IIT Roorkee Hybrid Vehicle Project Information brochure

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IITalent does what it can; genius does what it must."

- Edward George Bulwer - Lytton

ments

» First IC engine car launched in 2011. »The only Indian team among the 30 registred international

teams to participate in Formula SAE Australasia 2011 held at Melbourne in Dec 2011.

» 1st position in the fuel economy. » First Indian team to finish the final 32 lap race in Australia. » 6th Position in the cost presentation. » 16th position in the final race (Endurance Event).

»The car was also exhibited in the design pavilion of AUTO EXPO 2012, held at New Delhi in Jan 2012.

Formula Student {FS) is world's most established and prestigious educational motorsport competition, run by the Institution of Mechanical Engineers. It receives a participation of about 150 teams from over 30 nations,

i and is a breeding ground for innovative and enterprising

The high performance plug-in hybrid electric vehicles participate in the class lA segment of the competition to compete with the conventional vehicles.

Teams are judged by the stalwarts of the automotive industry like team bosses of the Mercedes GP, Renault Fl and engineers of Airbus, shell, Jaguar-Land Rover, Electronics engineers at Bosch and other experts of the automotive industry.

Students are challenged to design and build a single seat racing car. They compete at Silverstone Circuit UK, the home of the British Grand Prix, in a 3 day event where the car's performance, design and sustainability as well as the student's ability to present the business case, is assessed.

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C O NCEPT H!::l

1 Suspension and Steering

• Multi-link A-arms, made from 1020 mild steel, with push/pull rod and bell-crank actuated spring-damper system. • Gas filled shock absorbers with custom springs made from Penske USA. • Rockers : CNC machined from Al 6063 T6 • Under-steered behavior in steady state. • Anti-Ackermann geometry

2 Powertrain • Drive motor : Air cooled Brushless DC (peak 30 kW, continuous 12 kW) (from Motenergy USA) • Motor controller : Brushless DC motor controller with regenerative braking feature allowing kinetic energy to be recovered from the motor and capable

of operating the motor at peak power with 72 V battery. • Battery : 72 V, 48 Ah Li-ion battery pack (Peak discharge current 450 A, max continuous discharge current 180 A) from China • Battery Management System : to check overcharge, undercharge, temperature, etc. • Generator : Air cooled Permanent Magnet DC (14kW peak power, continuous 6kW) • Engine : Air cooled 125 CC carbureted (9.64 Kw at 8500 rpm; 11.88 Nm at 6500 rpm) • Power Electronics : DC-DC convertor, Power flow control using MOSFET’s, IGBT’s and contactors.

3 Vehicle Control Unit

• Vehicle Controller based on FPGA: Several Control blocks including the inputs from acceleration brake pedal, BMS, engine generator servo control processed in parallel on single FPGA board.

• Engine Generator Voltage control using the Smith Predictor model by controlling the engine throttle through a servo motor.

4 Drive train • Differential : Limited Slip ATB having chain drive • Sprocket : Mild steel double stranded (final drive ratio 5:1)

5 Brakes • Front and Rear disc brakes, Dual piston fixed calipers (max deceleration 11 m/s2) • Regenerative braking • Potentiometer based regenerative brake pedal design

6 Wheel assembly

• Wheels : 13” x 6” light weight Al-alloy with customized wheel center • Tires : 20.5” x 7-13” Hoosier racing slicks • Hub and Uprights : CNC machined from Al 6351 T6

7 Roll cage & Body

• TIG welded 1020 mild steel space frame chassis • Fully triangulated space-frame with minimized bending of tube members. • Glass fiber body panels with semi aerodynamic package, front and rear wings analyzed in FLUENT.

8 Cooling • Air cooling of components using aerodynamics and forced convection. • Air enters from side pods and directed via ducts to the battery, motor, generator and engine. • Fan mounted at the air entry on the side pods.

9 Safety and Ergonomics

• High Voltage insulation conduits with safety glands and Insulation Monitoring Device • Crash sensor, Brake over travel switch, Brake Plausibility device • Impact attenuator in front and Firewall separating cockpit from drivetrain compartment • FIA certified 6 point safety harness • Glass fiber adjustable seat • Steering wheel with quick release • Dash Board : mater switch, LCD showing speed, temperature, expected distance that can be covered with current state of charge of the batteries, etc

Technical Features of 2013 Vehicle

Home of British Grand Prix

Previous Sponsors

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ANAND>> PRAMA~ fZJ J y 0 T I ROCKMAN INDUSTRIES llU.

OVERDRIVE 7. V. . 1/ f 1 I Ill U /IIIII SolldWorks

Dr. Pramod Agarwal Professor & Head Electrical Engineering [email protected]

Dr. Akshay Dvivedi Assistant Professor Mechanical Engineering +91-941176136 [email protected]

Digendra Singh Rathore Team Leader +91-8791194920 +91-9557020813 [email protected]

Saurabh Dudani Marketing Executive +91-7579087524 [email protected]

Virender Pratap Singh Marketing Executive +91-8266800562 singh. [email protected]

IIT Roorkee Hybrid Vehicle Project Information brochure

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