2013 Asia Rules

SEM GENERAL DESIGN RULES
Official Rules 2013

Chapter 1
Shell
®
Eco-marathon
ASIA 2013
Colin Chin
Technical Lead, Shell Eco-marathon Asia 2013
Copyright of Shell Global Solutions Sdn. Bhd. 1

Agenda
1.1. Rule changes

Rule changes in SEM
in SEM 20132011 If you have any questions please
submit them via the Q&A section of
2.2. General overview
General overview of rules
of rules Chapter
Chapter 1 1 the Live Meeting menu bar. The
question will be answered at the end
Identification
1. 2.1 Identification of the webcast. Copies of the webcast
well be made available later on the
Driver
2. 2.2 Driver Shell Eco-marathon Asia website
General
3. 2.3 rules
General rulesfor
forvehicle
vehicle design
design
Prototype
4. 2.4 Prototype
UrbanConcept
5. 2.5 UrbanConcept
6. Energy
2.6. sources
Electrical systems
7. Internal combustion engines
2.7 Internal combustion engines
8. Electric motors
2.8 E-mobility
9. The event in July
3. The event in July
3. Questions & Answers
4. Questions & Answers
Back Agenda
1.0
Rule Changes in SEM 2013
Rules 2013

Back Agenda
Rule Changes – Key Changes
 Only 2 drivers per team
 Solar energy category removed
 Battery Electric category can include solar panels, and energy

produced will be subtracted from the total energy consumed
2012
Gasoline Diesel FAME GTL Ethanol H2 Battery Solar

2013
Battery
Gasoline Diesel FAME GTL Ethanol H2
(+ solar)

Back Agenda
Battery Electric with Solar Panels (1)
 Battery Electric category can include solar panels
 Energy produced will be subtracted from the total energy consumed
 BUT
 Limited size (0.17 m² for prototype, 0.65 m² for UrbanConcept)
Solar panels
0.17 0.65 m²
m²

Back Agenda
Battery Electric with Solar Panels (2)
 Battery Electric category can include solar panels
 BUT
 Must be incorporated in vehicle body
Solar panels
70 70

Back Agenda
General
Article 25: Vehicle design

f) Energy compartment cover must be easy to open for inspection
g) All parts of the drive train (fuel tank, H2 system, etc.) must be within
the body cover.
h) All objects must be securely mounted, (bungee cords/ elastic
material not permitted for securing heavy objects like batteries.
Article 41:
e) Wheels must not touch other parts of the vehicle (i.e. cables, wires,
hoses, and engine compartment components like batteries, etc.)

Back Agenda
General
Article 42: Turning Radius and Steering

a) If rear wheel steering is used it should be easy for the driver to
locate the straight ahead position.
b) Electrically operated indirect steering systems
 Only steering wheel or similar (rotary potentiometer), joystick operation is not
permitted.
 When steering wheel is released by the driver or electrical failure, the vehicle
should revert to the straight ahead position.
Article 46: Vehicle body

b) The covering of wheels & suspension must be a rigid integral part of
the vehicle body

Back Agenda
Lithium Batteries
Article 57: b) Lithium batteries

 The BMS must AUTOMATICALLY isolate the battery under the
following conditions
 During off-track charging:
 Cell balancing
 Over voltage protection
 For e-mobility vehicles, the additional requirement of

 Over discharge protection
 Over current protection
 Over temperature protection
 For accessory batteries, the BMS cell balancing and overvoltage protection
may be contained as part of the off-board charger.

Back Agenda
Hydrogen
Article 65
j) (ii) 2 measurement points (super-capacitor voltage + and -) outside
the vehicle for voltage measurement on the start line
k) External starter battery connectors must be securely fastened to the
vehicle

Back Agenda
Rule Changes - Recommendations
 Read the Rules thoroughly,
 More information:
 Rules: http://www.shell.com/home/content/ecomarathon/for_participants/general_information/rules/
 SEM Asia: http://www.shell.com/home/content/ecomarathon/events/asia/
 Questions: https://secure.shell.com/home/forms/ecomarathon/events/asia/contact_us/form_asia_feedback.html
or email to
Eco-marathon-Asia@shell.com
 FAQs:
 Newsletters:
 The Track: http://www.shell.com/home/content/ecomarathon/events/asia/track/
11
Back Agenda
2.1
Identification

Back Agenda
Article 4: Identification
 For each side & front

 Shell Logo (20x20 cm)
 Racing number/stickers (20x26 cm) x
 For each side (lower part of 10 cm space

around Shell logo Other sponsor names/ logos
body) smaller than Shell logo
 Partner streamer (90x6 cm)
 Logos
 A10 cm space on all four sides of
the Shell logo Race number Partner streamer
 Any other sponsor names/logos Shell logo
must be smaller than the Shell logo

Back Agenda
Article 4: Identification Examples

Back Agenda
Identification of driver coveralls
 These rules apply to drivers when they are on track
Shell pecten placed

at chest level on
the right side
Shell Eco-
marathon logo
placed at chest
level over the
heart

Back Agenda
2.2
Driver

Back Agenda
Article 20: Driver Weight
 Driver weight
 In full driving gear – helmet,
gloves Prototype
 50 kg minimum for Prototype

 70 kg minimum for 50 kg
UrbanConcept
 Ballast provided by team
UrbanConcept
 Must be secured
 For UC cars: part of luggage
 Will be weighed before and 70 kg
after each run

Back Agenda
Articles 21 & 22: Driver Attire
 Article 22: Helmet

 Proper motorcycle helmet
 Not bicycle helmet
 Must comply with standards
 Face shield or safety goggles
must be used
 Article 23:
 Fire retardant clothing
recommended
 Gloves and shoes mandatory
 Synthetic clothing forbidden

