Coversheet
The Coversheet mustcontain the following:
-Heading “ElectricalSystemFormFSAE-E2017”
-University and Team Name
-Carnumber
-Main Team Contact for ESF related questions
Feelfreetoaddteamlogo,carpicture,andthelike.
Requirements(deletethissectionafteryouhavereadandunderstoodit):
Readthedocument “HowtocompleteESF” whichisavailableat:
Maximum number of pages for the complete ESF is 100 pages!
Links to video or audio data are prohibited.
If you did not fill out the tables or if you changed the format of the ESF Template, you will fail by default.
Everysinglepart/headingoftheESFTemplatemustbefilledwithcontent.Iftherespectivepartisnotrelevantforyourconcept,describeshortlywhynot.
Thetableofcontentsmustbehyperlinked.
ThegeneratedPDFmustcontainhyperlinkedbookmarks (an example can be found in the FSAE Electric 2017 rules for example).
Useinternalreferencelinks.Forexample,whendescribingwiringandmentioningafigureinthetext thenlinkittothefigure.
Donotjustcopyallyourdatasheetsintheappendix,e.g.wedonotneedtoknowwhatyoumustdotoprogramyourmotorcontroller;wedonotneedthewholeusermanualsofmicrocontrollerstoreviewyourESF,etc. Similarly, do not just paste only a link to the entire data sheet. We should not need an internet connection to obtain the information necessary to review your ESF.
Singlepages/figures/tablesextractedfromthecompletedatasheetshowingtheimportantparameters,figures,etc.areusuallysufficient,butthesource/linktothecompletedatasheetmustbeprovided.Ifthedatasheetdescribesmorethanonetype,clearlymarkinthedatasheettowhichtypeyouarereferring/whichtypeyouplantouse.
Datasheetsshouldonlybeusedasareference.Pleasecovertheimportantdatainyourtextbyusingtables,figures, etc.
If you refer to parts of a data sheet, then you need to provide an internal document linksfromthetexttotherespectivedatasheetandanother internal document linkbackfromthedatasheettothetextsection.
Forexamplealinkinthemotorcontrollersection “Thedatasheetcanbefoundhere(clickable)” andalinkabovethemotorcontrollerdatasheetintheappendix “Thesectioncoveringthemotorcontrollercanbefoundhere(clickable)”.
Ifyouareunsurewithrespecttofeedbackofthereviewer,donothesitatetowriteane-mailandask.
Parts of the ESF which are changed because of reviewer’s feedback must be marked in red.
Followingtheseguidelineswillguaranteeaswiftreviewprocess.
UniversityName,CarNumberTableofContents
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TableofContents
2017 Formula SAE Electric1
UniversityName,CarNumberTableofContents
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TableofContents
IListofFigures......
IIListofTables......
IIIListofAbbreviations......
1SystemOverview......
2ElectricalSystems......
2.1ShutdownCircuit
2.1.1Description/concept
2.1.2Wiring/additionalcircuitry
2.1.3Positionincar
2.2IMD
2.2.1Description(type,operationparameters)
2.2.2Wiring/cables/connectors/
2.2.3Positionincar
2.3Inertia Switch
2.3.1Description(type,operationparameters)
2.3.2Wiring/cables/connectors/
2.3.3Positionincar
2.4Brake Plausibility Device
2.4.1Description/additionalcircuitry
2.4.2Wiring
2.4.3Positionincar/mechanicalfastening/mechanicalconnection
2.5Reset / LatchingforIMDandBMS
2.5.1Description/circuitry
2.5.2Wiring/cables/connectors
2.5.3Positionincar
2.6Shutdown System Interlocks
2.6.1Description/circuitry
2.6.2Wiring/cables/connectors
2.6.3Positionincar
2.7Tractivesystemactivelight
2.7.1Description/circuitry
2.7.2Wiring/cables/connectors
2.7.3Positionincar
2.8Measurementpoints
2.8.1Description
2.8.2Wiring,connectors,cables
2.8.3Positionincar
2.9Pre-Chargecircuitry
2.9.1Description
2.9.2Wiring,cables,currentcalculations,connectors
2.9.3Positionincar
2.10Dischargecircuitry
2.10.1Description
2.10.2Wiring,cables,currentcalculations,connectors
