2015 Project Plan Report

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1 2015 Project Plan Report Jack Haiston, (970) Tyler Norris, (513) Loren Christensen, (719) Nathan Houser, (970) Andrew Sullivan, (970) Darrin Minnard, (303) Phil Meister, (802) Jack Haiston Tyler Norris Loren Christensen Nathan Houser Andrew Sullivan Darrin Minnard Phil Meister Project Advisor Dr. Mitchell Stansloski Date Page 1

2 Table of Contents Introduction... 3 Problem Statement... 4 Objectives... 4 Constraints... 5 Design Evaluation & Work Plan... 6 Management Plan... 7 Conclusion... 8 Budget Request... 9 Works Cited List of Figures Figure 1: Project plan for the RREV Figure 2. Preliminary Budget... 9 List of Tables Table 1: Objectives for the 2016 RREV Table 2: Constraints for the 2016 RREV Page 2

3 Introduction The Society of Automotive Engineers established Formula SAE in It began as a Baja competition with highly defined rules limiting innovation that could be done. Shortly after the competition was created, a new competition called Formula SAE was purposed to allow for a greater range of innovation among the students competing. Formula SAE is a fictional manufacturing company contracted to design small Formula-style racecar for the amateur racing market. Each team designs, builds, and tests a prototype based on a well-defined compilation of rules purposed both to ensure safety and to promote clever problem solving. The competitions provide teams the chance to demonstrate their abilities with respect to innovation, creativity and engineering knowledge when faced with real world problems and constraints. Ram Racing was established in 1996 with the original Formula SAE competition, producing and competing with internal combustion cars. Currently, Ram Racing is headed by senior participating in senior design and supported by club members attending Colorado State University. Today s Formula SAE club is made up of underclassmen from a variety of disciplines, with the majority being Mechanical and Electrical Engineering students. While the main goal of this club is producing a fully functioning vehicle for the 2016 Formula SAE competition in Lincoln, Nebraska, we are also very concerned with teaching the underclassmen good engineering practices and preparing them for a future iteration of our racecar. During the competition, teams compete in three scored Static Events as well as four scored Dynamic Events. The Static Events include Design Judging, Cost Report, and Project Presentation, as well as a technical inspection that is not scored. The vehicle then competes in an Acceleration, Skid pad, Autocross, and Endurance events during the Dynamic portion of competition. Ram Racing 2016 has elected to continue with FSAE Electric and build the EV2 car for this year s competition. Our senior design team is utilizing similar EV1 design concepts and lessons learned from last year to become CSU s first competitive electric Formula SAE racecar. The partial reuse of last year s design is a key strategy because it allows for a longer testing period before it is brought to competition in June, Again, the senior design team is a joint project between the Electrical and Mechanical Departments at Colorado State University, which allows for better integration of electrical components and mechanical components. Page 3

4 Problem Statement This year s senior design team s primary goal is to learn from last year s problems and build the team s first running electric vehicle for the Formula SAE competition. By improving a few key aspects from last year s car, CSU s Formula SAE senior design team is looking to become the 1 st EV team to successfully pass Technical Inspection and compete in all events. Due to a short one year design cycle, the main constraint is time, causing the design phase to have an early start and begin in the summer months. The current design team will be modifying the aerodynamic package, suspension uprights, drivetrain, battery case and all electrical components to build a successful racecar. Team members of all levels will use prior engineering knowledge with the help of faculty members to manage any engineering problems at hand. Formula SAE represents a unique engineering opportunity for the schools that choose to compete in the event. The skills and knowledge developed from designing, validating, fabricating and testing a competition vehicle are beneficial to the careers of students after college. Objectives For the 2016 Ram Racing Electric vehicle (RREV2), the team is focused primarily on passing tech and finishing endurance, as this is where last year s team fell short. The next largest focus is on ease of maintenance of the car, primarily the battery case as seen below: Objectives Priority Rating 5-Highest 1-Lowest Table 1: Objectives for the 2016 RREV2 Method of Measurement (Theoretical) Method of Measurement (Actual) Objective Direction Target Car Mass 1 Model 4 Point Scale Decrease <600 lb Electrical Safety 5 Bench Test Field Test Pass Pass Tech Packaging Frontrear Weight 4 Point Scale Maintain Distribution Left-right Technical Inspection 4.5 FSAE Rules Competition Inspection Pass Pass Tech Auto Cross Time 2 Lap Sim Field Test/Data Log Decrease 55s on average FSAE course Battery Removal/Replace 4 Creo Model Field Test Decrease 30 minutes Time Endurance Length 4 Lap Sim Field Test/Data Log Increase 25 km Page 4