Back Agenda
Article 23: Driver Comfort
 Heat
40 °C cockpit
 Cockpit temperatures of 40 °C temperature possible
are a possibility (depending on

Ventilation
vehicle design & weather).
 To avoid heat stress the
following are recommended Ventilation Ventilation
 Good ventilation
 Drinking bottle for driver
 Sunscreen / tinted windows
 Driver preparation
 Keep well hydrated
 Don‟t drive on an empty stomach
Hands free drinking bottle
(firmly attached)

Back Agenda
Article 25: Vehicle Design
Article 25: Vehicle design

f) Energy compartment cover
must be easy to open for
inspection Easily opened engine cover
All objects
g) All parts of the drive train (fuel within cover
tank, H2 system, etc.) must be

within the body cover.

Back Agenda
Article 25 / 41
Article 25: Vehicle Design Tank

Battery All objects tied
f) All objects must be securely Cables
down properly
mounted
 Should not come loose
 Bungee cords & elastic ties not
allowed
Article 41: Tires/Wheels

Wheels must not be in
e) Wheels must not touch other contact with any other parts
parts of the vehicle

Back Agenda
2.3
General Rules for Vehicle Design
For both Prototype and UrbanConcept vehicles

Back Agenda
Article 26: Chassis/Monocoque Stability
 Chassis/ monocoque
 Must be solid
 Wide and long enough to protect 5 cm min
5 cm min
driver
 (Foam no longer needed)
Chassis long enough
 Roll bar:
 >5 cm above helmet
Chassis wide enough
 >5 cm above fuel tank Roll bar
 Extend beyond shoulders
 Withstand 70 kgf
Roll bar extends

beyond shoulders

Back Agenda
Article 28: Visibility
 180° field of vision

 With the cover on
 2 mirrors each of 25
cm² min
2 mirrors 25cm2

Back Agenda
Article 28: Visibility Testing
 180° visibility check

1
2
4m radius
30° 3
4
 Checking mirrors

Back Agenda
Article 35: Exhaust System
 Exhaust pipe requirements

 Exhaust pipe should exit the
vehicle body
 BUT, it should not extend beyond Exhaust pipe
the rear of the vehicle
 Must be made of metal
 Emissions
 Exhaust emissions must be
reasonable (e.g no gross amount
of black smoke)

Back Agenda
Article 29: Safety Belts
 5 point safety belt

 Proprietary (not self
made) racing type belt
 Chassis mounting
 Single buckle
 Able to withstand 1.5x
driver weight

Back Agenda
Testing of Seat Belt Strength
 Tested by lifting with steel rod
 Force scale must register 70 kgf
70 kgf

Back Agenda
Article 30: Vehicle Access
 Exit
 Driver must exit unaided in 10
10 seconds to exit unaided
seconds
 Doors
 Door/opening should be securely
attached No adhesive tape allowed
Arrow to indicate method of opening
 No adhesive tape allowed
 No tools required for opening
 Method of opening marked by
red arrow on outside

Back Agenda
Article 33: Driver Position
 Only leg first position

is allowed
 No “head first”
position (for safety
reasons) Leg first

Back Agenda
Article 40: Cockpit Ventilation
 See article 23A

 Adequate ventilation
should be provided
Ventilation
especially due to the
heat in Malaysia
 For hydrogen vehicles Ventilation Ventilation

2 holes are needed:
 In the engine
compartment
 A the top of the
compartment

Back Agenda
Article 27: Engine Isolation & Fuel System Access
 Bulkhead Engine Driver compartment

compartment
 A permanent bulkhead must
completely separate the driver
compartment from the engine
compartment
 Fire retardant material
 Prevents driver access to engine
Permanent fire
compartment resistant bulkhead
No gaps
allowed
 Objective is to prevent liquids/
flames from reaching driver
 Fuel system must be accessible

for filling

Back Agenda
Article 27 – Example of Fuel System Access
 Fuel system should be accessible  Fuel system should be accessible

with a burette for fuelling with a burette

Back Agenda
Article 27: Example of Bulkhead
 Example of bulkhead  Example of bulkhead gap

Bottom part of car Big gap Body cover of car
Engine
compartment

Back Agenda
Article 27 – Example of Bulkhead Gaps
 The shape of the bulkhead should match shape of body/cover
 Gaps may be filled with aluminium foil or aluminium tape

 This will be rigorously checked during scrutineering
Not allowed OK
No gap
Cover/body
Bulk head
Bulk head
Gap Bulkhead

Back Agenda
Article 31: Horn
 A horn is mandatory
 Only the approved horn is

allowed (to ensure adequate
effectiveness) Horn
 Must be show in electrical circuit

diagram
 New rules:
 Tone (pitch) ≥ 420 Hz.
 Loudness
 ≥ 110 decibels (dBA
 ≥ 85dBA @ 4 meters distance

Back Agenda
Article 32: Fire Extinguisher
 Mandatory
Plumbed in
extinguisher
triggered by Handheld extinguisher
 ABC or BC type driver
 Full
 Valid at time of event
 Properly secured (not loose)

Firmly secured
 Can be plumbed in or hand-
held type
 Usage
 Driver must be trained in usage
 Exit vehicle before using hand-held
extinguisher
For SEM Asia this will be supplied by Shell

Back Agenda
Article 34: Clutch and Transmission
 Clutch
 To ensure that the vehicle can stop
with the engine running (can be
immobilized at starting line)
 Not required for electric motors
 Idling capability required for
UrbanConcept (Article 34 c) Engine
 Manual transmissions - starter motor Chain
interlock required (Article 34 d) Chain guard Clutch
 Auto transmissions - starter motor

speed < clutch engagement speed
(Article 34 b)

