Changes color when its temperature is too high. User Interface System Current Shows the system current. Battery Screen Average Temperature Displays the average temperature of the cells. Average Voltage Displays the average voltage of the cells. Power Displays the average percentage of voltage remaining in the cells. Cell Voltage Digital display of voltage. Cell Temperature Digital display of temperature. Auxiliary battery Displays the voltage level of the auxiliary battery. Changes color when any cell temperature is too high.

18. Design: Steering Wheel • Touch Screen for PLC mounted to steering wheel • Designed within constraints of touch screen and driver comfort • Quick release hub integrated behind touch screen

19. Design: Acceleration Pedal Design based around given Potentiometer Dimensions 1. Range of motion 2. Mounting holes All design dimensions based on functions due to missing Pot dimensions 1. Position links 2. Spring properties

20. Design: Brakes • The components of the brake system were taken from the 2002 FSAE Formula team’s car (the 69 car) • Wilwood Combination “Remote” Tandem Master Cylinder • Wilwood calipers and rotors built directly into the uprights • Brake calculations show that this setup provides enough braking force for our applications • Approximate stopping distance of 160 ft at 80 mph and 90 ft at 60 mph

21. Design: Wheels and Tires • The shells and centers or being reused from the 2002 FSAE Formula team’s car (the 69 car) • 13 inch three piece all aluminum Keizer shells • Tire selection was based on availability and distance for the tire to reach its optimum operating temperature • Using Goodyear 13” by 6.5” • Distance to reach operating temperature • 772.54 ft • Using Goodyear 13” by 7.5” • Distance to reach operating temperature • 1115.98 ft

22. Design: Drive System Front motor mount is designed to fit the frame, and to match the bolt pattern on the motor. Also, it’s designed to withstand the reaction forces of the motor. Front Motor Mount Rear motor mount is designed to fit the bolt pattern on the motor and constrain the back of the motor. Rear Motor Mount

23. Design: Drive System Kawasaki Prairie 700 4x4 Front Differential 4.375:1 Spiral Bevel Gear Reduction Lockable, Clutch Type Limited Slip Differential Cost: $455 Small, Light Differential Optimum Gear Ratio for usable torque at Wheels

24. Design: Body • Material for body is fiberglass because of weight considerations and formability. • Air vents added so that airflow can be directed across the controller and fed to the motor. Conceptual Design of Body

25. Cost Estimations:

26. Cost Estimations: Grand Total ~$34,000

27. Time Estimations: Mechanical Timeline

28. Time Estimations: Electrical Timeline

29. Milestones: • November 8 – Begin Build • January 19 – Finish Mechanical Build • January 20-21 – Battery Beach Burnout • March 30 – Finish optimization and testing • April 2 – Present completed car • May 1-3 – Formula Hybrid Competition

30. Resource Requirements: TOOLS: SPONSORS: PERSONNEL: • Bridgeport Machine • CNC Mill • Lathe • Band Saw • Drill Press • Welder • Tube Bender • Chassis Fixture • A-Arm Fixture • Lowes • C2 Design • Dr. Morrow – Team Advisor • Dr. Grossman – Team Advisor • Dr. Kozaitis – Team Advisor • Larry Buist – Electrical Tech. • Bill Bailey – Shop Supervisor/Welder • John Amero – Machinist • Stephanie Hopper – Lab Director • Kevin Abergel – Development • Brian Wright – Industrial Advisor • Jason Powell – Industrial Advisor • Larry Davis – Industrial Advisor FLORIDA TECH: • Dean’s Office • Development • Machine Shop • MAE Dept. • ECE Dept. WORK AREA: • Machine Shop • Work Bay • Trailer

31. Conclusion: We hope you enjoyed our presentation and would like to hear any questions, comments, or suggestions at this time. Your support is invaluable in helping is bring this project to a successful completion.