P15280: Hot Wheelz Test Bench

Problem Definition-Dyno

Table of Contents

Project Summary

The RIT Hot Wheelz Electrical Vehicle team is taking on a large challenge and building their first ever Formula SAE Electric vehicle. There is currently no method to test the electro-mechanical drive system. Due to the scope of the project, the team is in need of a user friendly, size appropriate testing platform. Key electrical drive system performance data, such as torque output and battery life, are required to optimize the system capabilities. Safe operation of the electrical components, smooth integration of the completed drive system onto the chassis of the vehicle, and the ability to verify the system's compliance to the SAE rules are desired. The project will be constrained by a limited budget, strict timeline and desired size limitations.

Project Goals and Key Deliverables

Expected end result of the project, what the customer can expect to receive at the end of the project.

User Scenarios

1. Hot Wheelz Team Member who is looking to test their electro-mechanical design for a long duration of time. May be looking at battery drainage or heat generated during a long run.

2. Hot Wheelz Team Member who is looking to test their electro-mechanical system for a short amount of time. May be looking at maximum power output over a short period.

3. Hot Wheelz Team Member who is looking to test their electro-mechanical drive system on manual mode. May be looking to troubleshoot faults in their system design.

Customer Requirements (Needs)

Customer Requirement Description Importance
1 Electro-Mechanical Drive System transferable from the test bench to the Vehicle 3
2 The Hot Wheelz Powertrain rigidly mounts to the existing KGCOE Dynamometer 9
3 Include a DAQ system to record and log performance parameters 9
4 Variable loading on the Electro-Mechanical Drive System 9
5 Electrically and Mechanical Safe for User 9
6 User Friendly Interface/ Simple to Operate 9
7 Targets faults in the system as they occur 3
8 Real time results are visible 9
9 Instruction manuals available to user 3
10 System has manual and automatic control features 1
11 Complies with all safety standards and rules in the Formula Hybrid SAE Rulebook 9
12 System is fully compatible with the components the Hot Wheelz Team has chosen for their car 9
13 System is easy to set up 3

Engineering Requirements (Metrics & Specifications)

Engineering Requirement Description Corresponds to Customer Requirement Measure Value
1 Electro-Mechanical Drive System mimics layout on vehicle. 1 in +/- 2 mounting locations within a 3' X 4' Area
2 Max Dimensions to Mount the Motor (Length, width, height not including space to mimic drive system layout) 2 in < (19 X 40)
3 Couple with Current Motor Shaft 2 in 9" up from the baseplate
4 Max Weight (Excluding Vehicle electro-mechanical system) 2 lb < 250
5 Software GUI will be Windows compatible. 3, 6 Binary NA
6 Vary the loading on drive system 4 lb-ft > EV motor
7 System set up time in dynamometer room 13 hr < 2
8 Emergency Fail Safe 5 Binary At least 1
9 Correctly Rated Components 5 Watts for resistors, V/I for fuses, AWG for Wiring 25% > than expected wattage for resistors, 15% > I ratings than expected for fuses, 25% > V/I for wiring in addition to using a step up in AWG size.
10 Adheres to all safety standards and limits per Formula SAE Rules 5, 11 Binary Article EV3-EV9
11 Current Sensors with LED indicators to identify error for troubleshooting 7, 8 Binary 1/accumulator segment
12 Display graphical representations of data as it is being collected versus time. Parameters such as torque and power consumption 8 Binary Display measurable parameters intuitively
13 Detailed manual for usage including power up, power down, LOTO procedure and how results are outputed for further use 9 Binary Video/PDF
14 Have a manual system testing and control. Also have automatic features so that user can input simulation of a course and iterate through for long term testing on the system. 3, 10 Binary Type of simulation
15 Data transfers reliably 7,8 Bit error rate Ideally 0
16 System is compatible with HPEV AC-35 144 V motor, Curtis 1239 Controller, Enerdell Custom Lithium-Ion battery packs, Gear ratio of 4 12 Volts, Amps Rated for 144 V and 550 Amps

Constraints and Current Gaps

1. Limited Budget determined by the RIT Hot Wheelz Formula SAE Electric Team

2. Strict Timeline- Must adhere to MSD I and MSD II Timeline and also be completed in time to test the electro-mechanical system for the vehicle prior to competition

3. Interdependence between MSD team and Hot Wheelz Team-Unknown vehicle specifications

4. Scheduling with other dynamometer users such as Formula SAE Team

--> Suggestion:Machine Shop Staff to manage Dynamometer scheduling

5. Unable to simulate exact loading- can only simulate linear ramp and step profiles

6. Integrating with the current Dyne Control

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