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2016 Formula Hybrid Electrical System Form (ESF)

INTRODUCTION

The goal of the ESF is to ensure that vehicles are as safe as possible, and that they comply with the
Formula-Hybrid completion rules. The ESF is divided seven main sections:

1 – Overview
2 – Cables, Fusing & Grounding
3 – Isolation & Insulation
4 – Electric Tractive System
5 – Accumulator System
6 – Safety Controls and Indicators
7 – GLV System
The Cables and Fusing, and Insulation and Isolation sections are at the beginning of the ESF as
these are the areas where teams most often have trouble in complying with FH rules.

A clear, concise ESF will help you to build a better car. It will also help you to pass tech testing as
most common tech problems can be addressed before the car reaches the track.

IMPORTANT INSTRUCTIONS AND REQUIREMENTS


1. Every part of this ESF must be filled with content. If a section is not relevant to your vehicle,
mark it as “N/A” and describe briefly why not.
2. Leave the written instructions in place and add your responses below them.
3. All figures and tables must be included. An ESF with incomplete tables or figures will be
rejected.
4. The maximum length of a complete ESF is 100 pages.
5. Note that many fields ask for information that was submitted in your ESF-1. This information
must be reentered – in some cases will be different than what was entered in ESF-1, which
is OK.
6. When completed, this document must be converted to a pdf and submitted to:
http://formula-hybrid.com/uploads/

2016 Formula Hybrid ESF (Rev 0) i


Please submit any questions, corrections and suggestions for improvement to:
http://www.formula-hybrid.org/level2/support

REVIEW PROCESS
Once submitted, your ESF will be reviewed by at least two FH reviewers. One will be the designated
primary reviewer for your team.

Feedback on your ESF occurs through the Formula Hybrid upload system. You will receive emails
via this system from your reviewers offering guidance and feedback. You will also submit revised
versions of your ESF in this system. When you submit a revised ESF, please indicate the REVISION
DATE AND LETTER (starting with Letter A) and which sections have been updated in the following
table:

REVISION DATE:
REVISION: (A, B, C, etc…)

Section Revised (Yes / No)

1 – Overview
2 – Cables and Fusing
3 – Insulation and Isolation
4 – Electric Tractive System
5 – Accumulator System
6 – GLV System
7 – Safety Controls and Indicators
8 – Appendices / Datasheets

2016 Formula Hybrid ESF (Rev 0) ii


TITLE PAGE

Please include team logo, car picture, etc.

University Name: Illinois Institute of Technology


Team Name: IIT Motorsports
Car Number: 217

Main Team Contact for ESF related questions:

Name: Alejandro Pozo

e-mail: apozoarr@hawk.iit.edu

2016 Formula Hybrid ESF (Rev 0) iii


Table of Contents

TITLE PAGE ...................................................................................................................... iii

I List of Figures ........................................................................................................... vii

II List of Tables ............................................................................................................ viii

III List of Abbreviations ................................................................................................. ix

Vehicle Overview ........................................................................................... 1

Cables, Fusing & Grounding ........................................................................ 8


2.1 Fusing & Overcurrent Protection ....................................................................................... 8
2.2 Component Fusing ............................................................................................................ 8
2.3 System Wire Tables ........................................................................................................ 10
2.4 Grounding System .......................................................................................................... 12
2.5 Conductive Panel Grounding........................................................................................... 12

Isolation & Insulation .................................................................................. 13


3.1 Separation of Tractive System and Grounded Low Voltage System ................................ 13
3.2 Isolation & Insulation ....................................................................................................... 16
3.3 Conduit ........................................................................................................................... 17
3.4 Shielded dual-insulated cable.......................................................................................... 17
3.5 Firewall(s) ....................................................................................................................... 18

Electric Tractive System ............................................................................. 22


4.1 Motor(s)........................................................................................................................... 22
4.2 Motor Controller .............................................................................................................. 23
4.3 Tractive System Measurement Points (TSMP) ................................................................ 24
4.4 Pre-Charge circuitry ........................................................................................................ 24
4.5 Discharge circuitry........................................................................................................... 29
4.6 HV Disconnect (HVD)...................................................................................................... 30
4.7 Accelerator Actuator / Throttle Position Sensor ............................................................... 31
4.8 Accelerator / throttle position encoder error check ........................................................... 32

Accumulator System ................................................................................... 34


5.1 Accumulator System ....................................................................................................... 34
5.2 Accumulator Pack ........................................................................................................... 34
5.3 Cell description................................................................................................................ 36
5.4 Cell configuration ............................................................................................................ 37
5.5 Segment Maintenance Disconnect .................................................................................. 37
5.6 Lithium-Ion Pouch Cells .................................................................................................. 38

2016 Formula Hybrid ESF (Rev 0) iv


5.7 Cell temperature monitoring ............................................................................................ 42
5.8 Accumulator Isolation Relays (AIR) ................................................................................. 42
5.9 Accumulator Management System (AMS) ....................................................................... 43
5.10 Accumulator wiring, cables, current calculations ............................................................. 45
5.11 Accumulator indicator ...................................................................................................... 46
5.12 Charging ......................................................................................................................... 46
5.13 Accumulator Container/Housing ...................................................................................... 47

Safety Controls and Indicators ................................................................... 49


6.1 Shutdown Circuit ............................................................................................................. 49
6.2 IMD ................................................................................................................................. 52
6.3 Reset / Latching for IMD and AMS .................................................................................. 53
6.4 Shutdown System Interlocks ........................................................................................... 53
6.5 Tractive System Energized Light (TSEL) ......................................................................... 54
6.6 Tractive System Voltage Present light (TSVP) ................................................................ 54
6.7 Ready-To-Drive-Sound (RTDS) ...................................................................................... 55

GLV System.................................................................................................. 56
7.1 GLV System Data ........................................................................................................... 56
7.2 Electronic control unit ...................................................................................................... 57

Appendices .................................................................................................. 58
8.1 IMD specs and datasheet ................................................................................................ 59
8.2 Nomex paper specifications ............................................................................................ 61
8.3 Cell data – A123.............................................................................................................. 62
8.4 Analog to Digital Converter ............................................................................................. 63
8.5 Torque encoder – rotary potentiometers.......................................................................... 64
8.6 Brake sensor ................................................................................................................... 65
8.7 Motor controllers: AMC DPCANIE-100A400 .................................................................... 66
8.8 Accumulator isolation relays ............................................................................................ 67
8.9 Accumulator and Motor controller fuses .......................................................................... 68
8.10 Time delay relay: AUTOMATION DIRECT ST7P-2DE5S-ADC ....................................... 69
8.11 Omron relays: OMRON G2RL-2-24V .............................................................................. 70
8.12 Power resistors for pre-charge/discharge circuit: TE HSA50 1kΩ .................................... 72
8.13 DC/DC Converter 300V-to-24V : VICOR POWER DCM300P240T600A40 ..................... 73
8.14 DC/DC Converter 300V-to-24V: AIMTEC AM10EW-11024S-NZ ..................................... 74
8.15 DC/DC Converter 24V-to-12V: GE EHHD010A0B HAMMERHEAD ................................ 75
8.16 DC/DC Converter 24V-to-24V: MURATA UWE-24/3-Q12P-C ......................................... 76
8.17 DC/DC Converter 24V-to-5V: GE EHHD010A0B HAMMERHEAD .................................. 78
8.18 Voltage regulator 12V-to-5V ............................................................................................ 79
8.19 Low voltage battery 24 V ................................................................................................. 80
8.20 Low voltage BMS ............................................................................................................ 81
8.21 Dashboard ...................................................................................................................... 82
8.22 Banana Jack specs ......................................................................................................... 83

2016 Formula Hybrid ESF (Rev 0) v


8.23 CAN repeater: ESD Electronics: C.1330.06 – Repeater I Opto ....................................... 84
8.24 Optoisolator: Avago ACSL-6400-50TE ............................................................................ 85
8.25 TSVP lights ..................................................................................................................... 86
8.26 Molex cable data ............................................................................................................. 87
8.27 Molex receptacle data ..................................................................................................... 88
8.28 Hook-up wire 22AWG 300V ............................................................................................ 89
8.29 Hook-up wire 18AWG 300V ............................................................................................ 90
8.30 Hook-up wire 16AWG 300V ............................................................................................ 91
8.31 AlphaWire 10AWG .......................................................................................................... 92
8.32 Battery pack wire 4AWG ................................................................................................. 93
8.33 Main fuse: Edison JDL100 .............................................................................................. 94
8.34 Motor controller fuses: Edison EDCC30 .......................................................................... 95
8.35 Low power fuses: LittelFuse 477 Series .......................................................................... 96
8.36 High-Strength Electrical Insulating Ultem PEI .................................................................. 97
8.37 Continuous Flex Liquid Tight Conduit .............................................................................. 98
8.38 Electri-Flex Liquid-Tight Conduit ..................................................................................... 99

2016 Formula Hybrid ESF (Rev 0) vi


I List of Figures
Figure 1 – Electrical System Block Diagram .................................................................................... 3
Figure 2 – Drawings showing the vehicle from the front, top, and side ............................................ 4
Figure 3 – Locations of all major TS components ............................................................................ 5
Figure 4 – TSV - GLV Wiring Schematic ......................................................................................... 6
Figure 5 – TS and GLV separation ................................................................................................ 13
Figure 6 – Team Designed PCB Layout ........................................................................................ 14
Figure 7 – Firewall position 1 ......................................................................................................... 19
Figure 8 – Firewall position 2 ......................................................................................................... 20
Figure 9 – Firewall position 3 ......................................................................................................... 21
Figure 10 – Pre-charge/discharge circuit schematic ...................................................................... 26
Figure 11 Pre-charge/discharge PCB picture ................................................................................ 26
Figure 12 – Pre-charge voltage (at the motor controllers terminals) - time curve ........................... 27
Figure 13 – Pre-charge current (current through each resistor) – time curve ................................. 27
Figure 14 – Pre-charge resistance – time curve ............................................................................ 28
Figure 15 – Discharge voltage (at the motor controllers terminals) - time curve ............................. 29
Figure 16 – Discharge current (current through each resistor) – time curve................................... 29
Figure 17 – Discharge resistance – time curve .............................................................................. 30
Figure 18 – HVD wiring diagram.................................................................................................... 31
Figure 19 – Position of the throttle position sensor and ADC ......................................................... 32
Figure 20 Pull-down resistors of the thorttle sensors ..................................................................... 33
Figure 21 – Cell discharge curves: Voltage vs SOC at different C-rates ........................................ 36
Figure 22 – Cell configuration: Cell frames (I)................................................................................ 39
Figure 23 – Cell configuration: Cell frames (II)............................................................................... 40
Figure 24 – Cell configuration: Segment and frame assembly ....................................................... 41
Figure 25 – AIRs time/current chart for TE LEV100 ....................................................................... 43
Figure 26 – CAN repeater diagram ................................................................................................ 45
Figure 27 – Accumulator indicator schematic diagram .................................................................. 46
Figure 28 – Accumulator pack expansion limiter ........................................................................... 48
Figure 29 – Safety Shutdown Circuit Schematic ............................................................................ 49
Figure 30 – Location of Shutdown Circuit Components (I) ............................................................. 51
Figure 31 – Location of Shutdown Circuit Components (II) ............................................................ 52
Figure 32 – Wheel interlock position on the A-arms....................................................................... 53
Figure 33 – TSVP schematic ......................................................................................................... 54

Must be hyperlinked!