5 Constraints As stated earlier, the FSAE competition has a well-defined and very comprehensive set of rules to which all competition cars must comply. These rules restrict the design a significant amount as well as increase the challenge of the design in making sure the car adheres to these constraints. The following table outlines a few of the more important and challenging rules: Table 2: Constraints for the 2016 RREV2 Constraint Method of Measurement Limits Driving Factor Wheelbase Length in inches >60in. Track Width Width in inches >75% wheelbase Power Output Kilowatts <80kW Accumulator Voltage Volts 300 V DC Max FSAE Rule T2.3, pg 25 FSAE Rule T2.4, pg 25 FSAE Rule EV2.2 FSAE Rule EV1.1.2 Chassis Reused last year s design Packaging Team decision Suspension Inches of bounce and jounce 1in in both directions, min FSAE Rule T6.1 Funding Amount of money raised >$50,000 Budget Time Days until E-days April of 2016 Senior design Ideally the FSAE rules would be the primary driving factor behind design decisions, but because this is a senior design project with a design cycle of less than one year, time constraints must also be carefully considered and monitored to ensure the team is successful in executing their design. The limited time caused the need for some constraints that are based off of team decisions such as reusing the chassis. Reusing the chassis limits the design in most other areas due to packaging but allows for more time for manufacturing, assembly, and testing. Another main noncompetition driven constraint is money. The team is primarily self-funded, which limits some design decisions in order to keep within a reasonable budget. The budget was laid out at the beginning of the design to include all necessary components and reflects an amount the team believes is achievable. The budget is outlined in Figure 2. Page 5

6 Design Evaluation & Work Plan Work Plan The project timeline illustrates the overall expected build-cycle for electrical and mechanical designs, assembly, and test phases as well as financial aspects of construction. As issues or concerns arise, the timeline will be updated to accommodate any timeline changes (Figure 1). Figure 1: Project plan for the RREV2 Page 6

7 Key milestones include the project deliverables, financial sponsorship events, chassis completion, and competition dates in Lincoln, Nebraska. These dates do not indicate pass or fail conditions for the team, rather they are a rough guide from build time data acquired from previous FSAE teams. Design Evaluation The majority of the objectives and constraints for this project will ultimately be evaluated during either testing or at competition. It is crucial that the team utilize modeling and simulation software for all components as we do not have the time required to test, break, and redesign components and the overall design. To accomplish theoretical simulation and testing of systems, different software packages must be used. Creo is the general 3D CAD software used to design most of the mechanical components, such as chassis, suspension, battery case, and aero package. The electrical systems are designed in Solidworks Electrical and AutoDesk Electrical. The chassis undergoes a series of engineering analyses with ANSYS to determine torsional stiffness and deflection, while sample joints are tested with Instron to determine tensile strength. The suspension is analyzed in Optimum K. Optimum Lap is used to evaluate the drivetrain in order to find compromise between torque, top speed, and motor efficiency while drivetrain mounting is analyzed with FEA in ANSYS. CFD is used to model the aerodynamics of the vehicle. Circuits are analyzed in Cadence and Matlab SimElectronics. Build-testing is conducted through circuit analysis on oscilloscopes and multi-meters in a benchtop environment. Functionality tests are driven by the FSAE EV rules and include both benchtop and in-car environments. Management Plan The addition, club involvement helps to distribute design and manufacturing load and facilitates the program growth. However, having club members also adds a complexity to management by including additional people and weekly meetings. The Project Manager was recently assigned the role of club manager, directing more project specific responsibilities to the remaining team members. The team has included a business student as manager finances and budget, including fundraising. With many stakeholders, in the form of sponsors, it curtail to complete the car successfully, as well as provide progress to date. Page 7