2.10.3Positionincar
2.11HVDisconnect(HVD)
2.11.1Description
2.11.2Wiring,cables,currentcalculations,connectors
2.11.3Positionincar
2.12Ready-To-Drive-Sound(RTDS)
2.12.1Description
2.12.2Wiring,cables,currentcalculations,connectors
2.12.3Positionincar
3Accumulator
3.1Accumulatorpack1
3.1.1Overview/description/parameters
3.1.2Celldescription
3.1.3Cellconfiguration
3.1.4Celltemperaturemonitoring
3.1.5Batterymanagementsystem
3.1.6Accumulatorindicator
3.1.7Wiring,cables,currentcalculations,connectors
3.1.8Accumulatorinsulationrelays
3.1.9Fusing
3.1.10Charging
3.1.11MechanicalConfiguration/materials
3.1.12Positionincar
3.2Accumulatorpack2
4Energymetermounting
4.1Description
4.2Wiring,cables,currentcalculations,connectors
4.3Positionincar
5Motorcontroller
5.1Motorcontroller1
5.1.1Description,type,operationparameters
5.1.2Wiring,cables,currentcalculations,connectors
5.1.3Positionincar
5.2Motorcontroller2
6Motors
6.1Motor1
6.1.1Description,type,operatingparameters
6.1.2Wiring,cables,currentcalculations,connectors
6.1.3Positionincar
6.2Motor2
7Torqueencoder
7.1Description/additionalcircuitry
7.2Torque Encoder Plausibility Check
7.3Wiring
7.4Positionincar/mechanicalfastening/mechanicalconnection
8AdditionalLV-partsinterferingwiththetractivesystem
8.1LVpart1
8.1.1Description
8.1.2Wiring,cables,
8.1.3Positionincar
8.2LVpart2
9Overall Grounding Concept
9.1Description of the Grounding Concept
9.2Grounding Measurements
10Firewall(s)
10.1Firewall1
10.1.1Description/materials
10.1.2Positionincar
10.2Firewall2
11Appendix
2017 Formula SAE Electric1
UniversityName,CarNumberTableofContents
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2017 Formula SAE Electric1
UniversityName,CarNumber
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IListofFigures
Has tobehyperlinked!
2017 Formula SAE Electric1
UniversityName,CarNumber
II
III
IV
VListofTables
Table 1.1 General parameters
Table 2.1 Listofswitchesinthe shutdown circuit
Table 2.2 Wiring – Shutdown circuit
Table 2.3 Parameters of the IMD
Table 2.4 Parameters of the Inertia Switch
Table 7.1 Torque encoder data
Table 2.6 Parameters of the TSAL
Table 2.7 General data of the pre-charge resistor
Table 2.8 General data of the pre-charge relay
Table 2.9 General data of the discharge circuit
Table 3.1 Main accumulator parameters
Table 3.2 Main cell specification
Table 3.5 Wire data of company A, 0.205 mm²
Table 3.3 Basic AIR data
Table 3.4 Basic fuse data
Table 3.5 Fuse Protection Table
Table 3.6 General charger data
Table 5.1 General motor controller data
Table 5.2 Wire data of company A, 0.205 mm²
Table 6.1 General motor data
Table 7.1 Torque encoder data
Has tobehyperlinked!
2017 Formula SAE Electric1
UniversityName,CarNumber ______
VIListofAbbreviations
2017 Formula SAE Electric1
UniversityName,CarNumber ______
1SystemOverview
- Shortdescriptionofthesystem’sconcept
- RoughSchematic(blocks)showingallpartsaffectedwiththeelectrical systemsandfunctionofthetractive-system
- Nodetailedwiring
- Additionally, fill out the following table, replacing the values with your specifications:
Maximum Tractive-system voltage: / 600VDC
Nominal Tractive-system voltage: / 560VDC
Control-system voltage: / 12VDC, 24VDC
Accumulator configuration: / 200s3p
Total Accumulator capacity: / 200Ah
Motor type: / Permanent excitated synchronous motor
Number of motors: / Total 4, one per wheel
Maximum combined motor power in kW / 150
Table 1.1 General parameters
2017 Formula SAE Electric1
UniversityName,CarNumber
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2ElectricalSystems
2.1ShutdownCircuit
2.1.1Description/concept
Describeyourconceptoftheshutdowncircuit,themasterswitches,shutdownbuttons,brakeovertravelswitch,etc.