2016 Formula Hybrid ESF (Rev 0) vii List of Figures


II List of Tables
Table 1 – General Electrical System Parameters ............................................................................ 7
Table 2 – Fuse Table ...................................................................................................................... 8
Table 3 – Component Fuse Ratings ................................................................................................ 9
Table 4 – System Wire Table ........................................................................................................ 11
Table 5 – PCB Spacings ............................................................................................................... 14
Table 6 – List of componenets with TS and GLV connections ....................................................... 15
Table 7 – List of Containers with TS and GLV wiring ..................................................................... 16
Table 8 – Insulating Materials ........................................................................................................ 17
Table 9 – Conduit Data ................................................................................................................. 17
Table 10 – Shielded Dual Insulated Cable Data ............................................................................ 17
Table 11 – Motor Data ................................................................................................................... 22
Table 12 – Motor Controller Data .................................................................................................. 23
Table 13 – Motor controller fuse data ............................................................................................ 24
Table 14 – TSMP Resistor Data .................................................................................................... 24
Table 15 – Data for the pre-charge resistor ................................................................................... 28
Table 16 – Data of the pre-charge relay ........................................................................................ 28
Table 17 – Data of the discharge circuit. ....................................................................................... 30
Table 18 – Throttle Position encoder data ..................................................................................... 32
Table 19 – Main accumulator parameters ..................................................................................... 34
Table 20 – Main cell specification .................................................................................................. 37
Table 21 – SMD Data .................................................................................................................... 37
Table 22 – Cell Temperature Monitoring ....................................................................................... 42
Table 23 – AIR data ...................................................................................................................... 43
Table 24 – AMS Data .................................................................................................................... 44
Table 25 – Basic fuse data ............................................................................................................ 46
Table 26 – Charger data................................................................................................................ 47
Table 27 – Switches & devices in the shutdown circuit .................................................................. 50
Table 28 – Shutdown circuit Current Draw .................................................................................... 51
Table 29 – Parameters of the IMD ................................................................................................. 52
Table 30 – GLV System Data ........................................................................................................ 56
Table 31 – GLV Loads .................................................................................................................. 57

Must be hyperlinked!

2016 Formula Hybrid ESF (Rev 0) viii List of Tables


III List of Abbreviations

AC Alternating current
ADC Analog to Digital Converter
AIR Accumulator Isolation Relay
AMS Accumulator Management System
AWG American Wire Gauge
BMS Battery Management System
BOTS Brake Over Travel Switch
CAN Control Area Network
DC Direct Current
DOD Depth of Discharge
DPDT Double Pole Double Throw
ECU Electronic Control Unit
FH Rules Formula Hybrid Rules
HV High Voltage
HVD High Voltage Disconnect
IC Integrated Circuit
GLV Grounded Low-Voltage
GLVMS Grounded Low-Voltage Master Switch
IMD Insulation Monitoring Device
MC Motor Controller
PCB Printed Circuit Board
RTDS Ready To Drive Sound
SDB Shut-Down Button
SDC Shut-Down Circuit
SMD Segment Maintenance Disconnect
SOC State of Charge
SPDT Single Pole Double Throw
SPST Single Pole Single Throw
TS Tractive System
TSEL Tractive System Energized Light
TSMP Tractive System Measurement Point
TSMS Tractive System Master Switch
TSV Tractive System Voltage
TSVP Tractive System Voltage Present

(Add more as needed)

2016 Formula Hybrid ESF (Rev 0) ix List of Abbreviations


Vehicle Overview
Person primarily responsible for this section:

Name: Alejandro Pozo


e-mail: apozoarr@hawk.iit.edu

Check the appropriate boxes:

Vehicle is
☐ New (built on an entirely new frame)
☒ New, but built on a pre-existing frame (FSAE, FS, FH-HIP, FH electric-only, etc.)
☐ Updated from a previous year vehicle

Architecture
☐ Hybrid
☐ Series
☐ Parallel

☐ Hybrid in Progress (HIP)


☒ Electric-only

Drive
☐ Front wheel

☐ Rear wheel
☒ All-wheel

Regenerative braking
☐ Front wheels
☐ Rear wheels

☒ All wheels
☐ None

2016 Formula Hybrid ESF (Rev 0) 1 Vehicle Overview


NARRATIVE OVERVIEW
Provide a brief, concise description of the vehicles main electrical systems including tractive
system, accumulator, hybrid type (series or parallel) and method of mechanical coupling to
wheels. Describe any innovative or unusual aspects of the design.

Include the following figures:


 Figure 1 – an electrical system block diagram showing all major parts associated with the
tractive-system. (Not detailed wiring).
 Figure 2 – Drawings or photographs showing the vehicle from the front, top, and side
 Figure 3 – A wiring diagram superimposed on a top view of the vehicle showing the locations
of all major TS components and the routing of TS wiring.
 Figure 4 -- Include a complete TSV wiring schematic per FH Rule S4.4.1 showing
connections between all TS components. This should include accumulator cells, AIRs, SMDs,
motor controller, motor, pre-charge and discharge circuits, AMD, IMD, charging port and any
other TS connections. NOTE: Figure 4 is the most important diagram in the ESF

The powertrain is based on a 4 wheel drive configuration. The motors are Brushless DC motors, in-
wheel, with no transmission. As shown in Figure 1 – Electrical System Block DiagramError!
Reference source not found., each motor is independently controlled with its own motor controller.
Power is provided by a battery back with a configuration 80s1p, composed of Lithium iron phosphate
(LiFePO4) cells. All the systems required by the rules are present in the design and will be covered
in detail. These systems, together with the battery pack, motor controllers and motors will
continuously monitored and controlled by the electronic control unit (ECU).

2016 Formula Hybrid ESF (Rev 0) 2 Vehicle Overview


Figure 1 – Electrical System Block Diagram

2016 Formula Hybrid ESF (Rev 0) 3 Vehicle Overview


Figure 2 – Drawings showing the vehicle from the front, top, and side

2016 Formula Hybrid ESF (Rev 0) 4 Vehicle Overview


Figure 3 – Locations of all major TS components

2016 Formula Hybrid ESF (Rev 0) 5 Vehicle Overview


Accumulator container
AIR Motor controllers
MC fuses (30A)
plug
30A MC 1 M
Main 30A

100A
MC 2 M
Fuse 30A
MC 3 M
Precharge/ 30A
discharge MC 4 M
24V (A IRs)
AMS Charger
A MS DO/ central plug
CAN
unit

2A
12V HVB
AIR 70k 70k

GLVMS
Signals (A MS DO) 24V (A IRs)
10A
CAN
12V/GND

TSMP LV bat
HVD
SB(R) LV battery (24V)

SB(L)
High Voltage Box (HVB) 24V
TS – Galvanic Isolation - GLV
10A

10A 5A Motor
HV DC/DC 1
controllers
12V
8A
DC/DC 5 Cooling
radiators
24V (TS VP )
1A
HV DC/DC 2 TSVP

IMD Fault
HV HV IMD 2A 24V
Shutdown circuit
2A 2A

24V
2A
24V (A IRs) 24V (A IRs) DC/DC 3 24V (A IRs)
24V Pedals Lights

2A 24V 12V 2A

12V DC/DC 4 TSEL 0.5A

Brake 1A
VR 0.5A 12V
Optocoupler (x4) 12 to 5 RTDS 0.5A

AMS DO AMS DO
ECU &
24V
Signals (A MS DO) 1A 24V 12V
2A
2A Breakout
CAN
12V/GND CAN CAN repeater board
CAN

Dash

Figure 4 – TSV - GLV Wiring Schematic

2016 Formula Hybrid ESF (Rev 0) 6 Vehicle Overview


Fill in the following table:

Data
Item

Nominal Tractive System Voltage (TSV) 264 VDC

Max. TSV (typically this is during charging) 288 VDC

Control System voltage (GLV) 24/12 VDC

Total Accumulator capacity (Wh)1 264*19.5*0.8 = 4118 Wh

Accumulator type (Lead-acid, Li-Ion, NiMH, Ultracap..) LiFePO4

Number of electric motors, total 4

Are wheel motors used? ☒Yes / ☐ No

Table 1 – General Electrical System Parameters

1
Calculate accumulator capacity per 2016 FH Rules Appendix A. Be sure to use the 2C (0.5 hour)
discharge rate for the Ah value.