Back Agenda
Article 34: Clutch and Transmission > Chain Guard
 Chain guard 
 Mandatory if chain or belt drive is
used
 Should be made of metal
 Must be able to protect
driver/technician) in case of chain
or belt breakage
Chain
guard

Back Agenda
Article 41 & 48: Wheels, Axles, Wheel Hubs
 Wheels
Wheel securely
 Suitable for the car mounted
 Securely mounted
 Prototype:
 Any type allowed
 Urban
 Rim 13-17 inch
 > 80 mm width
 > 1.6 mm thread depth D
D = Rim
diameter 13 to Tire width > 80
17 inches mm
Back Agenda
Article 41 & 48: Wheel Bulkhead
 Wheel bulkhead
 Isolate wheel from driver
 No manipulation of wheel by driver
 Example of wheel mounting &
bulkhead 
Bulkhead to isolate wheel from driver Bulkhead to isolate wheel

(protection against manual handling/ Wheel securely from driver (protection
accidental contact) mounted against manual handling/
accidental contact)

Back Agenda
Article 42: Steering & Handling (Prototype)
 Steering should be precise (no Steering wheel in straight position
excessive play)
 No specific steering mechanism
 Indirect steering is permitted as

long as adequate fail safe and No excessive play. Wheels respond to slight turn
of steering wheel
backup measures are in place
 Turning radius should be < 6 m
 Turning diameter < 12 m
Excessive play. Wheels do not respond

immediately to slight turn of steering wheel

Back Agenda
Article 47: Steering & Handling (UrbanConcept)
 Vehicle steering typical of

production vehicles
 Must be precise, with no
excessive play, no delay
 Turning radius should be < 6 m
 Turning diameter < 12 m
 Real steering wheel
 Steering bars, tillers, joysticks,
Turning
indirect or electric systems are not diameter
<12 m
permitted
 Applies for both UrbanConcept Turning radius
<6m
& Prototypes

Back Agenda
Vehicle Handling Course
 A slalom course will be used to 5m
test the vehicle handling 5
 No speed specified
22 m
4
11 m

Back Agenda
Article 43: Brakes (Prototype)
 2 independent braking systems
 Each must be capable of being operated separately
 Hydraulic brakes recommended
 Disc or V-brake acceptable
 Ergonomical (easy driver access, without lifting hands from steering)
One system for front wheels One system for rear wheel

Back Agenda
Disc brake V-brake

Back Agenda
Not ergonomical

Back Agenda
Article 51: Brakes (UrbanConcept)
 4-disc hydraulic brake system
 X - pattern or front and rear
 Brake pedal: 5 cm x 5 cm
 Must be effective
Disc brakes Hydraulic system

Back Agenda
Article 51: Brake System (UrbanConcept)
x-Pattern
Wheel Wheel
Brake Brake
Brake Brake
Wheel Wheel

Back Agenda
Article 43 & 51: Braking (Effectiveness Test)
 The 2 separate systems will be

tested separately
 Each system alone must hold the
vehicle in place (with driver on
board)
 Slope is 20% (20:100)
 Height: Length = 20:100
Height
Length

Back Agenda
Article 36: Sound Level
 Must not exceed 90 dB from 4 meters away
 Not an issue for electric motors
4m
90 dB

Back Agenda
Article 37: Emergency Shutdown Mechanism
 Mandatory
Starter motor Starter light
 Must stop engine and isolate M
battery (1) Ignition coils
 Show in electrical circuit diagram

 Additional requirements for
hydrogen cars Horn
 New rules Lights
 Two (2) emergency shutdown

switches needed – External &
Internal (Article 37a) External
e-stop
 Physical isolation required for Solar
Internal
& Battery Electric vehicles (Article 37 e-stop
Accessory -
b) +
battery

Back Agenda
Article 37: Emergency Shutdown Button
 “Must be permanently installed

on all vehicles”
 i.e. not fixed on a detachable
part of body
 i.e. not on the top cover but on
the bottom part of body

Back Agenda
Article 37: Emergency Shutdown Button > Location
 CORRECT  WRONG
 Shut down button on permanent  Shut down button on removable
part of body part of body
 Remains fixed even if cover is  No longer part of vehicle if cover

removed is removed

Back Agenda
Article 37: Emergency Shutdown Button > Arrow
 External shut down button

mandatory
 Location of button must be
indicated by a red arrow on a
white background 3cm x 10 cm
3 cm
10 cm

Back Agenda
2.4
Prototype Vehicles

Back Agenda
Prototype
 Characteristics
 3 wheels (usually)
 Driver in horizontal position (leg first)
 Limited cabin space
 Sleek & aerodynamic
 No car lights (except starter light)

Back Agenda
Article 25: Vehicle Design
 3 or 4 wheels
No sharp objects inside
 No aerodynamic appendages
 No sharp edges outside
 No sharp edges inside
3 wheels
No aerodynamic appendages No sharp edges
4 wheels

Back Agenda
Article 39: Dimensions – Prototype
50 kg min (driver
Parameter Limits
only)
Height < 100 cm 140 kg max

(car only)
< 1.25 x track width

Height < 100 cm &
Width < 130 cm
Length < 350 cm
Track width >50 cm
Height:Track width
< 1.25
ratio
Track width > 50 cm

