2013 Electric Vehicle Grand Prix Championship Washington DC

1. 2013 Electric Vehicle Grand Prix Championship Washington DC

2. The Electric Vehicle Association, Greater Washington DC Charlie Garlow US EPA, EVADC

3. EVADC Sponsors EV racing

4. EVADC Sponsors Solar Education

5. EVADC Supports modern EVs

6. Solar Decathlon and California EV Challenge Richard King US DOE

7. The Washington DC Electric Vehicle Grand Prix Championship Dr. Nabih Bedewi Global EEE

8. Question? What do you get when you combine some of the latest technologies from Formula 1 racing, satellites, and F-16 jets with the most energetic and innovative minds in universities worldwide?

9. Advanced Kevlar and Nomex fabrication for solar panel substructure Aerodynamic body designs with thousands of hours of wind tunnel testing and computer simulations Advanced cockpit instrumentation and control interface Most efficient terrestrial and space grade solar cells Advanced telemetry systems and computer control Advanced peak power trackers and PV electronics Lightest and most efficient Lithium based battery technology Latest encapsulation films for solar array Sophisticated battery monitoring and management system Most efficient LED technology for turn signals & brake lights Most efficient custom wheel-mounted electric motors on the planet Advanced carbon-fiber composite chassis fabrication Lowest rolling resistance high performance tyres Lightweight and efficient custom wheels and low-loss bearings Lightweight and efficient low-scrub suspension and steering Sophisticated weather prediction and energy management/strategy systems and software Answer? Solar Race Cars

10. University Projects Engineering schools look for high school students with demonstrated involvement and hands-on experience with similar projects

11. Overview video New York State EV Competition

12. 2013 EV Grand Prix in DC • Opportunity for high schools in DC, MD and VA to get started • First year competition limited to “novice teams” • Cap on cost – level playing field • Partnered with NuGen Mobility to create kit • Minimize risk and unknowns for school/teacher • Allow time to build program, know-how and track record • Add more capabilities (design, welding, etc) following years • Plenty of room for technical creativity and innovation • Partnered with EVA/DC to support schools and event • Top finishers have opportunity to compete in Irvine, CA • Teams can participate in other competitions in the US

13. 2013 EV Grand Prix in DC • Competition to be held in DC Metro Area (location TBD) • F1 style closed track – 0.5 to 1 mile • One day race • Run on battery only • One hour heats • Longest distance wins • More than one team per institution may participate • Registration fee: $250 • Includes membership in EA – can compete elsewhere • Receive official car number and design/rules handbook • Covers track liability insurance

14. Awards • Overall Grand Prix winner – longest distance in one hour • Fastest 0.25 mile dash • Best overall graphics design • Sportsmanship • Best team photo • Best team video • Trophies, awards, cash prizes

15. Schedule • Registration deadline: January 5 • Kit orders: February 1 • Shipping considerations/lead time: 30 days • Kit delivery: March 5 • Construction time: March 5 to May 15 • Test/optimization/driver training: May 15 – June 15 • Race: week of June 15

16. Teacher and Student Support • Technical support available throughout • Assembly overview session when kits arrive • Guidance session for F&M students • Help students develop strategy and action plan • Assist with fundraising proposals • Critique “elevator pitch”

17. Vehicle Options

18. The Vehicle

19. What is important? • Efficiency • Motor • Controller • Charger (in between events) • Electronics • Tires • Vehicle weight • Driver weight not an issue – ballasted • Gear ratio selection • Strategy

20. DC Electric Vehicle Grand Prix Kit and Components Eric Takamura NuGen Mobility, Inc.

21. Key Categories • Chassis, Body & Wheels & Tires • Reliable • Tested • Easy to build / assemble • Drive System: Motor, Controller, connection and mounting • Reliable • Efficient • Correct operational Zones • Safety & Electrical • Five Point Seat belt • All components to complete safe, functional and reliable circuit • Power & Energy: Batteries & Battery Charger

22. Component Selection • Several suppliers exist • Time and decisions to make choices and find suppliers could take weeks if not months • Quality/performance varies • Knowing what is required • Cost: $4,500 - $5,500 • Individual Shipping is high • Adds another $500+ • Result: Logistic Nightmare • High risk • Unknown Costs

23. Key Objectives • Hands On Experience • Students focus on assembly, learning & Strategy • Don’t get bogged with logistics • Affordable and level playing field • Reduce effect that “$” win • Fun – • “Doable” : • “Competitive” • **** Safe !