2016 Formula Hybrid ESF (Rev 0) 7 Vehicle Overview


Cables, Fusing & Grounding
Person primarily responsible for this section:

Name: Alejandro Pozo


e-mail: apozoarr@hawk.iit.edu

2.1 Fusing & Overcurrent Protection

List TS and GLV fuse (or circuit breaker) data, and where used

Fuse Part Cont. DC Voltage DC Interrupt Where Used


Mfg.
Number Rating (A) Rating Rating (A)
TE Kilovac LEV100 100 900 1000 (break) AIRs
Edison JDL100 100 300 20,000 Main fuse
Edison EDCC30 30 300 20,000 Motor controller fuses
Littelfuse 477 Series 0.5-12 400 1,500-400 High voltage low power fuses (IMD,TSVP,etc.)
Littelfuse 477 Series 0.5-12 400 1,500-400 Low voltage low power fuses (GLV)
Copper ATC Series
10A 32V 1,000 Low voltage battery box
Industries Blade fuse

Table 2 – Fuse Table

2.2 Component Fusing

List major components (e.g., motor controller, dc-dc converter) and data sheet max fuse rating.
Ensure that the rating of the fuse used is less than the maximum value for the component
Max. Installed
Fuse Part Notes
Component Fuse Fuse Rating
No.
Rating A A

2016 Formula Hybrid ESF (Rev 0) 8 Cables, Fusing & Grounding


Main Fuse JDL100 140A 100A
Motor controller EDCC30 55A 30 Input fuse rating not specified
After the AIRs to feed TS voltage to GLV, TSVP
TS connection to DC/DCs 477 Series 14A 2A
and IMD. PCB ref.: F2 in HVB2 (TS side).
Output fuse to GLVMS. PCB ref.: F3 in HVB2 (GLV
300V/24V DC/DC (24V) 477 Series 20A 10A
side).
Output of the LV battery to the GLVMS. Inside LV
24V from LV bat. To GLVMS ATC Series 20A 10A
battery box.
From the GLVMS to +24V GLV system. PCB ref.:
24V from GLVMS 477 Series 20A 10A
F8 in HVB1 (GLV side).
Output fuse to TSVP light. PCB ref.: F10 in HVB2
300V/12V DC/DC (12V) 477 Series 1A
(GLV side).
Output fuse to BMS +12V power supply. PCB ref.:
24V/12V DC/DC (BMS) 477 Series 2A
F11 in HVB1 (TS side).
Protection for IMD from +24V GLV system. PCB
IMD +24V supply 477 Series 14A 1A
ref.: F1 in HVB1 (GLV side).
Protection for Pre-charge/Discharge from TS
Pre-charge/Discharge 477 Series 14A 2A
system. PCB ref.: F1 in Pre-charge/Discharge.
Protection for shutdown circuit from +24V GLV
Shutdown Circuit 477 Series 14A 2A
system. PCB ref.: F6 in HVB1 (GLV side).
From the shutdown circuit, before DC/DC for AIRs.
24V/24V DC/DC 477 Series 3A 2A
PCB ref.: F12 in HVB1 (TS side)
Protection for CAN repeater from +24V GLV
CAN repeater 477 Series 1A
system. PCB ref.: F7 in HVB1 (GLV side).
Protection for voltage regulator from +24V GLV
12V/5V Volt. Reg 477 Series 1A
system. PCB ref.: F9 in HVB1 (GLV side).
Protection for MC 24V supply from +24V GLV
Motor controller (24V) 477 Series 14 5A
system. PCB ref.: F5 in HVB1 (GLV side)
Protection for Radiators 12V supply from +12V
Radiators (12V) 477 Series 14 8A
GLV syst. F15 in HVB1 (GLV side).
Protection from +12V GLV system. PCB ref.: F1 in
Brake light 477 Series 7 1A
NI_Breakout.
Protection from +24V GLV system. F2 in
RTDS siren 477 Series 7 1A
NI_Breakout.
Protection from +24V GLV system. F3 in
TSEL light 477 Series 7 1A
NI_Breakout.
Protection from +12V GLV system. F4 in
LEDs in Dash board 477 Series 5 1A
NI_Breakout.

Table 3 – Component Fuse Ratings

2016 Formula Hybrid ESF (Rev 0) 9 Cables, Fusing & Grounding


2.3 System Wire Tables

List wires and cables used in the Tractive System and the GLV system - wires protected by a fuse of 1 A or less may be omitted.
Cable capacity is the value from FH Rules Appendix E (Wire Current Capacity). A revised version of Appendix E that includes metric
wire sizes is available at the FH web site. Show available fault current and how calculated. Available fault current can be calculated from
𝐹𝑎𝑢𝑙𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 = 𝑉𝑠𝑜𝑢𝑟𝑐𝑒 / (𝑅𝑠𝑜𝑢𝑟𝑐𝑒 + 𝑅𝑤𝑖𝑟𝑖𝑛𝑔)

Size Insul- Fuse Interr- Where Used & How fault current is
Volt. Temp. Cable Fuse Fuse Avail. Fault
Mfg. Part No. AWG / ation upting Rating calculated
Rating Rating Capacity A Part # Cont. A Current A
mm2 Type Adc
Accumulator high power wiring
McMaster-Carr 6848K92 4 EPDM 600 90°C 140 JDL 100A 20,000 2400A 𝑉
𝐼𝐹 = 𝑆⁄𝑅 = 288⁄0.12 = 2400𝐴
Motor controller plugs
AlphaWire 6719 10 mPPE 600 90°C 55 30A 20,000 2400A 𝑉
𝐼𝐹 = 𝑆⁄𝑅 = 288⁄0.12 = 2400𝐴
mPPE+ Motor controller plug – motor
AlphaWire 6719 10 Polyest 600 90°C 55 EDCC 30A 20,000 1920A controllers-motors
𝑉
er 𝐼𝐹 = 𝑆⁄𝑅 = 288⁄0.15 = 1920𝐴
Hook-up wire (TS, GLV)
477 TS: 1920A 𝑉
McMaster-Carr 6513T1 22 PVC 300 105°C 3 1A-10A ≥ 400 𝑇𝑆: 𝐼𝐹 = 𝑆⁄𝑅 = 288⁄0.15 = 1920𝐴
Series GLV: 400A
𝑉
𝐺𝐿𝑉: 𝐼𝐹 = 𝑆⁄𝑅 = 24⁄0.06 = 400𝐴
Hook-up wire (TS, GLV)
477 TS: 1920A 𝑉
McMaster-Carr 6513T3 18 PVC 300 105°C 18 1A-10A ≥ 400 𝑇𝑆: 𝐼𝐹 = 𝑆⁄𝑅 = 288⁄0.15 = 1920𝐴
Series GLV: 400A
𝑉
𝐺𝐿𝑉: 𝐼𝐹 = 𝑆⁄𝑅 = 24⁄0.06 = 400𝐴
Hook-up wire (TS, GLV)
477 TS: 1920A 𝑉
McMaster-Carr 6513T4 16 PVC 300 105°C 20 1A-10A ≥ 400 𝑇𝑆: 𝐼𝐹 = 𝑆⁄𝑅 = 288⁄0.15 = 1920𝐴
Series GLV: 400A
𝑉
𝐺𝐿𝑉: 𝐼𝐹 = 𝑆⁄𝑅 = 24⁄0.06 = 400𝐴
McMaster-Carr 6513T4 16 PVC 60 80°C 28 - Grounding
120087- Connection between pedal sensors
Molex 22 PVC 250 105°C 7 -
0074 and ADC
Connection between GLV side of HV
130010- 477 Box and LV battery
Molex 16 PVC 600 105°C 12 12 500 240A
0147 Series 𝑉
𝐼𝐹 = 𝑆⁄𝑅 = 24⁄0.1 = 240𝐴

2016 Formula Hybrid ESF (Rev 0) 10 Cables, Fusing & Grounding


Table 4 – System Wire Table

Note: Its has been assumed that the Rsource for the batteries (DCR) is 1.5mΩ (since there are 80 in series, 120mΩ), Rwire is
1mΩ/m (4AWG), 3.5mΩ /m (10AWG), 5mΩ/m (12AWG) and 14mΩ/m (16AWG). DCR for the LV battery is 5mΩ

2016 Formula Hybrid ESF (Rev 0) 11 Cables, Fusing & Grounding


2.4 Grounding System

Describe how you keep the resistances between accessible components below the required levels
as defined in FH Rules EV4.3. If wire is used for ground bonding, state the AWG or mm2 of the wire

As per EV4.3.1 – EV4.3.3 all metal/conductive part of the vehicle that are not part of the GLV or TS
are connected to the roll-hoop, which serves as the vehicle ground. The connecting is realized with
a 16AWG stranded wire and ring terminals in order to comply with EV4.3.1 (grounding resistance <
300 mΩ).

2.5 Conductive Panel Grounding

If carbon fiber or coated conductive panels are used in your design, describe the fabrication methods
used to ensure point to point resistances that comply with EV4.3.2. Describe results of
measurements made per EV4.3.3.

A copper mesh is embedded in the carbon fiber monocoque chassis and tied to the roll-hoop.

2016 Formula Hybrid ESF (Rev 0) 12 Cables, Fusing & Grounding


Isolation & Insulation
Person primarily responsible for this section:

Name: Alejandro Pozo


e-mail: apozoarr@hawk.iit.edu

3.1 Separation of Tractive System and Grounded Low Voltage System

Describe how the TS and GLV systems are physically separated (EV4.1). Add CAD drawings or
photographs of how TS and GLV are segregated in key areas of the electrical system.

The interaction/connections between GLV and TS has been limited to a single container, shown in
Figure 4 – TSV - GLV Wiring Schematic, as the “High Voltage Box”. All the DC/DC converters, IMD,
CAN repeater and Optocoupler are mounted on the same PCB, along a line that will serve as a
dividing line between TS and GLV. No electrical connection is established between components from
both sides without the appropriate isolation. Besides, a physical isolating barrier will be positioned
perpendicularly to the PCB board and right on the dividing line. This physical barrier will be
constructed with a core of acrylic and a layer of Formex on both sides. This way, in the unfortunate
case of a wire becoming loose, it will be physically impossible for it to touch a component with
exposed voltage on the other side of the dividing line.

The tractive system wires present outside the accumulator container are listed next and will always
be running through an appropriate conduit. TS wire outside the accumulator container:

- Positive lead from accumulator to motor controllers


- Negative lead from accumulator to HVD back to accumulator
- Wires from accumulator to TSMP
- Wires from motor controllers to motors

See Figure 4

Figure 5 – TS and GLV separation

List all electrical circuit boards designed by team that contain TS and GLV voltage in the following
table.
TS
Voltage Minimum Thru Air
Present Spacing of Over Notes
Device / PCB (V) mm Surface

2016 Formula Hybrid ESF (Rev 0) 13 Isolation & Insulation


High voltage Box 288 9.5 6.4

Table 5 – PCB Spacings

Add a figure (board layout drawing) for each team-designed PCB showing that spacings comply with
EV4.1.8
The team is finalizing the design of the PCBs listed in Table 5 – PCB Spacings. Pictures showing
the spacings and isolation requirements will be provided as soon as they are available.