Wheelbase > 100 cm
Width <130 cm
Driver weight >50 kg
Vehicle weight < 140 kg

Wheel base 100 cm min
Length 350 cm max

Back Agenda
Article 39: Dimensions - Track Width and Width
 Track width is the distance between the centre line of the left and right
wheels
 Width is the distance between the widest parts of the whole vehicle
 2 different scenarios are shown below
Track width
Vehicle with
Width
wheels inside
Track width
Vehicle with
Width
wheels outside

Back Agenda
2.5
UrbanConcept Vehicles

Back Agenda
UrbanConcept Vehicles
 Characteristics
 4 wheels only
 Upright seating of driver
70
 Typical of road car
 Lights

Back Agenda
Article 25: General Vehicle Design
 4 running wheels only
 No sharp appendages inside or

outside the vehicle

Back Agenda
Article 45: Dimensions UrbanConcept
Dimension Limits
70 kg min
(driver)
Height 100-130 cm
Driver compartment
height >88 cm
205 kg max
Height 100 -130 cm

Width 120-130 cm
(car only)
Length 220-350 cm 70
Track width (front) > 100 cm
Track width (rear) > 80 cm

Ground clearance >10 cm
Wheelbase > 120 cm

Driver compartment width
Width 120 - 130 cm
at shoulders > 70 cm
Driver compartment
> 88 cm
height
Track width Track width
Driver compartment >80 cm > 100 cm
> 70 cm
width (at shoulders)
Ground clearance > 10 cm
Wheel base >120 cm

Vehicle weight < 205 kg
Vehicle length 220 - 350 cm
Back Agenda
Article 46: Vehicle Body (1)
 Roof mandatory
Roof mandatory
Windscreen mandatory
 Windscreen mandatory
 Body
70
 The body must cover all
mechanical parts
 Commercial body not allowed No aerodynamic Body must cover all
appendages mechanical parts
 Wings must be integral part of
body (not only attached to the
wheel)
 No sharp edges 70
No sharp edges inside

No sharp edges outside

Back Agenda
 Accessories
 Towing hook capable of
withstanding 200 kgf
 Space for suitcase of 40 x 50 x
20cm
 Orientation does not matter
 The suitcase-like object must be Suitcase Towing hook
(2000 N)
provided by the team (and should
look like a suitcase)
20 cm
Suitcase to be
40 provided by team
cm
50 cm

Back Agenda
 The cover of wheels and

suspension must be a rigid
integral part of the vehicle body

Back Agenda
Article 30: Access
 Typical of production car
 Mandatory side door
 Easy access inside or outside
 Driver can exit in 10 seconds

without assistance
 Handles inside and outside
OK OK

Back Agenda
Article 30: Access
 Door opening specified as

500 mm x 800 mm (Article
46 e)
500
70
x 800
mm

Back Agenda
Article 48: Wheels/Tyres
 Suitable for the car D = Rim diameter 13 or 17 inches (33 -43.2 cm)
 Securely mounted
 Proper isolation from driver

D
 No manipulation by driver Thread
depth >1.6
allowed
mm
 Tyre width > 80 mm
 Rim diameter 13-17 inches (33-

Tyre width
> 80 mm
43.2 cm)
 Tyre tread depth > 1.6 mm
D

Back Agenda
Article 50: Lighting
 2 headlights Rear light

Brake light
Head light
Front indicator
 2 rear lights
 2 rear indicator lights
 2 front indicator lights
 2 brake lights
Starter light
 Starter light (for ICE vehicles) Rear indicator

Back Agenda
Article 52: Wet Weather Running
 Capable of running in light

rain/drizzle Ventilation
 Effective electric windscreen Electrical

system
wiper(s).
+ -
 Sufficient ventilation to prevent

driver‟s compartment from
Tread 1.6 mm min Windscreen wiper
fogging.
 Electrical system must be suitable
Brake system effective in wet
for wet weather conditions

Electrical
 Minimum tread of 1.6 mm

system
+ -
 Brake effectiveness under wet

conditions

Back Agenda
2.6
Electrical Systems

Back Agenda
Batteries
There are 3 types of batteries used in the SEM event.

 Propulsion battery (e-mobility & hybrid vehicles
 It‟s main function is to provide power to the power train
 A BMS (battery management system) is needed for lithium batteries
 A super capacitor may be used in place of this battery for solar vehicles
 Accessory battery (all vehicles)
 It‟s main function is to start engine (for ICE only), power accessories &
cooling for driver
 External battery (hydrogen vehicles only)
 This may be used to start fuel cells only at the start line)
 The same rules apply for ALL batteries:
 Max 60 V (48 V nominal), “single” unit, 2 connections

Back Agenda
Article 57 a: Battery Definition
 Source of electrical energy
 Only two connectors
 Comes as a single unit (may contain more than one sub-unit)
 Voltage:
 Maximum of 60 V
 Nominal voltage of 48 V
Electrical
system 1
Electrical system
60V max
48 V nominal Electrical
system 2
+ - + - + - + - + - + -
Sub- Sub- Sub-
Battery Battery Battery
battery battery battery
1 2 3
1 2 3
“Single” battery

Back Agenda
Article 57 h: Accessory Battery
Operates Cannot be used for

 All safety devices (e.g. horn,  Compressors
hydrogen sensor)  Blowers
 Starter motor  Engine cooling systems
 Ignition  Electric motors
 Instrumentation  Fuel pumps
 Electronic management systems
 Ventilation / cooling fan for the The above can only be powered
driver by the engine/fuel cell or
All other additional sources of propulsion battery
electricity are forbidden.