24. Kit components • As mentioned, first year parts are standardized into kit • Experience: most suitable chassis/outer body - Blue Sky Design • Costs $1950 plus shipping from west coast ( $300) • Steel Chassis • ABS outer body and FRP seat pan • Acrylic tinted canopy • Wheels, brakes, steering

25. Kit Components • 24V High Efficiency electric motor • 24-48V, 300A controller • Reliable Sealed lead acid batteries • Compatible Battery charger • Five point seat belt system • Aluminum sprocket adaptor with freewheel and chain guards • Sprocket set (three, to allow different drive ratio's) • 20” rear and 16” front high pressure tires and tubes • All electrical components including sensors and display, battery power cable, copper connectors, 3 stage master power switch, main power fuse, shunt resistor, potentiometer for accelerator, foot pedal, etc

26. Estimated Effort • Rolling Chassis Assembly: 5 hrs • Electrical & Drive System Integration: 10 hrs • Outer body and canopy integration: 10 hrs • Vehicle paint, decals, other finishes: 10 hrs • Testing and adjustments: 15 hrs • Some of these tasks run in parallel (total under 50 hrs) • Group of 6-8 students can complete vehicle in 8 weeks

27. Ordering Procedures • Collect all orders at once • Everything ships to NuGen facility near Dulles Airport • Overall shipping costs reduced • Bring pickup or U-Haul to transport kits back to school • NuGen personnel available for technical support • Teacher session when kits arrive • Kit price $4,500 + shipping

28. Project Management, Marketing and Fundraising Charles Gabrial Deloitte and Touche

29. Project Management • Project teaches leadership, team work, and management • Create project organization chart • Faculty Adviser • Student Project Leader • Group leaders • Chassis, steering, wheels, brakes & tires group • Outer body and canopy group • Drive system and electrical group • Graphics design and paint/decals group • Marketing and fundraising group • Logistics and testing group

30. Project Management • Create and agree on project schedule and tasks upfront • Meeting days and times • After school M, W, F 3:00 PM – 5:00 PM • Saturdays 9:00 AM – 3:00 PM • Class time • All-hands team meeting at least once a week, not long • Student Project Leader review schedule and make updates • Marketing/fundraising group activities important • Schedule testing and optimization phase

31. Marketing • Important component of the project • Dovetails with fundraising • Recruit creative students not interested in the science • Create flyers, pamphlets, emails • Develop and maintain project web site • Use social media to rally the school community • Keep people informed • Announce fundraising and sponsor events • Solicit ideas and feedback for fundraising • Integrate with school PR to reach out to parents and alums

32. Marketing • Work with graphics design and paint/decals group • Hold student competition • Team/car name • Car and helmet colors and graphic design • Team uniform (T-shirt design) • Develop plan for sponsor logo space and size on car • Size proportional to sponsorship • Integrate throughout web site, T-shirts, pamphlets

33. Fundraising • Set realistic expectations for amounts and schedule • Understand school rules and guidelines for fundraising • May need commitment from school for front funding • Invite teachers, students, and staff to brainstorming session • Target corporate sponsors (car dealerships, stores in vicinity, etc) • T-shirt sales on campus • Car/team appearances at athletic events, sponsor locations • $1 drive around the parking • Grants: corporate/family foundations – www.foundationcenter.org • Create action plan, student elevator pitch – rehearse

34. Safety Dr. Tarek Omar FRA R&D - DOT

35. Overview • Safety is critical to the success of any student competition • Address it with the students early on in the project • Make it a culture of the project • When making any decision - is it safe? • No shame in asking for help or getting instructions • Always work in pairs, watch out for your buddy • Two aspects to safety • Phase leading up to competition (tools, lab, testing, etc) • Vehicle safety and the competition

36. Construction Phase • Use tools properly especially drills, saws, knives, etc. • Exercise care around electrical systems and magnets • Wear goggles and mask when cutting fiberglass • Insure proper ventilation • Use common sense

37. Testing Phase • Supervised testing of the vehicle on campus or parking lot • DO NOT drive the car on public roads • Initial testing at low speed • Adequate communication with driver (radios or vocal) • Team members surround test area with flags • Area well lit • Use common sense

38. Car Design Safety • Race rules specific about safety requirements • Chassis, roll bar, bumper • Outer body protection • Five-point seat belt • DOT certified helmet • Stopping distance • Head behind knees seating • Rearview mirror • Electrical disconnect and labeling • Driver egress • Cars will be inspected prior to, and during race • Any changes made to kits need to be reported and inspected

39. Drive Topology

40. Race Safety • Race safety rules will be published in advance • Learn meaning of flag colors (slow down, do not pass, etc) • Driver/teacher meeting prior to the race • Stewards will issue warnings and disqualify drivers • It’s a race against the clock, not other cars • Use common sense -- Have fun!