12V, DIOs, CAN (AMS)

24V (AIRs) 288V

1 inch
1

Opto-coupler

Tractive System

CAN repeater

12V 24V 160V 288V

DC/DC DC/DC IMD DC/DC DC/DC

24V 24V 24 24

GLV System

Figure 6 – Team Designed PCB Layout

List all purchased components with both TS and GLV connections (at min motor controller and AMS)
Isolation Link to Document Notes
Component Method Describing Isolation

2016 Formula Hybrid ESF (Rev 0) 14 Isolation & Insulation


DC/DC,
AMS CANrepeater, The AMS is entirely located in the TS
optocoupler
Motor controllers
DC/DC 1 Follow links in
DC/DC 2 column 1 of this
DC/DC 3 table
DC/DC 4
IMD
Optocoupler
CANrepeater

Table 6 – List of componenets with TS and GLV connections

Galvanic isolation between TS and GLV is provided and continuously monitored by the IMD, which
will indicate a fault in case the measured resistance between TS and GLV drops below 150 kΩ.
Since our maximum voltage is 288V, the 500Ω/Volt limit stated in EV5.9.3, sets our minimum IMD
response value to be 144 kΩ.
Galvanic isolation between TS and GLV is realized with isolated DC/DC converters with the following
Vdc isolation specifications:
- Vicor DCM300P240x600A40: 4.242kV (see link)
- Murata PS UWE-24/3-Q12: 2.25kV (see link)
- GE EHHD010A0B: 2.25kV (see link)
- AIMTEC AM10EW-11024S-NZ: 1.5kV (see link)
- CAN repeater ESD Electronics: C.1330.06 – Repeater I Opto (see link, page 3). Isolation
voltage is not provided neither on the datasheet nor on the manual. However, a diagram
shows the isolation for CAN1

- Opto-coupler ACSL-6400 - 4CH: 2.5kVrms (see link).

2016 Formula Hybrid ESF (Rev 0) 15 Isolation & Insulation


3.2 Isolation & Insulation

Provide a list of containers that have TS and GLV wiring in them. If a barrier is used rather than
spacing, identify barrier material used (reference Table 8 – Insulating Materials).

EV4.1.4 applies for the design of the High Voltage Board, containing components from the TS and
GLV systems. Since these components are mounted on a PCB board, the distances determined by
EV4.1.8 (also shown in Table 15 of the rules) apply.

In order to satisfy this rule, a cut on the board has been performed. The width of the cut is different
for different parts of the board:
- In areas exposed to high voltage (150V-300V), the cut is 3.5mm wide.
- In areas exposed to 24V that belong to the tractive system, the cut is 2mm wide.
- Underneath the optocoupler, the cut is 1mm wide, being the width limited by the size of the
device. The distance between pads is 2.8mm which satisfies the spacing over surface for
50VDC or less.
Those components with exposed conductive parts, such as the IMD will be covered with a sheet of
High-Strength Electrical Insulating Ultem PEI.

Segregation How is Actual


by Spacing Spacing Measured Alt – Barrier Notes
Container Name (Y or N) maintained Spacing mm Material P/N
High-Strength
Electrical
High Voltage Box N
Insulating Ultem
PEI

Table 7 – List of Containers with TS and GLV wiring

List all insulating barrier materials used to meet the requirements of EV1.3 or EV4.1.5
Insulating Rated
UL Recog- Thickness Notes
Material / Part Temper-
nized ? mm
Number ature ºC

2016 Formula Hybrid ESF (Rev 0) 16 Isolation & Insulation


High-Strength
Electrical
Yes 168°C 2.4
Insulating Ultem
PEI + Kapton

Table 8 – Insulating Materials

3.3 Conduit

List different types of conduit used in the design. Specify location and if manufacturer’s standard
fittings are used. Note Virtual Accumulator Housing FH Rules EV3.3.1 requires METALLIC type
LFMC.

Describe how the conduit is anchored if standard fittings are not used.
Diameter Standard
Part Location / Use
Conduit Type MFR Inch or Fittings
Number
mm (Y or N)
Continuous
McMaster-
Flex-Liquid- 8465K22 ½ inch Y TS wires running from motor controllers to motors
Carr
Tight
Electri-Flex
NMHT- Wiring inside the chassis (accumulator pack to HVD and
Liquid-Tight Zoro 3/8" Y
10x50 BLK motor controllers)
Conduit

Table 9 – Conduit Data


Is all conduit contained within the vehicle Surface Envelope per EV4.2.1? (Y or N). No
Does all conduit comply with EV4.5.10? (Y or N). Yes

3.4 Shielded dual-insulated cable

If Shielded, dual-insulated cable per EV4.5.8 used in the vehicle, provide specifications and where
used:

Shield
Cross
Part grounded at Location / Use
MFR Section
Number both ends (Y
mm2
or N)
AlphaWi
79236 5.26 Y It is 3x1 cable
re

Table 10 – Shielded Dual Insulated Cable Data

2016 Formula Hybrid ESF (Rev 0) 17 Isolation & Insulation


3.5 Firewall(s)

Description/materials
Describe the concept, layer structure and the materials used for the firewalls. Describe how all
firewall requirements in FH Rules T4.5.1 are satisfied. Show how the low resistance connection to
chassis ground is achieved.

The firewall consists of a 1.6 mm thick aluminum sheet backed by an insulating layer of Nomex type
410 sheeting on both sides of the firewall. The Nomex sheeting is 0.38 mm thick and directly bonded
to both faces of the of the aluminum sheet using a high temperature epoxy. The firewall is positioned
directly behind the driver’s see and extends from the bottom to top of the monocoque. It completely
isolates the rearmost monocoque section which houses the powertrain components. The firewall is
directly bolted to the main roll hoop’s shoulder harness mount to provide a conductive path to the LV
ground. Further details of the firewall position and shape are shown in Figure 7 – Firewall position.

Position in car
Provide CAD-rendering or photographs showing the location of the firewall(s).

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Figure 7 – Firewall position 1

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Figure 8 – Firewall position 2

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Figure 9 – Firewall position 3

2016 Formula Hybrid ESF (Rev 0) 21 Isolation & Insulation


Electric Tractive System
Person primarily responsible for this section:

Name: Alejandro Pozo

e-mail: apozoarr@hawk.iit.edu

4.1 Motor(s)

Describe the motor(s) used and reason for this particular choice. Add additional tables if multiple
motor types are used

The motors used by the team are a customized version of the commercial product sold by Allied
Motion Framless Servo Motor Megaflux 0210025. The novelty of the motors used by the team is a
custom housing for the stator, that mounts inside the wheel rims. This custom housing includes water
cooling jackets to realize water cooling and boost the continuous and peak power rating of the motors.
With such design, the motors have power rating shown on Table 11 – Motor Data.

Allied Motion Framless Servo Motor Megaflux


Manufacturer and Model: 0210038

Motor type (PM, Induction, DC Brush.) PM - Brushless DC motor

Number of motors of this type used 4

Nominal motor voltage (Vrms l-l or Vdc) 266 Vrms

Nominal / Peak motor current (A or A/phase) Nom: 23A / Peak: 62A

Nominal / Peak motor power Nom: 6.5kW / Peak: 17.5kW

Motor wiring – conductor size and type 12 AWG

Table 11 – Motor Data


Provide calculations for currents and voltages. State how this relates to the choice of cables and
connectors used.

The power listed in Table 11 – Motor Data refers to the electrical power consumed by the motors
(the real power delivered by the motors is affected by the efficiency). The output voltage of the motor
controllers is listed in Table 12 – Motor Controller Data as 285Vrms.

𝑃 6.5𝑘𝑊
𝐶𝑜𝑛𝑡𝑖𝑛𝑢𝑜𝑢𝑠: = = 22.8𝐴
𝑉 285𝑉

2016 Formula Hybrid ESF (Rev 0) 22 Electric Tractive System


𝑃 17.5𝑘𝑊
𝑃𝑒𝑎𝑘: = = 61.4𝐴
𝑉 285𝑉

The wires selected are AlphaWire 10AWG with a voltage rating of 600Vdc/Vac. The motor controllers
will be programmed to protect the motors during motoring and regenerating modes. Hence there is
no need for fuses between the motor controllers and the motors.

4.2 Motor Controller

Describe the motor controller(s) used and reason for this particular choice. Add additional tables if
multiple motor controller types are used.

Advanced Motion Controls, DigiFlex®


Manufacturer and Model: Performance™ Servo Drive DPCANIE-
100A400

Number of controllers of this type used 4

Maximum Input voltage: 400Vdc

Nominal Input Current (A) Not specified by manufacturer

Max Input Fuse (A) per Mfr. Not specified by manufacturer

Output voltage (Vac l-l or Vdc) 285Vac

Isolation voltage rating between GLV (power Not specified by manufacturer


supply or control inputs) and TS connections

Is the accelerator galvanically isolated from ☒Yes / ☐ No


the Tractive System per EV2.3?

Table 12 – Motor Controller Data

If the answer to the last question is NO, how to you intend to comply with rule EV2.3 (an external
isolator is acceptable).

Provide calculations for currents and voltages. State how this relates to the choice of cables and
connectors used.

The calculations shown in section 4.1 Motor(s) are also applied to this section. Each motor is
powered by its own motor controller. The voltage, current and power ratings of each motor controller
is larger than the motors. For this reason, the wires connecting the motor controllers with the
accumulator pack are also AlphaWire 10AWG with a voltage rating of 600Vdc/Vac. In this case,

2016 Formula Hybrid ESF (Rev 0) 23 Electric Tractive System


fuses will be installed to protect wires in case of failure on the motor controllers side. Information of
these fuses is listed on Table 13 – Motor controller fuse data.

Dual element class CC fuse


Fuse type:
30A
Continuous current rating:
300VDC
Maximum operating voltage
Time-delay
Type of fuse:
150A10s
I2t rating:
300000A
Interrupt Current (maximum current at which
the fuse can interrupt the current)
Table 13 – Motor controller fuse data

4.3 Tractive System Measurement Points (TSMP)

The TSMP must comply with FH Rule EV4.4. Describe the TSMP housing and location. Describe
TSMP electrical connection point.

Bryant 3056BRY Outlet Box Lift Cover with spring door will be used to cover custom made housing
for shrouded Banana jack connectors of the measurement points.

Hook-up wire 18AWG 300V voltage rating connect TSMP directly to the motor controllers’ side of
the AIRs, inside the HV Box. A series of seven 10kΩ resistors will be placed close to controllers to
limit the current and at the same time allow for IMD testing. Electri-Flex Liquid-Tight Conduit is to be
used for cable routing from bus bars to TSMP housing.

In addition, Hook-up wire 18AWG 300V connect GLVMP to monocoque grounding point.

TSMP Output Protection Resistor Value 70 kΩ (7x10kΩ)

Resistor Voltage Rating 350 V

Resistor Power Rating 0.25 W

Table 14 – TSMP Resistor Data

4.4 Pre-Charge circuitry

Describe your design for the pre-charge circuitry. Describe wiring, connectors and cables used.