Back Agenda
Article 57 h: Accessory Battery
 Requirements  Only one

 Enough electricity for safety  May consist of more than one
devices sub unit, but only 2 terminals
 Should be located behind the  Voltage
bulkhead, in the engine
 Maximum 60 volts
compartment
 Nominal voltage 48 V
 Restrictions
 Not allowed to power engine
cooling fans/devices (cooling
fans can only be powered by
electricity generated by the
engine)
 May be used to power a cooling
fan for the driver
Back Agenda
Article 57 f: Propulsion Battery (Super capacitor)
 Must be electrically isolated from the vehicle frame and the accessory
battery circuit
 Only one propulsion battery (super capacitor) allowed
 Types:
 For battery electric vehicles only lithium ion batteries are allowed
 For fuel cell vehicles only super a super capacitor is allowed
 For hybrid vehicles only a super capacitor is allowed
Battery electric Lithium ion

Types of
propulsion
batteries Fuel Cell
Super
/super caps
capacitor
allowed Hybrid

Back Agenda
Article 57 f: Propulsion Battery Isolation (Battery & Solar)
Motor
Motor Motor
Motor controller
controller
MC M
MC M
Internal External
Internal External
e-stop e-stop
e-stop e-stop
BMS
Propulsion
+ -
battery
Horn
Horn
Lights
Lights
BMS
Propulsion Accessory
+ - + -
battery battery
<60 V max
< 48 V nom

Back Agenda
Battery Electric & Solar – Alternative Wiring
MC shutdown via relay MC shutdown in series

Motor Motor
controller Motor controller Motor
MC M MC M
Interna External
l e- e-stop
stop
Internal External
e-stop e-stop
BMS BMS
Propulsion Propulsion
+ - + -
battery battery
Horn Horn
Lights Lights
Accessory Accessory
+ - + -
battery battery
<60 V max <60 V max

< 48 V nom < 48 V nom

Back Agenda
Article 57: Electrical System
 Maximum voltage at any point must be

 ≤ 48 Volts nominal
 ≤ 60 Volts max
 This includes on-board batteries, external batteries, super capacitors, fuel cell stack, solar panels, etc
 Lithium batteries must have BMS system which

 During off-track charging: Provides cell balancing & prevent overcharge
 During use: Prevent over-discharge, over-current and over-temperature
 All batteries and super capacitors must be short circuit protected
 All vehicle electrical circuits must be protected against electrical

overload
 Propulsion battery & super capacitors must be electrically isolated
from the vehicle frame and the accessory battery circuit
 Accessory battery must have negative ground
Back Agenda
Article 57: Requirements For Electrical System
 Voltage Starter Starter

motor light
 ≤ 48 Volts nominal M
 ≤ 60 Volts max Ignition coils
 Overload protection of all circuits Overload

protection
on all
 Short circuit protection for circuits
batteries & supercapacitors Horn
 External & internal e-stop

Lights
 Accessory battery should have

negative ground External
e-stop Short circuit
protection (Fuse
Internal or fusable link on
e-stop +ve terminal)
Accessory
+ -
battery
<60 V max
< 48 V nom

Back Agenda
Article 57 d: Overload Protection
No overload protection
Starter Starter Starter Starter
motor light motor light
M M
Ignition coils Ignition coils
Overload
protection
on all
circuits
Horn Horn
Lights Lights
External External
e-stop e-stop
Internal Short circuit Internal Short circuit

e-stop protection (Fuse e-stop protection (Fuse
Accessory Accessory
+ - + -
battery battery
or fusible link on or fusible link on
+ve terminal) <60 V max +ve terminal) <60 V max
< 48 V nom < 48 V nom

Back Agenda
 Overload protection (57 d) Starter Starter

motor light
 Individual overload protection for all M
circuits
Ignition coils
Overload
protection
on all
circuits
Horn
Lights
External
e-stop
Internal Short circuit

e-stop protection (Fuse
Accessory
+ -
battery
or fusible link on
+ve terminal) <60 V max
< 48 V nom

Back Agenda
 Overload protection (57 d) Starter Starter

motor light
 Overload protection for starter motor M
circuit could be removed and share a
Ignition coils
fuse with short circuit fuse
Overload
 Individual overload protection for protection
on all
accessories and ignition circuits
Horn
Lights
External
e-stop

Accessory
+ -
battery
or fusible link on
< 48 V nom

Back Agenda
 Overload protection Starter Starter

motor light
 Overload protection for accessories M
and ignition could be combined
Ignition coils
Horn
Lights
Overload
protection for
ignition &
accessories
External
e-stop

Accessory
+ -
battery
or fusible link on
< 48 V nom

Back Agenda
Article 57 c: Short Circuit Protection
 Short circuit protection Starter Starter

motor light
 Must be as close to the accessory M
battery as possible
Ignition coils
 Could be either a:
 Fuse
 Circuit breaker
Horn
 Fusible link
Lights
Overload
protection for
ignition &
accessories
External
e-stop

Accessory
+ -
battery
or fusible link on
< 48 V nom

Back Agenda
Article 37: Emergency Shutdown (E-stop)
 E-stop action: Motor Solenoid Ignition /

controller valve spark plug
 For battery electric vehicles – isolate
motor controller Diesel
Battery Gasoline
 For gasoline/ethanol vehicles – isolate FAME
Ethanol
ignition coil / spark plugs GTL
 For diesel / FAME / GTL vehicles –
Fuel cell
close fuel solenoid valve
Hybrids
 For fuel cell vehicles – isolate motor
controller & close solenoid valve
 For hybrid vehicles - isolate motor
controller & close solenoid valve (or
isolate ignition coil/spark plugs)
 External & Internal e-stop needed

Back Agenda
Article 37: Emergency Shutdown (Battery Electric only)
 Emergency shutdowns must ensure:

