Objective: Provide Information Necessary to Relate Customer Requirements and Expectations s8

Project Readiness Package Rev 7/22/11

CLU ADMINISTRATIVE INFORMATION:

 Project Name (tentative): RIT EV Team TTXGP Transmission and Controls System Proof of Concept

 Project Number, if known: R12900

 Preferred Start/End Quarter in Senior Design: Fall/Winter Fall/Spring Winter/Spring

 Faculty Champion:

Name Dept. Email Phone Needed ME

 Other Support, if known:)

Name Dept. Email Phone Dr. Gomes ME [email protected] 585-475-2148 John Kennedy (EV TEAM IT [email protected] 914-275-1481 Club President) John Marshall: Virginia Tech ME [email protected] BOLT Team Leader Dan Taylor (Borg Warner) EE [email protected]

 Primary Customer, if known (name, phone, email): The RIT Electric Vehicle Team: Club President John Kennedy (914)-275-1481 [email protected] Vice President Dan Brownlee (619)-733-3466 [email protected]  Sponsor(s):

Name/Organization Contact Info. Type & Amount of Support Committed Electric Vehicle Team Primary Customer $400 (Pending new advisor) KGCOE MSD Funding $500

of 8 Project Readiness Package Rev 7/22/11

PROJECT OVERVIEW: This year the RIT Electric Vehicle club intends to compete in the TTXGP eGrandPrix competition. The TTXGP is an international electric superbike competition drawing teams from top electric motorcycle manufacturers and universities. The mission of the race series taken from the website is to have “an international race series providing a high profile platform for the development of electric vehicles. Using motorcycles as a resource effective development platform, TTXGP enables the futuristic technology behind them to be tested in an exciting and challenging way. TTXGP aims to drive low carbon technological innovation forward, to demonstrate that clean-emission transport technologies have matured and can be fun, fast and exciting”. The competition pushes teams to develop high performance drive trains capable of pushing their vehicles to perform at the highest level current technology allows while ensuring their power packs have enough juice to cross the finish line. The demands of racing force teams to explore new technology and new approaches to power train design in order to get the most out of their racing package. The club aims to be a part of this emerging industry, and establish a reputation as a world class player in the development of electric vehicles by incorporating electronic traction control and a multi-speed transmission into our vehicle. These technologies are ubiquitous in conventional ICE racing vehicles, but have yet to be used in the TTXGP. The club’s experience building their electric drag bike last spring has taught us the importance of proper gearing and automatic power modulation when excess torque is available. The senior design team will be creating a multi-speed transmission that will allow the motor to remain closer to its optimal rpm while still providing the power needed to accelerate the vehicle as fast as the limitations of the wheels allow. In order to compensate for the limitations of the wheels and the abundance of torque available in a high performance electric motor, the team will be creating an electronic traction control system that will limit the power available when the rear wheel begins to slip or the front wheel begins to lift. The first objective of the senior design project is to create a model demonstrating the effectiveness of a simple multi-speed transmission, a design for the transmission, and develop a traction control system and correlated test bench. The model of the transmission will allow the user to modify battery capacity and vehicle weight, the weight of the transmission, and the number and ratios of the gears of the transmission to determine what transmission design will best offset its weight with efficiency and best improve race performance. The model will allow us to determine whether the transmission will improve our overall performance vs. a conventional direct drive system. The team will then make a design of the the transmission that can be built by the the club. The second objective of the team will be to design a traction control system and construct a test bench on which it can be tested. The control system will include sensors for collecting data on the temperature of power train components such as the batteries, controller, and motor as well as motor rpm, front and rear wheel rpm, controller output voltage and amperage, battery voltage and amperage, power consumption, and efficiency in Wh/Km. The objective of the traction control system will be to prevent front wheel lift and rear wheel slippage under acceleration in order to increase the efficiency of the vehicle and improve handling. The combination of the two systems will allow the vehicle to accelerate much closer to its theoretical maximum while decreasing our overall power consumption. Should the systems prove to be effective they will provide the club with a significant performance advantage in the competition.

DETAILED PROJECT DESCRIPTION:

 Customer Needs and Objectives: Customer Need Category Description # CN1 Safe Meets all TTXGP race safety regulations CN2 Safe Be Controllable CN3 Enable Conform to all race regulations Participation CN4 Enable Can be integrated into an existing rolling chassis Participation CN5 Enable Be ready to integrate by end of winter 2012-2 Participation CN6 Efficient Be lightweight CN7 Efficient Consume minimal amount of electricity CN8 Provide Display drivetrain and vehicle parameters Feedback CN9 Provide Provide driver prompts (e.g. upshift, downshift etc.) Feedback

 Functional Decomposition: Specifications (or Engineering/Functional Requirements):

Unit of Customer Need Function Specification Measu Ideal Value Comments/Status Source re