2016 Formula Hybrid ESF (Rev 0) 24 Electric Tractive System


The pre-charge circuit controls the inrush current result of the connection of a discharged capacitor
to a voltage source. The same circuit can be used to discharge this capacitor to prevent electric
shocks during deactivation of the TS.

In our system, the motor controllers have a capacitor bank at the input. The objective of the pre-
charge/discharge circuit is to charge/discharge them 95% of final voltage in 5 seconds. This is
realized by connecting current limiting power resistors between the accumulator and the motor
controllers during the specified time.

The pre-charge circuit is included in the TS so the 24V control signal for the AIRs needs to be isolated
with a 24V-to-24V isolated DC/DC converter. During the first 5 seconds the top part of the schematic
shown in Figure 10 – Pre-charge/discharge circuit schematic does not deliver the turn-on command
to the AIRs. These delay is controlled with a time delay relay. In the meantime, the bottom part of
the schematic shows how the AIRs are bypassed with a 250Ω that charges the motor controllers
filtering capacitors. After 5 seconds, the resistor is disconnected and the control signal for the AIRs
is finally delivered to the AIRs.

When the control signal for the AIRs is driven low in order to open the AIRs, the Motor controllers
are tied to ground through the same 250Ω power resistor. This connection remains until the next
turn-on cycle.

The 250Ω resistor is realized with 4 paralleled power resistors of 1000Ω, each of them with a
continuous power rating of 20W and 100W for 15 sec. each. These resistors were selected according
to the following calculations:

Each motor controller DC link capacitor is 1.5mF.


Required voltage variation: 0V – 95% of 288V → ΔV = 273.6V
Charging time: Δt = 5 sec.
Current peak: IPEAK = 288V / 1000 = 0.288A (each resistor).

Maximum power 288V * 0.288A = 82.9W < 100W (peak power). Also, the average power dissipated
by each resistance is 12.7W during the 5 seconds the charging or discharging process lasts, which
is within the nominal power rating.

 Include a schematic of the pre-charge circuit

2016 Formula Hybrid ESF (Rev 0) 25 Electric Tractive System


Figure 10 – Pre-charge/discharge circuit schematic

Figure 11 Pre-charge/discharge PCB picture

The following three figures show the calculated time evolution of the voltage, current and resistance
during the charging time. The current refers to a single resistor.

 Include a plot of calculated TS Voltage vs. time

2016 Formula Hybrid ESF (Rev 0) 26 Electric Tractive System


Figure 12 – Pre-charge voltage (at the motor controllers terminals) - time curve

 Include a plot of calculated Current vs. time

Figure 13 – Pre-charge current (current through each resistor) – time curve

 Include a plot of resistor power vs time.

2016 Formula Hybrid ESF (Rev 0) 27 Electric Tractive System


Figure 14 – Pre-charge resistance – time curve

Provide the following information:

Resistor Type: Chassir mount power resistor TE Connectivity

Resistance: 1000Ω / 4 = 250Ω

Continuous power rating: 20W * 4 = 80W

Overload power rating: 100W for 15 sec. each, 400W for 15 sec. total

Voltage rating: 1250 V

Table 15 – Data for the pre-charge resistor

For the calculation of the current rating of the relays in the pre-charge/discharge circuit, the
currents calculated previously for each resistor need to be multiplied by 4 since a single
relay will be conducting all the current. For this reason the current rating needs to be at least
4 * 0.288A ~ 1.2A. In our design, the relays are capable of operating at 300V and 8A.

Relay MFR & Type: OMRON G2RL-2-24V

Contact arrangement (e.g. SPDT) 2x DPDT

Continuous DC contact current (A): 8A

Contact voltage rating (Vdc). 300 V

Table 16 – Data of the pre-charge relay

2016 Formula Hybrid ESF (Rev 0) 28 Electric Tractive System


4.5 Discharge circuitry

The discharge circuit is the same as the pre-charge circuit. All the calculations for the resistors, relays
and wires is also valid for the discharge.

Describe your concept for the discharge circuitry. Describe wiring, connectors and cables used.

 Include a schematic of the pre-charge circuit

See Figure 10 – Pre-charge/discharge circuit schematic

 Include a plot of calculated TS Voltage vs. time

Figure 15 – Discharge voltage (at the motor controllers terminals) - time curve

 Include a plot of calculated “Discharge current” vs. time

Figure 16 – Discharge current (current through each resistor) – time curve

2016 Formula Hybrid ESF (Rev 0) 29 Electric Tractive System


 Include a plot of resistor power vs time.

Figure 17 – Discharge resistance – time curve

Provide the following information:

Resistor Type: Chassir mount power resistor TE Connectivity

Resistance: 1000Ω / 4 = 250Ω

Continuous power rating: 20W * 4 = 80W

Overload power rating: 100W for 15 sec. each, 400W for 15 sec. total

Voltage rating: 1250 V

Maximum expected current: 0.3 A (per resistor)

Average current: 0.085 A (per resistor)

Table 17 – Data of the discharge circuit.

4.6 HV Disconnect (HVD)

Describe your design for the HVD and how it is operated, wiring, and location. Describe how your
design meets all requirements for EV4.7

The HVD consists of one connector that has both power and signal. The main HV connector will be
mounted on the rear of the car with a non-conductive handle attached directly to the plug. Pulling on
the handle will disconnect one pole of the battery from the rest of the circuit. The signal wires on the
connector will be part of the Shutdown Circuit, as such, will also open AIRs when the plug is

2016 Formula Hybrid ESF (Rev 0) 30 Electric Tractive System


disconnected, having the same effect as one of the shutdown buttons. In the event that the HVD is
activated a dummy connector will be put in place to maintain HV insulation.

An Anderson Power SBX-175 connector is used as main HV connector and interlock. For the power
lead, a 4AWG with 600V rating will be used and since this wire is part of the TS it will be contained
inside a Electri-Flex Liquid-Tight Conduit. Hook-up wire 18AWG 300V wire is used for the interlock.
The wiring diagram for the HVD is shown in Figure 18 – HVD wiring diagram.

Accumulator container
AIR Motor controllers fuses Motor controllers
plug
MC 1 M

Main MC 2 M
Fuse
MC 3 M

Precharge/ MC 4 M
24V (A IRs)
AMS discharge Charger
A MS DO
central plug
unit

12V HV
AIR

Signals (A MS DO) 24V (A IRs)

CAN
12V/GND

TSMP
HVD

Figure 18 – HVD wiring diagram

4.7 Accelerator Actuator / Throttle Position Sensor

Describe the accelerator actuator and throttle position sensor(s) used, describe additional circuitry
used to check or condition the signal going to the motor controller. Describe wiring, cables and
connectors used. Provide schematics and a description of the method of operation of any team-built
signal conditioning electronics. Explain how your design meets all of the requirements of FH Rules
IC1.6 and EV2

Three through-shaft rotary potentiometers mounted on the pedal shaft are used as throttle position
sensors. The potentiometers give analog signals as output. The output varies from 6 to 9.6V
depending on the position of the pedal. These analog signals are digitized with a 14bit Analog-to-
CANopen converter (ADC).

Actuator / Encoder manufacturer and model: Honeywell through-shaft rotary potentiometer

2016 Formula Hybrid ESF (Rev 0) 31 Electric Tractive System


Encoder principle (e.g.Potentiometer): 10kOhm, 90°, linear potentiometer

Output: 6-9.6V

Is motor controller accelerator signal isolated ☒Yes / ☐ No


from TSV?

If no, how will you satisfy rule EV2.3?

Table 18 – Throttle Position encoder data

The position of the throttle position sensors and ADC is behind the pedals, as shown in Figure 19 –
Position of the throttle position sensor and ADC.

Figure 19 – Position of the throttle position sensor and ADC

Molex M8 3pin and 5pin cables and receptacles are used for all connections.

4.8 Accelerator / throttle position encoder error check

Describe how the system reacts if an error (e.g. short circuit or open circuit or equivalent) is detected.
Describe circuitry used to check or condition the signal going to the motor controller. Describe how
failures (e.g. Implausibility, short circuit, open circuit etc.) are detected and how the system reacts if
an error is detected. State how you comply with EV2.2

Pull-down resistors (100kΩ) are used to make sure that all ADC input goes to 0 in case potentiometer
disconnection/failure. No additional resistors are used in line with potentiometer, however in case of
loose wire output voltage will be either 0 or 12V, which is outside plausible region 6-9.6 V. Therefore,
loose wire can be easily detected.

2016 Formula Hybrid ESF (Rev 0) 32 Electric Tractive System


The Main controller (cRIO unit from National Instruments) compares plausible potentiometers
outputs to be within 10%. If any 2 of 3 are within 10%, their averaged value is used.

Main controller assures that ADC is in normal operation mode using standard CANopen heartbeat
procedure. In case of any wiring failure between ADC and Main Controller, heartbeat procedure
detects the error immediately and treats it as implausibility.

Throttle
sensors

ADC INPUTS

12V
1P
1G

Pull down
resistors

Figure 20 Pull-down resistors of the thorttle sensors

2016 Formula Hybrid ESF (Rev 0) 33 Electric Tractive System


Accumulator System

5.1 Accumulator System

Person primarily responsible for this section:

Name: Alejandro Pozo

e-mail: apozoarr@hawk.iit.edu

5.2 Accumulator Pack

Provide a narrative design of the accumulator system and complete the following table.

The accumulator pack has a configuration 80s1p, and it is divided in four segments connected in
series with a configuration of 20s1p each. Each segment is composed of 10 repeating frames, each
of them holding 2 cells. The cells are A123’s Nanophosphate Li-Ion Prismatic pouch cells AMP20.
The connection between cell tabs within the same segment will be realized with ultrasonic welding.

Maximum Voltage (during charging): 288VDC

Nominal Voltage: 264VDC

Total number of cells: 80

Cell arrangement (x in series / y in parallel): 80s1p

Are packs commercial or team constructed? ☐Commercial / ☒ Team

Total Capacity (per FH Rules Appendix A): 4188 Wh

Maximum Segment Capacity 4.633 MJ

Number of Accumulator Segments 4

Table 19 – Main accumulator parameters

Describe how pack capacity is calculated. Provide calculation at 2C (0.5 hour) rate? How is capacity
derived from manufacturer’s data? If so, include discharge data or graph here. Include Peukert
calculation if used (See FH Rules Appendix A)

Show your segment energy calculations. The segment energy is calculated as

2016 Formula Hybrid ESF (Rev 0) 34 Accumulator System


𝑉𝑛𝑜𝑚 𝑥 𝐶𝑒𝑙𝑙 𝐴𝐻 (2𝐶 𝑟𝑎𝑡𝑒) 𝑥 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶𝑒𝑙𝑙𝑠 𝑥 3.6 (𝑘𝐽)

(The 80% factor is not applied for this calculation.)