 Physical isolation of propulsion battery from electrical system
 Shutdown via power controller/logic systems are not permitted
 If relays are used, the relays must be a normally open contact type
Motor Normally Motor

controller Motor open controller Motor
MC M MC M
Electronic
controller
Internal External Internal External
e-stop e-stop e-stop e-stop
BMS BMS
Propulsion Propulsion
+ - + -
battery battery

Back Agenda
E-Stops Should Be On Positive Terminal
Starter Starter Starter Starter

motor light motor light
M M
Ignition coils Ignition coils
Horn Horn
Lights Lights
External
External
e-stop
e-stop
Internal
Internal
e-stop
e-stop
Accessory Accessory
+ - + -
battery battery

Back Agenda
E-Stop Location (Internal Combustion)
 In this diagram E-stop covers all Starter Starter

motor light
circuits including starter motor M
 However, Ignition coils
 E-stop doesn‟t have to be on starter

motor circuit as this is a high
current circuit Horn
 Sufficient to put e-stops on ignition Lights

/ solenoid valve circuit and
accessory circuits (see next slide)
External e-
stop
Internal
e-stop
Accessory
+ -
battery
<60 V max
< 48 V nom

Back Agenda
E-Stop Location (Internal Combustion)
 It is sufficient to put E-stops on Starter Starter

motor light
ignition / solenoid valve circuit M
and accessory circuits only Ignition coils
Horn
Lights
External
e-stop
Internal
e-stop
Accessory
+ -
battery
<60 V max
< 48 V nom

Back Agenda
2.7
4B: Internal combustion engines

Back Agenda
Article 59: Propulsion
 The type or design of the

combustion engine is not
restricted, BUT
 Must run only on the fuel
provided by the Organisers
 Must not consume any engine oil.

Back Agenda
Article 60: Other On-board Energy Sources
 Non renewed energy (from  No electrical pumps for fuel, oil

Accessory battery) or water circulation systems
 May only be used for injection,  Flow/circulation only via:
ignition, starter, instrumentation,  Gravity feed
horn, EMS, emergency shut down
 Pressurized system
 If engine is water cooled
 Mechanical pump
 Only pure and unpressurised
water allowed
 No auxiliary calorific energy
source + -
 i.e. no additional fuel Battery
- +
Electric
Injector Pump

Back Agenda
Article 60: Other On-board Energy Sources
 No additional batteries or
power sources allowed
 This will result in immediate
disqualification

Back Agenda
Article 61: Fuel Tank - Requirements
 Only 1 SHELL fuel tank

 Other types of fuel tanks are NOT For gravity
allowed fed fuel
systems, drill
 If pressurized fuel system a hole here
 APAVE certification required

 Safety valve set to 5 bar max
 Hole
 Please remember to drill a hole in
the cover for gravity fed systems
(otherwise the fuel won‟t flow)
APAVE
 Fuel tank tips
 http://www.shell.com/home/content/ecomarathon/asia/
for_participants/handling_fuel_tank/

Back Agenda
Article 61: Fuel Tank - Position
 Fuel tank position Tank should not stick out of body cover
 Inside body cover (not sticking

out)
 Must be 5 cm below the roll bar
 Vertical (not slanted) Tank should be inside body cover
 It should be positioned in such a Roll bar 5 cm
way that a 1 m long burette can

access it for fuelling and
measurement
Vertical NOT slanted

Back Agenda
Article 62: Fuel System
 Description and technical

drawing must be submitted
 Filters & valves

 No additional filters & valves on
the fuel line before the carburetor Filter
 A solenoid cut-off valve is needed Extra

for diesel engines valve
 Must be able to be drained Carburetor / Carburetor /

injector injector
completely before inspection
Drain Drain
 Float chambers/carburetors valve valve
must have a drain valve at the

bottom
Back Agenda
Article 62: Fuel System – Fuel Line
 Fuel return line

 If there is a fuel return line it must
return below the fuel tank
 Fuel circuit
Fuel return
 Semi rigid, translucent hoses line
 2 sizes provided by Shell with OD

and ID of tubing are 8X6 and
6X4 mm respectively Carburetor Carburetor
Engine Engine
/ injector / injector

Back Agenda
Typical Pressurized Fuel Injection System
 Components required: Pressurized Air line (translucent)

bottle
 Translucent compressed air bottle
Air pump Pressurization valve
 Pressurization & pressure
Safety valve (5 bar)
adjustment valve
 Safety valve set to 5 bars max Pressure gauge
 Pressure gauge with normal Pressure

regulator
operating pressure marked
Pressure gauge
 The driver must not modify the
pressure during the competition
Fuel line (translucent)

Injector
Back Agenda
Examples - Pressurized Fuel Injection Systems

Back Agenda
Article 62: Fuel System
 Air intake manifolds:

 No fuel or blow by gas
 No blow by gas recycling
 Fuel temperature
 The fuel cannot be heated or
cooled
 If capable of >1500 km/l

 Entire fuel system should be
removable for weighing

Back Agenda
Article 63: Hybrid Vehicles
 ICE as primary power source in combination with electrical energy

 Electrical energy derived either directly (generator) or indirectly (energy
recovery during braking) from the internal combustion engine.
 Electric only cars are not considered hybrids in SEM
 However they may regenerate energy during braking and the net energy
consumed used as the basis for the result.
Wheel
Super
Convertor Electric motor
capacitor
Transmission Differential
Fuel tank Engine
Wheel