8 Time management will be individual based. Every member is responsible for establishing a timeline that they feel will provide an adequate time to complete their design and manufacturing while still meeting the deadlines and milestones set by the project. The team has a no fail policy on all portions of the timeline. The no fail policy allows for a shift in resources from less crucial tasks to more crucial tasks to keep on track for meeting deadlines and milestones. An example of the policy at work would be if the suspension fixtures are running behind schedule the members working on bodywork and battery case would step in to help bring the fixture design back onto schedule to meet the deadline set. The biggest risks associated with the car involve shipping and customs of key items. To allow time for foreign parts to be shipped, orders will be place well in advance of intended arrival dates, allowing buffer time if parts are held at customs. These high risk items include the batteries and motor and are highlighted in the Gantt chart. Budgeting and money management is a large portion of designing a FSAE car. To keep everyone accountable and on track with budget spending decisions are made as a group. All high priced items are discussed and decided on by all members of the design and business teams. A preliminary budget including all parts needed for each subsystem was created. (Figure 2) This budget includes the prices needed to buy or produce everything that is not regularly donated by sponsors or being reused from past cars. Conclusion The Formula SAE design project can be considered as one of the most involved senior design projects at Colorado State University. One of the largest obstacles that the team anticipates is getting enough funding to build a competitive FSAE electric car. For assistance with the problem, the Ram Racing team has worked closely with a small team of business students, prepared to contact local businesses in hopes of receive the funding necessary for successful completion of the car. Another difficulty facing the team is the completion of all manufacturing and assembly of the car with enough time to test and train potential drivers before the competition date. In order to ensure the car is finished with ample test time, the team has decided to only redesign the components that failed on the previous RREV1. Ultimately the goal of this year s Ram Racing team is to pass technical inspection and complete all events at competition. To accomplish this task the team is going to utilize the assistance from all of the club members as well as the knowledge gained during our respected undergraduate studies. Page 8

9 Budget Request Item price per unit Number required Total Expenses Status Total Required RMS PM100DZ Controller $6, $6, Reused $0.00 Battery Pack $5, $5, New $5, Battery Management System $2, $4, New $4, Battery Connectors $ $ New $ Battery Charger $3, $3, Reused $0.00 Battery Cart $ $ Reused $0.00 Emrax 207 Motor $4, $4, New $4, High Voltage Componets $1, $1, New $1, Impact attenuator $ $ Reused $0.00 Steering Rack w/ sensor $1, $1, New $1, Low Voltage Componets $1, $1, New $1, PrePreg Carbon $1, $1, Reused $0.00 Chassis Tubes $2, $2, New $2, Carbon Tubes $ $ New $ Brake Components $ $2, New $2, Spring/Dampers $ $1, New $1, Bearings and Rod Ends $ $ New $ Rims $ $1, Reused $0.00 Tires $ $1, New $1, Taylor Race TRE Differential $2, $2, Reused $0.00 Pump $ $ New $ Radiator $ $ Reused $0.00 Safety Harness $ $ Reused $0.00 IR Tire $ $ New $ Gyroscope $ $ New $ Steering input $ $ New $ Speed Sensors $ $ New $ Sensata Crash Sensor $ $ Reused $0.00 ISO IR Monitoring Device $ $ New $ Testing Budget $5, $5, New $5, Car up keep $3, $3, New $3, Travel Budget, Lincoln $6, $6, New $6, Sponsorship Appreciation $1, $1, New $1, Misc 10% of budget $6, $4, TOTAL $66, $48, Figure 2. Preliminary Budget Page 9

10 Works Cited [1] SAE International, "FSAE Online," [Online]. Available: [Accessed 28 September 2014]. Page 10

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