Using the equation given in Appendix A of the FH Rules:

𝐸𝑛𝑒𝑟𝑔𝑦 (𝑊ℎ) = 𝑉𝑛𝑜𝑚 ∙ 𝐶𝐴ℎ (2𝐶) ∙ 0.8 = 3.3 ∙ 80 ∙ 19.5 ∙ 0.8 = 4118 𝑊ℎ

the capacity obtained is 4.224 kWh. The energy per segment shown in Table 19 – Main accumulator
parameters was calculated using the following formula:

𝑉𝑛𝑜𝑚 ∙ 𝐶𝐴ℎ (2𝐶) ∙ 𝑁𝑐𝑒𝑙𝑙𝑠/𝑠𝑒𝑔𝑚𝑒𝑛𝑡 ∙ 3.6(𝑘𝐽) = 3.3 ∙ 19.5 ∙ 20 ∙ 3.6 = 4.633 𝑀𝐽

Moreover, all the cells used for the accumulator pack have been tested and fully discharged at 1C
in order to verify the capacity specified by the manufacturer. Even though the pack requires 80 cells,
100 cells were purchased. After testing all of them, the best 80 were chosen to build the battery pack.
The fact that the pack capacity is limited by the cell with the lowest capacity motivated this decision.

A thermally conductive interface material is placed in between the cells to ensure even thermal
distribution across the entire cell surface. No further thermal management is included in the team’s
accumulator pack design.

The discharge curves provided by the manufacturer at different C-rates show no degeneration of the
cell capacity, see Figure 21 – Cell discharge curves: Voltage vs SOC at different C-rates. This does
not mean the performance of the cells is the same regardless the C-rate. As the C-rate increases,
the discharge curves are shifted down, providing lower terminal voltage (due to a higher voltage drop
across the internal resistance); which, in the end, translates into lower average power and higher
power losses and heating issues.

2016 Formula Hybrid ESF (Rev 0) 35 Accumulator System


Figure 21 – Cell discharge curves: Voltage vs SOC at different C-rates

5.3 Cell description

Describe the cell type used and the chemistry and complete the following table.

Cell Manufacturer and Model A123 AMP20M1HD-A

Cell type (prismatic, cylindrical, pouch, etc.) Pouch

Are these pouch cells ☒Yes / ☐ No

Cell nominal capacity at 2C (0.5 hour) rate: 19.5 Ah

Data sheet nominal capacity 19.5 Ah at 1C rate

Maximum Voltage (during charging): 3.6V

Nominal Voltage (data sheet value): 3.3V

Minimum Voltage (AMS setting): 2.0V

Maximum Cell Temperature (charging - AMS setting) 50°C

Maximum Cell Temperature (discharging - AMS setting) 55°C

Cell chemistry: LiFePO4

2016 Formula Hybrid ESF (Rev 0) 36 Accumulator System


Table 20 – Main cell specification
Show your calculations for 2C nominal AH capacity if the data sheet uses a different discharge rate.
Refer to FH rules Appendix A

See previous section.

5.4 Cell configuration

Describe cell configuration, show schematics, cover additional parts like internal cell fuses etc.
Describe configuration: e.g., N cells in parallel then M packs in series, or N cells in series then M
strings in series.

Does the accumulator combine individual cells in parallel without cell fuses? ☐Yes / ☒ No
If Yes, explain how EV6.1.7 is satisfied.

As mentioned previously the battery pack does not parallel cells and is a series of 80 cells divided
into 4 separate segments. Detailed description of the materials used and pictures of the assembly is
provided in 5.6 Lithium-Ion Pouch Cells.

5.5 Segment Maintenance Disconnect

Describe segment maintenance disconnect (SMD) device, locations, ratings etc.

Is HVD used as an SMD? ☒Yes / ☐ No

Number of SMD Devices 2 + HVD

Amphenol SurLok PSL-


SMD MFR and Model 574K

SMD Rated Voltage (if applicable) N.A.

SMD Rated Current (if applicable) 125A (continuous)

Segment Energy (6 MJ max) 1158 MJ

Segment Energy Discharge Rate (Ref FH Rules Appendix A) xxC

Table 21 – SMD Data

The battery pack is divided in four segments. The component listed in Table 21 – SMD Data
will be used as SMDs between sements 1 and 2, and also between segments 3 and 4. The
HVD will be used between segments 2 and 3.

2016 Formula Hybrid ESF (Rev 0) 37 Accumulator System


5.6 Lithium-Ion Pouch Cells

The vehicle accumulator uses individual pouch cells. Yes ☒ No ☐

Note that designing an accumulator system utilizing pouch cells is a substantial engineering
undertaking which may be avoided by using prismatic or cylindrical cells.

If your team has designed your accumulator system using individual Lithium-Ion pouch cells, include
drawings, photographs and calculations demonstrating compliance with all sections of rule EV3.9. If
your system has been issued a variance to EV3.9 by the Formula Hybrid rules committee, include
the required documentation from the cell manufacturer.

The overall accumulator pack still consists of 4 segments with 20 cells in each of them. These 20
cells inside each segment are organized in 10, 2-cell repeating frames to comply with EV3.9.5.

The outer frame has slots to hold the edges of the batteries so they don’t move (EV3.9.5). The
material used for it is Polypropylene, which is non-conductive and fire retardant UL-94V0.

The two cells are separated internally by a filler material, which is a non-conductive cellular silicone
that meets the requirements specified in EV3.9.3.

On the other side of both cells, a thermal interface pad is covering the entire cell seeking for thermal
uniformity across the whole cell. This material is then covered with a layer of Formex on both sides.

The result is a 2-cell frame, with no conductive surfaces exposed, except for the battery tabs.
Datasheets of the materials:
- Polypropylene Flametec CP5 Flame Retardent
- Filler material
- Thermal interface pad
- Formex GK-10BK
The connection of the tabs is not shown in the pictures or diagrams since it has not been done yet.
However, the intention of the team is to ultrasonicly weld them. Further details and pictures of the
pack will be provided as soon as the pack is completed.

2016 Formula Hybrid ESF (Rev 0) 38 Accumulator System


Figure 22 – Cell configuration: Cell frames (I)

2016 Formula Hybrid ESF (Rev 0) 39 Accumulator System


Figure 23 – Cell configuration: Cell frames (II)

The following two pictures show assembly exploded views of the previous 2-cell repeating frames
and segment.

2016 Formula Hybrid ESF (Rev 0) 40 Accumulator System


Figure 24 – Cell configuration: Segment and frame assembly

2016 Formula Hybrid ESF (Rev 0) 41 Accumulator System


5.7 Cell temperature monitoring

Describe how the temperature of the cells is monitored, where the temperature sensors are placed,
how many cells are monitored, etc. Show a map of the physical layout. Provide schematics for team-
built electronics.

The accumulator pack is monitored by an Elithion Lithiumate™ HD BMS master, 2CN0002E. The
AMS is based on a distributed configuration. There is a main controller (Lithiumate HD BMS master)
and small cell boards installed on every cell. These cell boards perform the cell sensing and
balancing and temperature monitoring. The cells boards communicate with other cell boards in the
same segment. Only the bottom cell board (corresponding to the cell with the lowest voltage in that
segment) communicates with the Lithiumate HD BMS master. This way the amount of wiring can be
reduced.

Number of Cells with Temperature Monitoring (#1) 80

Total Number of Cells (#2) 80

Percentage Monitored (#1 / #2) 100%

Percentage Required by FH Rules Table 12 30%

If each sensor monitors multiple cells, state how many: 1 sensor for each cell

Table 22 – Cell Temperature Monitoring

5.8 Accumulator Isolation Relays (AIR)

Describe the number of AIRs used and their locations. Also complete the following table.

The AIRs are located inside the accumulator container as shown in Figure 4 – TSV - GLV Wiring
Schematic.

MFR & Model Tyco Electronics ( Kilovac LEV100 from TE)

Contact arraignment: SPST-NO-DM

Continuous DC current rating: 100 A

Overload DC current rating: 200 A for 180 sec *(See Figure 25)

Maximum operation voltage: 900 VDC

2016 Formula Hybrid ESF (Rev 0) 42 Accumulator System


Nominal coil voltage: 24 VDC

Normal Load switching: Make and break up to 200 A

Table 23 – AIR data

In order to obtain more information of the peak current rating for different peak durations, the team
contacted TE Connectivity for this specifications, which responded with the following e-mail:

“I spoke with our product engineer at Kilovac and he indicated the LEV100 would perform fine under the battery
system parameters you described and there should be no problem achieving 200 or more cycles. I believe what you
were asking for is a time/current chart that would apply to the LEV100? The below chart for our KCS01 contactor is
applicable to the LEV100 contactor also:”

Figure 25 – AIRs time/current chart for TE LEV100

5.9 Accumulator Management System (AMS)

Describe the AMS and how it was chosen. Describe generally how it meets the requirements of
EV3.7

As introduced in 5.7 Cell temperature monitoring, the AMS of the team’s (Elithion Lithiumate™ HD
BMS master, 2CN0002E) choice is based on a distributed configuration with individual cell boards
installed on each cell. Each board provides the temperature monitoring, voltage sensing and cell

2016 Formula Hybrid ESF (Rev 0) 43 Accumulator System


balancing. These cell boards communicate with the rest of the boards in the same segment. Only
the first and last cell boards of the segment communicate with the AMS main unit.

AMS MFR and Model Elithion, Lithiumate™ HD BMS master, 2CN0002E

Number of AMSs 1

Upper cell voltage trip 3.55V

Lower cell voltage trip 2.1V

Temperature trip 55°C

Table 24 – AMS Data


 Describe other relevant AMS operation parameters.
Voltage sensing, temperature monitoring and cell balancing during charging.
 Describe how many cells are monitored by each AMS board, the configuration of the cells,
the configuration of the boards and how AMS communications wiring is protected and
isolated.
Each cell board senses (±10mV), monitors and balances one cell. They are positioned in between
the cell tabs. The sensing circuit is protected with a fuse on each cell board.
 Describe how the AMS opens the AIRs if an error is detected
The AMS outputs a digital signal high during normal operation. In case of fault or broken wire, this
signal interrupts the shutdown circuit which directly power the control coils for the AIRs. The digital
signal is not generated with logic of the ECU. It only goes through an optocoupler to achieve galvanic
isolation between TS and GLV.
 Indicate in the AMS system the location of the isolation between TS and GLV
As shown in Figure 4 – TSV - GLV Wiring Schematic, the AMS is located within the accumulator
container, being part of the TS. Connections between AMS and GLV are fully isolated with:

- Isolated DC/DC converter 24V-to-12V: Power for the AMS


- Isolated CAN repeater (ESD Electronics: C.1330.06 – Repeater I Opto): CAN1 is TS and
CAN2 GLV. Power for the CAN repeater belongs to GLV. (See Figure 26 – CAN repeater
diagram for details).