Back Agenda
Article 63: Hybrid Vehicles
 A super capacitor (not a  Developments

battery) must be used to store  Prototype hybrids now allowed
the recovered/ generated  New joule meters that read both
energy ways may be available
 Maximum voltage 60 V (48 V
nominal)
2 external connectors must be
provided to measure the voltage
of the super capacitor
 The entire electrical circuitry
must be fused

Back Agenda
Article 64: Starter
 The starter motor should not

provide any forward propulsion
to the vehicle
 When used it should be indicated
by a red starter light placed
outside the vehicle
 Exceptions for mechanical/hand
pulled starters
Red starter light should
 The starter light should be located at be clearly visible from
both sides of the track
the rear end of the car and visible (ideally should be on rear
from both sides of the track of vehicle)
 Luminescence should be equivalent

to a 21 W light bulb

Back Agenda
Article 64: Starter - Starter Light Clarification
 Role of the starter light

The starter light should be shown
in the electrical circuit diagram
1
 Used to indicate when the Starter Starter Starter
switch motor light
electrical starter motor (if present) This is used only when
is switched on starting the engine so
the starter light should Engine
 Therefore it should be connected to light up when this is
activated Ignition coil +
the starter motor (1) 2
spark plugs
 If no electrical starter motor is used, Horn
Horn
switch
then there should be no starter light.
Light
Lights
 NOT used to indicate that the switch
Other
engine is running (2) Other
electrical
switches
systems
 For internal combustion engines Ignition
switch
vehicles only
Emergency
stop button Battery
When this is pressed the battery should be isolated from all

electrical devices and engine ignition stopped
Back Agenda
2.8
4C: Electric Propulsion

Back Agenda
Article 65: Hydrogen
 Component sequence:  Shutdown mechanism

 Hydrogen tank  Hydrogen sensor (@ 1% H2)
 Pressure regulator linked to shutdown mechanism
 Solenoid shutdown valve  Shuts both solenoid valve & motor
 Hydrogen flow meter  Shut down by either H2 leakage,

driver button or external button
 Fuel cell

Back Agenda
Article 65: Hydrogen - Example of Hydrogen System
Fuel cell vehicle should have the following features

 Note the sequence of the fuel system
Fuel system Flow meter and fuel cell must be at the same pressure
Solenoid Purge (if

H2 Pressure H2 flow
shutdown Fuel cell present)
Cylinder regulator meter
valve outside vehicle
Electrical storage
LEGEND Shutdown mechanism
Hydrogen (if present)
activated by either:
Hydrogen
Electricity should be Super
Electricity
Shutdown Hydrogen sensor capacitor only
Shutdown
control
control
Manual shutdown Shutdown Relay Motorization
button (driver)
External shut down

button (with label) Motor

Back Agenda
 Electrical system
 Accessory battery
 Cannot be used compressors, pumps or cooling components
 Is only for emergency shutdown, horn, lights
 Electrical/electronic casings must be transparent
 If fuel cell electricity is to be stored
 A super capacitor is mandatory
 2 external connections for measuring the super capacitor are necessary
Please bring a drawing of the fuel

and electrical systems to the
event
Back Agenda
Article 65: Hydrogen – Super Capacitor & Fuel Cell
 Super capacitor  Fuel cell

 Max 60 V (48 V nominal)  Max 60 V (48 V nominal)
 Fuse on +ve terminal  Fuse on +ve terminal
 Rating ≤ maximum usable power  Amps = active area of 1 cell (cm²)
divided by the rated voltage
Super +
capacitor - A = Power/V
A = S Amps
S = active surface area of

one cell in stack (in cm2)

Back Agenda
Article 65: Hydrogen – Flow Meter
 Hydrogen flowmeter  Teflon tape & Loctite must not be

 Will be calibrated before the used
event  These will actually damage the flow
meter as they could block the flow
 Must be visible from outside (with
over the sensor
the car cover on)
 Compression seal plus taper
coupling are sufficient to ensure
good sealing.
Coupling Coupling
with taper with
fitting ferrule

Back Agenda
Article 65: Hydrogen – Flow Meter Location
 Flow meters must be readable from outside car (with cover on)
Flow meter Inaccessible flow

visible from meter (deep inside
outside vehicle)

Back Agenda
 Ventilation  Materials
 Ventilation hole of 5 cm² at  Piping and fittings appropriate
highest point of fuel cell for hydrogen (stainless steel if
compartment >1.5bar abs). Evidence must be
 Also applies to driver available.
compartment if hydrogen can go  Hydrogen storage (Shell supplied
there cylinder - Catalina MD)
 No oxygen or compressed air
reserves

Back Agenda
Article 67: Battery Electric Vehicle
 Maximum 60 Volts on-board

(48 V nominal)
 Only lithium ion batteries
 Battery monitoring system for

lithium battery
 Auxiliary battery to power horn,
lights, data acquisition, etc is
permitted

Back Agenda
Article 57b) : Lithium Batteries
 The BMS must AUTOMATICALLY isolate the battery under the

following conditions
 During off-track charging:
 Cell balancing
 Over voltage protection
 For e-mobility vehicles, the additional requirement of

 Over discharge protection
 Over current protection
 Over temperature protection
 For accessory batteries, the BMS cell balancing and overvoltage protection
may be contained as part of the off-board charger.