Lbs on Performance S1 Amount of front wheel lift allowed front 0 Assume Even Weight Distribution COG Limits wheel Performance S2 Amount of rear wheel spin allowed sec .1 Assume Ideal Race/Track Conditions Limits Performance Allowable difference between font S3 % 10 Minimize Limit wheel and rear wheel RPM Total Time of race spent in high S4 Simulation Goal % 75 Maximize efficiency ranges

S5 Simulation Goal # of Transmission Gears # 3 Minimize Weight

S6 Simulation Goal Energy Remaining End of Race % 5 Minimize Battery Pack Weight

Real world comparison (times available S7 Simulation Goal Difference to fastest track lap time sec 0 on TTXGP website)

S8 Test Motor Power output HP 40 Perm132 DC

S9 Test Motor Power output Ft-lb 80 Provided By Club

Simulation S10 Wheel Base in 55.5 Taken From Brammo benchmark Constants Weight of competitor drivetrain Simulation S11 Total Weight Allowed lbs minimize (batteries/motor) minus weight of new Constant transmission straight line simulation, use series of Simulation S12 Race Length mi 20 running starts with average corner Constant speeds per course 100 (min) S13 Race Regulation Total Bike Weight Allowed kg 220 for Brammo Benchmark 300 (max) http://www.thunderstruck-ev.com/perm-pmg-132.html (Test Motor Perm132 Technical Information)

Constraints:

 Project Deliverables: o Optimized gear ratios identified. o Controls Planning and implementation of controls system into controller o Construction and assembly of bench test on peg board (motorcycle frame provided by club) o Proof of front wheel lift limit and drive wheel spin limit o Proof of mounting durability

 Budget Estimate: o Budget Includes Components for: . Controls Systems: Total $200  Motor rpm sensor  Throttle user input  Gear Position Sensor  Sensor to detect front wheel lift  Wiring Harness components . Controller (provided by club) . Motor (provided by club) . Micro Controller: $100 . Raw materials and mounting hardware for sensors: $100  Project Scope o Proof of concept peg board test of controls system with provided controller and active controls system in microcontroller. o Straight line race model simulation and duty cycle to show proof of energy efficiency gains by addition of transmission despite weight gains. o Vibration and durability testing of sensor mounting with ideal race bike in mind.

 Intellectual Property (IP) considerations:

 Other Information:

 Continuation Project Information, if appropriate:

STUDENT STAFFING:

 Anticipated Staffing Levels by Discipline:

How Discipline Anticipated Skills Needed Many?  EE1 o Design Active Controls system and wiring with data logging o Design controls peg board for simulation and testing w/ motor and batteries supplied o Design and perform testing and show proof of controls limits EE 2  EE2 o Spec out appropriate sensors and wiring harness o Construct controls wiring and sensors on peg board and design performance limits test. o If no CE student then write and code microcontroller for active controls system.  ME1 o Construct model of course based on simplified straight line acceleration and create duty cycle for transmission gearing optimization o Show proof of efficiency gains vs. additional weight  ME2 o Find optimal gears for a 3 speed transmission with middle gear based around direct drive gearing of current competitors o Simulate energy consumption with addition of transmission ME 3 and minimize onboard energy storage required to finish 20 mile race.  ME3 o Spec out appropriate transmission to make future purchase and future appropriate modifications o Draw in CAD software bench test and stand for supplied motor and future purchased transmission. o Design test procedure to show proof of front wheel lift limit. o Design test procedure to show proof of rear wheel spin limit. o Design of controls sensor mounting and durability analysis

OTHER RESOURCES ANTICIPATED:

Resource Category Description Available?

Faculty

ME, EE, CE consultants?

Environmen MSD Design Center t

EE Senior Design lab

Machine Shop & Brinkman lab

Equipment Power Supply Simulate Batteries/Charging

Materials Rolling Chassis for Mounting (Provided by EV team)

Raw materials and wiring connectors

Other $400 Club Funds

Perm132 DC Motor

Programmable Controller

Prepared by: Sean Harriman Date: 8/19/12

Top Twelve items to remember while designing to be ready for race day, note from discussion with John Marshall Head of BOLT at Virginia Tech:  Spend the money, get good batteries.  Design your pack so that it breathes (must be crash proof but don’t make a completely insulated box) this way water cooling won’t be necessary  Keep in mind the large factor of safety built in to industrial electric components, (if you keep them cool you can run them harder)  Don’t put things off, if you have something you can do get it done now.  You need way more testing than you think you will.  Determine the factor of safety you want, the electric bikes are notorious for breaking and I suggest consider being on the durable side  Determine a baseline profile that you know works before you go out making drastic changes and be able to come back to that.  Travel is the most likely way your bike will get damaged. Pit stuff:  Every time the bike goes on the track there should be a goal and you should learn something. DON’T waste track time.  Each person in the pit should have one job that is always their job, and they must do it quickly and efficiently and the same every time.  Have at least two sets of wheels for quick tire changes  Record every possible piece of data whenever the bike goes out and comes back