2016 Formula Hybrid ESF (Rev 0) 44 Accumulator System


Figure 26 – CAN repeater diagram
- Optoisolator (Avago ACSL-6400-50TE): Isolation for the Digital signal (up to 4 going from the
TS to GLV)

5.10 Accumulator wiring, cables, current calculations

Describe internal wiring with schematics if appropriate. Provide calculations for currents and voltages
and show data regarding the cables and connectors used.
Discuss maximum expected current, DC and AC, and duration
Compare the maximum values to nominal currents

Using the current and power calculations given in section 4.1 Motor(s), the current calculations for
the accumulator pack and be easily derived:

𝑃
𝐶𝑜𝑛𝑡𝑖𝑛𝑢𝑜𝑢𝑠: = 4 ∙ 22.8𝐴 = 91.2𝐴
𝑉
𝑃
𝑃𝑒𝑎𝑘: = 4 ∙ 61.4𝐴 = 245.6𝐴
𝑉

All the high power accumulator wiring will use 4AWG cables with 600V rating. Information of the
main fuse used for the accumulator is given in Table 25 – Basic fuse data.

Fuse type: JDL100, Class J, Dual-Element Fuse

Continuous current rating: 100 A

Max. operating voltage (specify AC or DC) 300 VDC

Type of fuse: Time-delay

2016 Formula Hybrid ESF (Rev 0) 45 Accumulator System


Interrupting Current (max. current at which 200 kA RMS Sym
the fuse can break the flow of current)
Table 25 – Basic fuse data

5.11 Accumulator indicator

If accumulator container is removable, describe the indicator, including indicating voltage range

Figure 27 – Accumulator indicator schematic diagram

A bright red LED is mounted inside the accumulator container to indicate the presence of high voltage
at the terminals of the accumulator pack. The circuit is shown in

5.12 Charging

Describe how the accumulator will be charged. How will the charger be connected? How is the
accumulator to be supervised during charging?

The accumulator will still be supervised by the same AMS while charging outside the car. For
charging, the charger will plug into the same plug as the motor controllers.

Complete the table

Charger Manufacturer and model: ElCon, PFC 2500 TCCH-288-8

Maximum charging power: 1.2kW

Isolation ☒Yes / ☐ No

UL Certification (If “no”, fill in the line below) ☐Yes / ☒ No (CE certified)

Do you have a waiver from the FH rules committee? ☐Yes / ☒ No

Maximum charging voltage: 3.60V

2016 Formula Hybrid ESF (Rev 0) 46 Accumulator System


Maximum charging current: 4.1A

Interface with accumulator (e.g. CAN, relay etc) Relay

Input voltage: 115VAC single phase

Input current: 14.2A

Table 26 – Charger data

5.13 Accumulator Container/Housing

Describe the design of the accumulator container. Include the housing material specifications and
construction methods. Include data sheets for insulating materials. Include information documenting
compliance with UL94-V0, FAR25 or equivalent.

If the housing is made of conductive material, include information on how the poles of the
accumulators are insulated and/or separated from the housing, and describe where and how the
container is grounded to the chassis.

Include additional photographs if required to comply with rule EV3.2.

Show how the cells are mounted, use CAD-Renderings, and include calculations showing
compliance with FH Rules EV3.4.

Information of the container/housing for each segment is provided in this section. It consists of two
pieces of aluminum that fulfill the functions of cell expansion limiters. Stress analysis has been
performed to ensure the integrity of the segments and the cells.

Expansion Limiter: This is done with an aluminum plate that is fastened by 32 #10-24 cap screws
that limit the expansion of the cells, the cell has a face area of 50 sq-in with will give the force required
for the expansion limiter to be 500lbf. An FEA analysis was done to prove the structural part of the
expansion limiter. See Figure 28 – Accumulator pack expansion limiter. The expansion of the cells
is allowed by neoprene foam that is place in between each cell. The foam need to allow expansion
of > 8% ans <12%. Our cells are 7.25mm thick which a value of greater than 0.58mm and less than
0.87mm is needed @ 10psi. at 10 psi our foam only compresses by 0.63mm (done by compression
test).

2016 Formula Hybrid ESF (Rev 0) 47 Accumulator System


Figure 28 – Accumulator pack expansion limiter

2016 Formula Hybrid ESF (Rev 0) 48 Accumulator System


Safety Controls and Indicators
Person primarily responsible for this section:

Name: Alejandro Pozo

e-mail: apozoarr@hawk.iit.edu

6.1 Shutdown Circuit

Include a schematic of the shutdown circuit for your vehicle including all major components in the
loop

Figure 29 – Safety Shutdown Circuit Schematic

2016 Formula Hybrid ESF (Rev 0) 49 Safety Controls and Indicators


Describe the method of operation of your shutdown circuit, including the master switches, shut down
buttons, brake over-travel switch, etc. Also complete the following table

The shutdown circuit provides the control signal for the AIRs, incorporating a series of safety
switches and system fault signals. Signal faults (IMD, BMS and ECU) are high under normal
operation, this way, wire loose, power loss or fault result in interruption of the AIRs control current.

The desired latching effect of IMD/BMS faults is achieved with the appropriate wiring using DPDT
relays (See Figure 29 – Safety Shutdown Circuit Schematic). Once, the IMD/BMS fault signal is low,
the shutdown circuit interrupts the control current for the AIRs. This current cannot be resumed until
the fault is cleared and the corresponding reset button is manually pressed. The driver does not have
access to this buttons.

The following systems are connected in series with the AIRs, the TSMS, three shutdown buttons
(two on each side of the roll-hoop, one in the cockpit), a break over-travel switch, an inertia switch,
the wheel interlocks (1 on each wheel) and the HVD interlock.

Function
(Momentary, Normally Open or Normally Closed)
Part

Main Switch (for control and tractive-system, SPST Normally open


TSMS)

Brake over-travel switch (BOTS) SPST Normally closed

SPST Normally closed (2 push-pull, 1 push-


Shutdown buttons (BRB) twist)
DPDT Normally open, latching (latching
Insulation Monitoring Device (IMD) disabled during first 5sec.)
DPDT Normally open, latching (latching
Battery Management System (AMS) disabled during first 5sec.)

Interlocks (if used) Closed when HVD and A-arms are in place

Inertia switch SPST Normally closed

Table 27 – Switches & devices in the shutdown circuit

Describe wiring and additional circuitry controlling AIRs. Write a functional description of operation

The control current for the AIRs comes from the shutdown circuit, located in the GLV side of the High
Voltage Box (see Figure 4 – TSV - GLV Wiring Schematic). It crosses the dividing line between GLV

2016 Formula Hybrid ESF (Rev 0) 50 Safety Controls and Indicators


and TS through an isolated DC/DC converter and goes into the pre-charge/discharge circuit (see
Figure 10 – Pre-charge/discharge circuit schematic).

Total Number of AIRs: 2

Coil holding current per AIR: 250mA

Current drawn by other components wired in 0A (Nothing else wired in parallel)


parallel with the AIRs.

Total current: 500mA

Table 28 – Shutdown circuit Current Draw

Provide CAD-renderings showing the shutdown circuit parts. Mark the parts in the renderings

High Voltage Box (HVB)


TS – Galvanic Isolation - GLV
24V
HV DC/DC 1 Motor
controllers
12V
DC/DC 5 Cooling
radiators
12V (TS VP )
HV DC/DC 2 TSVP

IMD Fault
HV HV IMD
24V
Shutdown circuit

24V (A IRs) 24V (A IRs) DC/DC 3 24V (A IRs)

24V
12V DC/DC 4

Optocoupler (x4)

AMS DO AMS DO

24V
Signals (A MS DO)
24V 12V
CAN
12V/GND CAN CAN repeater
CAN

Figure 30 – Location of Shutdown Circuit Components (I)

2016 Formula Hybrid ESF (Rev 0) 51 Safety Controls and Indicators


Figure 31 – Location of Shutdown Circuit Components (II)

6.2 IMD

Describe the IMD used and use a table for the common operation parameters, like supply voltage,
temperature, etc. Describe how the IMD indicator light is wired. Complete the following table.

The IMD unit the team uses is the Bender IR155-3204. The main purpose the IMD serves is to
ensure the safety of the driver by continuously measuring isolation resistance between TS and GLV.
This device has an automatic self-test with the ability to detect lost ground, power and high voltage
connections.

MFR / Model Bender IR155-3204

Set response value: 150kΩ ( 520Ω/Volt)

Table 29 – Parameters of the IMD


Describe IMD wiring with schematics.

IMD is wired in such way, that SDC will be triggered in case the IMD cable is disconnected or any
wire in the cable (Power, Ground or Signal) is damaged.

IMD is set to constantly monitor HV to be more than 200V. In case of failure of any HV wire, IMD will
connect output to the ground and trigger SDC. In case of power, ground or output wire failure, IMD
will not be able to supply SDC relay with current, so SDC will be triggered. Therefore, the IMD
connection is fail safe.

2016 Formula Hybrid ESF (Rev 0) 52 Safety Controls and Indicators


The high voltage connection of the IMD to the TS is achieved using a 16AWG wire with rated isolation
of 600V. On the low voltage side, power, signal and ground terminals will be connected to the GLV
side of the HV Box PCB board with the same 16AWG cables.

1A 400 VDC fuses with PCB-mount fuse holders are used for protection.

6.3 Reset / Latching for IMD and AMS

Describe the functioning and circuitry of the latching/reset system for a tripped IMD or AMS. Describe
wiring, provide schematics.

Lathing effect is achieved by properly wiring of DPDT relays, as described in Figure 29 – Safety
Shutdown Circuit Schematic. This latching effect for the IMD and AMS is mounted on the same PCB
board as the SDC.

6.4 Shutdown System Interlocks

(If used) describe the functioning and circuitry of the Shutdown System Interlocks. Describe wiring,
provide schematics.