Additionally, fill out the following table replacing the values with your specification and append additional switches from your setup:
Part / FunctionMain Switch (for control and tractive-system; CSMS, TSMS) / Normally open
Brake over travel switch (BOTS) / Normally closed
Shutdown buttons (SDB) / Normally closed
Insulation Monitoring Device (IMD) / Normally open
Battery Management System (BMS) / Normally open
Inertia Switch / Normally closed
Interlocks / Closed when circuits are connected
Brake System Plausibility Device / Normally Closed
Table 2.1 Listofswitchesinthe shutdowncircuit
2.1.2Wiring/additionalcircuitry
Describewiringandadditionalcircuitry,showextraschematicsforexampleifadditionaltransistorsetc.areused,alsodescribethefunctionofadditionalcircuitryandmakegooduseoffigures.
Additionally, fill out and add information to the following table:
Total Number of AIRs: / 10Current per AIR: / 0.5A
Additional parts consumption within the shutdown circuit: / 2A
Total current: / 7A
Cross sectional area of the wiring used: / 0.205 mm²
Table 2.2 Wiring – Shutdown circuit
2.1.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherenderings,ifnecessary.
2.2IMD
2.2.1Description(type,operationparameters)
DescribetheIMD used anduseatableforthecommonoperationparameters,likesupplyvoltage,set point,etc.Also,describehowtheIMDindicatorlightiswired,etc.
Additionally, fill out the following table replacing the values with your specification:
Supply voltage range: / 10..36VDCSupply voltage / 24VDC
Environmental temperature range: / -40..105°C
Selftest interval: / Always at startup, then every 20 minutes
High voltage range: / DC 0..1000V
Set response value: / 300kΩ (500Ω/Volt)
Max. operation current: / 500mA
Approximate time to shutdown at 50% of the response value: / 27s
Table 2.3 Parameters of the IMD
2.2.2Wiring/cables/connectors/
Describewiring,showschematics,describeconnectorsandcables used andshowusefuldataregardingthewiring including wire gauge/temp/voltage rating and fuses protecting the wiring.
2.2.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
2.3Inertia Switch
2.3.1Description(type,operationparameters)
DescribetheInertia Switch used anduseatableforthecommonoperationparameters,likesupplyvoltage,temperature,etc.
Additionally, fill out the following table replacing the values with your specification:
Inertia Switch type: / Sensata XYZSupply voltage range: / 10..36VDC
Supply voltage: / 12VDC
Environmental temperature range: / -40..105°C
Max. operation current: / 500mA
Trigger characteristics: / 6g for 50ms / 11g for 15ms
Table 2.4 Parameters of the Inertia Switch
2.3.2Wiring/cables/connectors/
Describewiring,showschematics,describeconnectorsandcables used andshowusefuldataregardingthewiring.
2.3.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
2.4Brake Plausibility Device
2.4.1Description/additionalcircuitry
Describe how your electronic hardware brake plausibility system works (this is in addition to your ECU controlled brake plausibility software),providetableswithmainoperationparameters,anddescribeadditionalcircuitryusedtocheckorfor an implausibility.Describehowthesystemreactsifanimplausibilityorerror isdetected.
Brake sensor used: / ABC SensorTorque encoder used: / potentiometer
Supply voltages: / 5V
Maximum supply currents: / 20mA
Operating temperature: / -20..180 °C
Output used to control AIRs: / Open a relay
Table 2.5 Torque encoder data
2.4.2Wiring
Describethewiring,showschematics including the circuit board,showdataregardingthecablesandconnectors used. If not detailed in section 2.1, be sure to show how the device open the shutdown circuit.
2.4.3Positionincar/mechanicalfastening/mechanicalconnection
ProvideCAD-renderingsshowingallrelevantparts anddiscussthemechanicalconnectionofthesensorstothepedalassembly.Markthepartsintherendering,ifnecessary.