Back Agenda
Article 67g) : Battery Electric with Solar Panels (1)
 Battery Electric category can now include solar panels
 BUT
Solar panels
0.17
0.65
m² m²

Back Agenda
Article 67g) : Battery Electric with Solar Panels (2)
 Battery Electric category can now include solar panels
 BUT
 Must be incorporated in vehicle body
Solar panels
70 70

Back Agenda
Article 67j) : Battery Electric Vehicle - Joulemeter
 Joulemeter must
 Be inaccessible to driver
 Be readable from outside vehicle
 Measure output of battery – between
battery & all electrical devices required
for vehicle operation (motor control,
battery control, motor, inverters, etc...)
excluding mandatory safety devices
Control Unit
All speed
Battery
Motor regulation

Back Agenda
Article 67j) : BEV - Joulemeter Connections (Layout)
INSTRUCTIONS
Solar  Note connection sequence
Cells
 Return the joulemeter for charging at
the end of each day
Max Power
Controller  Switch off when not in use
(optional)
 If voltage is low return for charging
Solar Motor (7.1 for silver joulemeter, 3.5 for red
panel
JMSOL (s)
module joulemeter)
(optional)
 Disconnect battery when joulemeter is
Motor removed
JMMTR Controller
 Install the joulemeters before coming
for technical inspection
Battery /
Electrical Motor  For vehicles with solar cells, label the
(s)
System joulemeters as „JM-solar‟ and „JM-
motor
Back Agenda
Article 67j) : BEV - Joulemeter Connections (Interface)
 Old Joulemeter (silver)
Battery Motor Controller &

Motor
Joule meter
 New Joulemeter (red) Joule meter

Battery
Motor Controller & Motor

Back Agenda
Article 67l) : BEV - Joulemeter Location
 Joulemeters must be readable from outside car (with cover on)
Joulemeter visible Inacessible joulemeter

from outside (deep inside vehicle)

Back Agenda
Final Comments
 This slide pack does not replace Chapter 1 of the Rules & Regulations.
 It is meant only as a guide to assist in visualizing specific items
 You are advised to go through the articles in Chapter 1, one by one and
ensure that your vehicle complies with each rule.
 Key areas to be aware of are:
 Roll bar (strength and clearance to helmet)
 Bulkhead (no gaps)
 Bulkhead between tyres and driver
 Brakes (must work properly)
 Chain guard
 Make sure your chains are strong enough (lots of chains broke in 2010)

Back Agenda
3.0
The Event in July

Back Agenda
Documentation Required At Event
 Please bring printed copies of:

 Fuel system drawings
 Electrical system drawings
 Supporting information on
 Material suitability
 BMS
 Motor controllers
 PV panels, controllers
 Battery information

Back Agenda
Race Format
 4 laps  The organizers reserve the right
 Number of attempts: 5 to make changes to the race

format during the event in the
 Time limits - 28 and 23 minutes
interest of driver safety
for the UrbanConcept and
Prototype cars respectively
 UrbanConcept car to stop 3 x
10 seconds
 No driver change
Race Format
Distance Average Pit stop 1 Pit stop 2 Pit stop 3 Time Number
Number covered Speed (end of Lap 1) (end of Lap 2) (end of Lap 3) limit Driver
Vehicle Category of
of laps change
attempts
km km/h seconds seconds seconds minutes
UrbanConcept 4 11.2 25 10 10 10 28 5 None
Prototype 4 11.2 30 - - - 23 5 None
Back Agenda
What‟s Next
 A separate webcast will be held to explain

 The processes at the event (scrutineering, practice, competition)
 Details about the track and venue
 Good luck in your preparations & see you in Sepang

Back Agenda
Q&A

Back Agenda
Back Agenda

2013 Asia Rules

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2013 Asia Rules

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SEM GENERAL DESIGN RULES

Official Rules 2013

Copyright of Shell Global Solutions Sdn. Bhd. 1

1.1. Rule changes

Copyright of Shell Global Solutions Sdn. Bhd. 3

 Only 2 drivers per team

 Solar energy category removed

 Battery Electric category can include solar panels, and energy

Gasoline Diesel FAME GTL Ethanol H2 Battery Solar

Copyright of Shell Global Solutions Sdn. Bhd. 4

 Battery Electric category can include solar panels

 Energy produced will be subtracted from the total energy consumed

Copyright of Shell Global Solutions Sdn. Bhd. 5

 Battery Electric category can include solar panels

 Energy produced will be subtracted from the total energy consumed

Copyright of Shell Global Solutions Sdn. Bhd. 6

Article 25: Vehicle design

Copyright of Shell Global Solutions Sdn. Bhd. 7

Article 42: Turning Radius and Steering

Article 46: Vehicle body

Copyright of Shell Global Solutions Sdn. Bhd. 8

Article 57: b) Lithium batteries

 For e-mobility vehicles, the additional requirement of

Copyright of Shell Global Solutions Sdn. Bhd. 9

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 Read the Rules thoroughly,

 SEM Asia: http://www.shell.com/home/content/ecomarathon/events/asia/

 The Track: http://www.shell.com/home/content/ecomarathon/events/asia/track/

Copyright of Shell Global Solutions Sdn. Bhd. 12

 For each side & front

 For each side (lower part of 10 cm space

 Partner streamer (90x6 cm)

Copyright of Shell Global Solutions Sdn. Bhd. 13

Copyright of Shell Global Solutions Sdn. Bhd. 14

 These rules apply to drivers when they are on track

Shell pecten placed

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 50 kg minimum for Prototype

Copyright of Shell Global Solutions Sdn. Bhd. 17

 Article 22: Helmet

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are a possibility (depending on

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Article 25: Vehicle design

tank, H2 system, etc.) must be

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Article 25: Vehicle Design Tank

Article 41: Tires/Wheels

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For both Prototype and UrbanConcept vehicles

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Chassis long enough

Roll bar extends

Copyright of Shell Global Solutions Sdn. Bhd. 23

 180° field of vision

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 180° visibility check

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 Exhaust pipe requirements

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 5 point safety belt

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 Tested by lifting with steel rod