Several shutdown system interlock are included in the shutdown circuit. For detailed information on
the type, function and momentary of the switches, refer to Table 27 – Switches & devices in the
shutdown circuit.

The location of the shutdown buttons, inertia switch, brake over travel switch and TSMS were already
shown in Figure 31 – Location of Shutdown Circuit Components (II). A detail view of the wheel
interlocks is shown in Figure 32 – Wheel interlock position on the A-arms.

Figure 32 – Wheel interlock position on the A-arms

2016 Formula Hybrid ESF (Rev 0) 53 Safety Controls and Indicators


The interlock included in the shutdown circuit is the HVD interlock, which will be located inside the
Anderson Power SBX-175 connector.

The wiring between all the shutdown circuit components located around the vehicle is realized with
Hook-up wire 18AWG 300V securely fastened to the chassis with zip-ties. This circuit is protected
with a 1A fuse and fuse holder, soldered onto the PCB board inside the HV Box board.

6.5 Tractive System Energized Light (TSEL)

Describe the tractive system energized light components and method of operation. Describe location
and wiring, provide schematics. See EV4.10

TSEL will be powered from the 24V in the GLV that power the AIRs.

The TSEL is a Beacon strobe light, mounted on the highest point of the roll-hoop. The circuitry is
protected with 2A fuses, mounted on a fuse holder, soldered to the PCB. 18 AWG is used between
the HVB PCB and the switches.

The TSEL schematic is integrated in Figure 29 – Safety Shutdown Circuit Schematic.

6.6 Tractive System Voltage Present light (TSVP)

Describe the tractive system voltage present light components and method of operation. Describe
location and wiring, provide schematics. See EV4.12

The tractive system active light is turned on when the voltage outside the accumulator container
exceeds 1/3 of the TS voltage or 32VDC. These will happen during pre-charge (after reaching 96V),
discharge (until going below 96VDC), when the motor controllers are connected to the accumulator
pack or even when the AIRs are closed but the fuses for the motor controllers are blown. An Isolated
DC/DC converter (Aimtec AM10EW-11024S-NZ) is used to power the TSVP lights directly from the
TS.

Figure 33 – TSVP schematic

2016 Formula Hybrid ESF (Rev 0) 54 Safety Controls and Indicators


The circuitry for the TSVP will be included in the HV Box PCB board and protected by a 1A
fuse. 18AWG cables are used for connections between the GLV side of the PCB board and
the actual TSVP lights, mounted on both sides of the roll-hoop, next to the shutdown buttons.

6.7 Ready-To-Drive-Sound (RTDS)

Describe your design for the RTDS system. See EV4.11

To switch the car to Ready-to-Drive mode driver should push a start button on the dashboard while
pressing the brake pedal. At that moment the main controller is switched to drive mode, start button
LED will become green and 70dB siren would be activated for 1 second. The RTDS will not be able
to function when shutdown circuit has been activated.

The circuitry for the RTDS will be included in the HV Box PCB board and protected by a 1A fuse.
Hook-up wire 18AWG 300V is used for connections between the GLV side of the PCB board and
the siren, mounted on the roll-hoop.

2016 Formula Hybrid ESF (Rev 0) 55 Safety Controls and Indicators


GLV System
Person primarily responsible for this section:

Name: Alejandro Pozo

e-mail: apozoarr@hawk.iit.edu

7.1 GLV System Data

Provide a brief description of the GLV system and complete the following table

The GLV system is always powered by a 24V 6s1p LiPo battery, with its own BMS, which ensures
under/over voltage protection, as well as thermal. This 24V system powers all the GLV and TS
components that need a power supply even before the AIRs are closed. Some of these systems
require 12V or 5V supply, for which a 24V-to-12V DC/DC converter, a 24V-to-5V DC/DC converter
and a 12V-to-5V voltage regulator are used. Both DC/DC converters provide isolation, even though
it is not required since the input and output are part of the GLV system. Once the AIRs are closed
the GLV 24V is also powered by an isolated 300V-to-24V DC/DC converter that steps down the
accumulator pack voltage.

The GLVMS is used to initially energize the GLV system from the LV battery. This LV battery, its
BMS and fuse are located in a separate box (see Figure 4 – TSV - GLV Wiring Schematic) and its
connection with the 24V of the GLV side in the HV Box is realized with a Molex Mini-Change 16AWG
cable assembly, 12A fuses (see Table 2 – Fuse Table) will protect this wire since power could flow
in both directions (charging and discharging).

GLV System Voltage 24 V

GLV Main Fuse Rating 12 A

Is a Li-Ion GLV battery used? ☒Yes / ☐ No

If Yes, is a firewall provided per T4.5.1? ☒Yes / ☐ No

Is a dc-dc converter used from TSV? ☒Yes / ☐ No

Is the GLV system grounded to chassis? ☒Yes / ☐ No

Does the design comply with EV1.2.7? ☒Yes / ☐ No

Table 30 – GLV System Data

2016 Formula Hybrid ESF (Rev 0) 56 GLV System


Voltage Component Max. power (W) p.u. Quantity Total max power (W)
Motor controllers 20.4 4 81.6
cRIO 20 1 20
TSEL 3.6 1 3.6
Brake light 5 1 5
24V TSVP 0.5 1 1
OMRON relays 0.4 6 2.4
Fuji relays (time delay) 1.1 2 2.2
IMD 4.8 1 4.8
Pedals ADC 1.2 1 1.2
Cooling radiators 30 3 60
AIRs 6 2 12
12V
Pedal sensors 0.5 3 1.5
Dashboard 3 1 3
Optocoupler 1 1 1
5V
Hydraulic brake sensor 2.5 1 2.5
Total (W) 286W

Table 31 – GLV Loads

The wiring for all the GLV components shown in Table 31 – GLV Loads, which includes all GLV
components except the LV battery uses 16AWG cables. Fuses are listed in Table 2 – Fuse Table.

7.2 Electronic control unit

The car uses a centralized controller, in charge of monitoring, processing and controlling the rest of
the systems in the car. The device used for such purposes is a Compact Rio 9065 from National
Instruments. This unit serves as a typical ECU.

The inputs from the pedals (acceleration and break) and steering wheel are transmitted to the ECU
via CANOpen protocol. This signals are then used to generate the torque commands that will be
sent using CANOpen communication to the motor controllers. Therefore, the ECU acts as an
electronic differential.

The same ECU is included in the shutdown circuit for safety purposes, being able to interrupt the
current for the control of the AIRs. It also communicates, using CAN communication, with the
dashboard and controls other systems such as the brake light or the RTDS sound.

2016 Formula Hybrid ESF (Rev 0) 57 GLV System


Appendices

Include only highly-relevant data. A link to a web document in the ESF text is often more convenient
for the reviewer.

The specification section of the accumulator data sheet, and sections used for determining
accumulator capacity (FH Rules Appendix A) should be included here.

2016 Formula Hybrid ESF (Rev 0) 58 Appendices


8.1 IMD specs and datasheet

2016 Formula Hybrid ESF (Rev 0) 59 Appendices


Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 60 Appendices


8.2 Nomex paper specifications

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 61 Appendices


8.3 Cell data – A123

Find link to request datasheet here.

2016 Formula Hybrid ESF (Rev 0) 62 Appendices


8.4 Analog to Digital Converter

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 63 Appendices


8.5 Torque encoder – rotary potentiometers

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 64 Appendices


8.6 Brake sensor

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 65 Appendices


8.7 Motor controllers: AMC DPCANIE-100A400

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 66 Appendices


8.8 Accumulator isolation relays

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 67 Appendices


8.9 Accumulator and Motor controller fuses

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 68 Appendices


8.10 Time delay relay: AUTOMATION DIRECT ST7P-2DE5S-ADC

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 69 Appendices


8.11 Omron relays: OMRON G2RL-2-24V

2016 Formula Hybrid ESF (Rev 0) 70 Appendices


Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 71 Appendices


8.12 Power resistors for pre-charge/discharge circuit: TE HSA50 1kΩ

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 72 Appendices


8.13 DC/DC Converter 300V-to-24V : VICOR POWER DCM300P240T600A40

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 73 Appendices


8.14 DC/DC Converter 300V-to-24V: AIMTEC AM10EW-11024S-NZ

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 74 Appendices


8.15 DC/DC Converter 24V-to-12V: GE EHHD010A0B HAMMERHEAD

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 75 Appendices


8.16 DC/DC Converter 24V-to-24V: MURATA UWE-24/3-Q12P-C

2016 Formula Hybrid ESF (Rev 0) 76 Appendices


Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 77 Appendices


8.17 DC/DC Converter 24V-to-5V: GE EHHD010A0B HAMMERHEAD

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 78 Appendices


8.18 Voltage regulator 12V-to-5V

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 79 Appendices


8.19 Low voltage battery 24 V

Find more information here.

2016 Formula Hybrid ESF (Rev 0) 80 Appendices


8.20 Low voltage BMS

More information can be found here.

2016 Formula Hybrid ESF (Rev 0) 81 Appendices


8.21 Dashboard

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 82 Appendices


8.22 Banana Jack specs

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 83 Appendices


8.23 CAN repeater: ESD Electronics: C.1330.06 – Repeater I Opto

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 84 Appendices


8.24 Optoisolator: Avago ACSL-6400-50TE

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 85 Appendices


8.25 TSVP lights

Find datasheet here.

2016 Formula Hybrid ESF (Rev 0) 86 Appendices


8.26 Molex cable data

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 87 Appendices


8.27 Molex receptacle data

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 88 Appendices


8.28 Hook-up wire 22AWG 300V

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 89 Appendices


8.29 Hook-up wire 18AWG 300V

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 90 Appendices


8.30 Hook-up wire 16AWG 300V

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 91 Appendices


8.31 AlphaWire 10AWG

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 92 Appendices


8.32 Battery pack wire 4AWG

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 93 Appendices


8.33 Main fuse: Edison JDL100

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 94 Appendices


8.34 Motor controller fuses: Edison EDCC30

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 95 Appendices


8.35 Low power fuses: LittelFuse 477 Series

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 96 Appendices


8.36 High-Strength Electrical Insulating Ultem PEI

Follow the link for further information.

2016 Formula Hybrid ESF (Rev 0) 97 Appendices


8.37 Continuous Flex Liquid Tight Conduit

Follow the link for further information.

2016 Formula Hybrid ESF (Rev 0) 98 Appendices


8.38 Electri-Flex Liquid-Tight Conduit

Full datasheet can be found here.

2016 Formula Hybrid ESF (Rev 0) 99 Appendices

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