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2015 Formula Hybrid Rules

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2015 Formula Hybrid Rules 2015 Formula Hybrid™ Rules (Revision 2 – 10/15/2014) The Formula Hybrid trademark is owned by the Trustees of Dartmouth College Preface Welcome to the 2015 edition of the Formula Hybrid rules. You will find many changes in these rules. Most of these changes were made to increase the percentage of vehicles that arrive at the competition ready to pass tech inspection and compete in all the events. NEW! Project Management Component Formula Hybrid is universally recognized as the most difficult and challenging of all the SAE CDS competitions. Many new student teams become aware of the magnitude of this challenge late in the program, and find themselves unable to bring their projects to completion in time for the competition. This results in withdrawals, or arriving at the competition with an incomplete vehicle. Utilizing project management techniques effectively in a complex project such as Formula Hybrid will guide the team to a successful completion within the established deadline. The new Project Management component replaces the Marketing presentation, and requires two additional submissions during the year, as well as a presentation before a review board at the competition. The first submission is due in December immediately following the close of registration. We have added an introductory tutorial in Appendix K, “Application of the Project Management Method to Formula Hybrid” authored by Dr. Ed March, acting co-director of the Master of Engineering Management (MEM) program at Dartmouth. We cannot stress strongly enough the importance of each student team reading this document and applying the methods described. We can state with a great deal of confidence that those teams that utilize a structured project management process will score better at the competition than those that don’t. Formula Hybrid is planning a webinar to cover project management basics which will take place before the close of registration. Watch the Formula Hybrid announcements page http://www.formula-hybrid.org/students/announcements for details. On-Site Electrical Pre-Inspection With the assistance of volunteers from the IEEE Power Electronics Society (PELS) the first electrical safety inspections will begin three weeks before the competition at the team’s home institution. This will give teams more time to correct rules and safety issues that might be discovered by the inspectors. Changes in electrical rules. The majority of changes in the electrical rules (section EV) were drafted by the electrical tech inspectors to address what they had observed as areas of misunderstanding or confusion. We expect that you will find the rewritten rules easier to understand and to comply with. We look forward to seeing you at the competition! -The Formula Hybrid rules committee 2 © 2014 SAE International Rev. 2 - October 15, 2014 Formula Hybrid Committees -The Formula Hybrid Rules Committee: Mr. Daniel Bocci, Coppia Advanced Solutions, Inc. Mr. Chris Farmer, Consultant Mr. Douglas Fraser, P.E., Thayer School of Engineering, Dartmouth College Mr. Tom Gee, HEV Control Systems Manager, Ford Mr. Donald J. Gobeille Jr., P.E., Environmental Systems Products, Inc. (Ret), (Chief of Timing/Scoring) Prof. Heath Hofmann, University of Michigan Ms. Amy Keeler, Formula Hybrid Ms. Kris MacCartney, IEEE (Chief Presentation Judge) Dr. Jenna Pollock, Tesla Motors Mr. Michael Royce, Albion Associates (Chief Mechanical Tech Inspector) Prof. Charles R. Sullivan, Thayer School of Engineering, Dartmouth College Prof. Douglas W. Van Citters, Thayer School of Engineering, Dartmouth College (Chief Technical Examiner) Prof. Darris L. White, Embry-Riddle Aeronautical University Dr. Rob Wills, P.E., Intergrid, LLC (Chief Electrical Tech Inspector and Electrical Rules Chair) Mr. Bob Wimmer, Toyota North America (Chief Design Judge) Ms. Kaley Zundel, SAE -The Formula Hybrid Corporate Advisory Committee: Mr. Tom Blackburn, Engineer, Electrified Powertrain, Ford Mr. Jerry Bretz, Human Resource Business Partner, Powertrain Engine Engineering, Chrysler Mr. Dennis M. Brown, Engineering Group Manager, General Motors Ms. Nathalie Capati, Test Engineer, HEV/EV, Global Battery Systems Lab, General Motors Ms. Alba Colon, Program Manager, NASCAR Sprint Cup Series, General Motors Mr. Harold Flescher, Fellow, IEEE Mr. Randy Floresca, Test Engineer, Cell and Module Test, General Motors Mr. Doug Fraser, P.E., Technical Director, Formula Hybrid Competition, Dartmouth Mr. Tom Gee, HEV Control Systems Manager, Ford Mr. Wayne Haider, Electrified Powertrain Engineer, Ford Mr. Rob Iorio, Manager, Electrified Propulsion System Implementation Engineering, Ford Ms. Amy Keeler, Coordinating Manager, Formula Hybrid, Dartmouth Mr. Scott Lananna, Test Engineer, Abuse and Safety Testing, General Motors Ms. Kristen MacCartney, University Partnership Program Manager, IEEE Mr. Zachary Mendla, Test Engineer, General Motors Mr. Anthony Modafferi, Engineering Group Manager, Global Battery Systems, General Motors Ms. Tara Rahmanifar, Business Manager, Electrified Powertrain Engineering, Ford Ms. Iva Shallvari, Engine Controls & Software Engineer, Chrysler Mr. Joe Tolkacz, Senior Manager, Chrysler Dr. Rob Wills, P.E., Principal Engineer, Intergrid, LLC Mr. Bob Wimmer, National Manager, Environment Research, Technical and Regulatory Affairs, Toyota 3 © 2014 SAE International Rev. 2 - October 15, 2014 RULES CHANGES FOR 2015 For the benefit of the teams, we have provided a summary of the significant changes to the 2015 Formula Hybrid rules. It is not a complete list and is not binding. If there are any differences between this summary and the official rules, the Rules will prevail. Therefore, it is the responsibility of the competitors to read the published Rules thoroughly. Rule Number System Change Table 1 Battery Capacities Changed to use more relevant (2C) rate A1.3 Design Objectives Updated to emphasize efficiency Table 4 Required Documents Added Project Management documents A9.4.3 Web-based submission Added team responsibility for time/date accuracy T3.30.3 Monocoque Laminate testing Added section T4.5.1 Firewall rules Added note. T11.2.1 Critical fasteners Clarified and expanded allowable fasteners Figure 22 Critical fasteners Added illustration ARTICLE D3 Running in rain Clarified damp in addition to wet EV1.3.1 Elect Insulating Materials Added Note EV3.3.3 Accumulator container Clarified and added HV disconnects Figure 26 Accumulator segmenting Added illustration EV3.3.4 Accumulator disconnects Rewritten EV3.3.6 Accumulator indicators Removed analog voltmeter option EV3.3.9 Accumulator spacings Added spacing requirements and table EV3.4.2 Accumulator mounting Changed deceleration requirements EV3.4.5 Accumulator attachments Changed specs and added monocoque requirements EV3.6.6 GLV isolation Added grounding requirement for external connections EV3.6.8 AMS Shutdown Clarified and added specific requirements EV3.6.9 Team-designed AMS Reduced watchdog requirements EV3.6.10 AMS Test point Added requirements for test port with illustrations EV3.7.6 GLV system Added grounding requirement EV3.8 Pouch Cells Added requirements for pouch EV4.1.5(a) GLV TSV separation Clarified EV4.1.5(c-f) GLV TSV separation Added insulation requirements EV4.1.6 GLV TSV separation Clarified EV4.1.7 GLV TSV separation Clarified EV4.1.8 GLV TSV separation Added documentation requirement EV4.1.9 Plated prototyping boards Added restriction EV4.2 Positioning of tractive parts Added cross-reference EV4.4.4 Shrouded banana jacks Clarified EV4.4.9 Shrouded banana jacks Clarified Figure 29 Shrouded banana jack Added illustration EV4.5.8 Tractive wiring Added allowable cable EV4.5.10 Tractive wiring Added termination requirements EV4.5.12 Tractive wiring Added shield termination requirements EV4.7.1 High voltage disconnect Clarified EV4.7.2 High voltage disconnect Added definition of ‘ready to race’ EV4.7 HVD Tools are no longer permitted for removing HVDs EV4.7.6 HVD Added lockout requirement and referenced OSHA document EV4.7.7 HVD Added recommendation for HVD location EV4.8.3 Tractive activation Added note re. Ready to drive sound 4 © 2014 SAE International Rev. 2 - October 15, 2014 EV4.9.5 Pre-charge circuit Must operate regardless of startup sequence EV4.9.6 Pre-charge and discharge Added temperature considerations EV4.10 Tractive System Active Light Changed operating requirements EV4.11.2 Ready to drive sound Added frequency and loudness specs EV4.12 TS Voltage Present New Added additional indicator requirements EV5.1.5 Driver system reactivation Added remote reset prohibition EV5.1.6 Motors must spin free Clarified EV5.1.7 Shutdown circuits Added example state diagram EV5.1.8 Shutdown circuits Added compliance with state diagram requirement Figure 31 Shutdown circuits Added state diagram Figure 33 Master switch diagram Revised EV5.5.4 IMD operation Clarified shutdown requirements EV6.1.1 Fusing Added note referencing tutorial EV6.1.5 Fusing Added fuse location requirement EV6.1.6 Fusing Added branch fuse location requirement ARTICLE EV7 System tests Added note regarding test order EV7.3.1 Rain test Reworded rain test rule EV8.2.12-13 Charging connections Added charging port requirements S2.3 Pre-Competition inspection Added on-site electrical inspection S2.5(c) Electrical scrutineering Removed rain test reference ARTICLE S3 Presentation event ALL NEW Removed marketing – added Project Management D1.3 Safety procedures Added section D1.4 Vehicle integrity Clarified requirement – Electric drive must be functional ARTICLE D3 Running in the rain Added
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