2.5Reset / LatchingforIMDandBMS
2.5.1Description/circuitry
Describetheconceptandcircuitryofthelatching/resetsystem for a tripped IMD or BMS. Describe the method for resetting the IMD and BMS.
2.5.2Wiring/cables/connectors
Describewiring,showschematics,describeconnectorsandcables used andshowusefuldataregardingthewiring. If not detailed in section 2.1, be sure to show how the device opens the shutdown circuit.
2.5.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
2.6Shutdown System Interlocks
2.6.1Description/circuitry
DescribetheconceptandcircuitryoftheShutdown System Interlocks.
Note: Interlocks are circuits used to open the shutdown circuit if a connector is disconnected or enclosure is opened. This is not the entire shutdown circuit.
2.6.2Wiring/cables/connectors
Describewiring,showschematics,describeconnectorsandcables used andshowusefuldataregardingthewiring.
2.6.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
2.7Tractivesystemactivelight
2.7.1Description/circuitry
Describethetractivesystemactivelightandadditionalcircuitry.
Additionally, fill out the table:
Supply voltage: / 12VDCMax. operational current: / 700mA
Lamp type / LED
Power consumption: / 4.5 W
Brightness / 100 Lumen
Frequency: / 1.5Hz
Size (length x height x width): / 20mm x 10mm x 50mm
Table 2.6 Parameters of the TSAL
2.7.2Wiring/cables/connectors
Describewiring,showschematics,describeconnectorsandcables used andshowusefuldataregardingthewiring. Include gauge, voltage and temperature rating of wiring used and any fuses or other overcurrent protection used.
2.7.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
2.8Measurementpoints
2.8.1Description
Describethehousing usedandhowitcanbeaccessed,etc. Describe how the measurement points protected/covered when not in use and how the electrical connections on the back of the measurement points are protected when the measurement points are being used.
2.8.2Wiring,connectors,cables
Describewiring,showschematics,anddescribeconnectorsandcables used andshowusefuldataregardingthewiring. Include details on the protection resistor including resistance, voltage and power rating.
2.8.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
2.9Pre-Chargecircuitry
2.9.1Description
Describeyourconceptofthepre-chargecircuitry.
2.9.2Wiring,cables,currentcalculations,connectors
Describewiring,showschematics,describeconnectorsandcables used andshowusefuldataregardingthewiring.
Give a plot “Percentage of Maximum Voltage” vs. time
Give a plot Current vs. time
For each plot, give the basic formula describing the plots
Additionally, fill out the tables:
Resistor Type: / ABC ResistorResistance: / 680Ω
Continuous power rating: / 60W
Overload power rating: / 200W for 30 sec
Voltage rating: / 1500V
Cross-sectional area of the wire used: / 0.205 mm²
Table 2.7 General data of the pre-charge resistor
Relay Type: / DEF RelayContact arrangment: / SPDT, SPST, SPCO, SPTT, DPST, ….
Continuous DC current: / 25A
Voltage rating / 2000VDC
Cross-sectional area of the wire used: / 0.205 mm²
Table 2.8 General data of the pre-charge relay
2.9.3Positionincar
ProvideCAD-renderingsshowingallrelevantparts.Markthepartsintherendering,ifnecessary.
2.10Dischargecircuitry
2.10.1Description
Describeyourconceptofthedischargecircuitry.
2.10.2Wiring,cables,currentcalculations,connectors
Describewiring,showschematics,describeconnectorsandcables used andshowusefuldataregardingthewiring.
Give a plot “Voltage” vs. time
Give the formula describing thisbehavior
Give a plot “Discharge current” vs. time
Give the formula describing your plot
Additionally, fill out the table:
Resistor Type: / ABC ResistorResistance: / 680Ω
Continuous power rating: / 350W
Overload power rating: / 600W for 20 sec
Voltage rating: / 1500V
Maximum expected current: / 0.7A
Average current: / 0.3A
Cross-sectional area of the wire used: / 0.205 mm²
Table 2.9 General data of the discharge circuit
2.10.3Positionincar
ProvideCAD-renderingsshowingallrelevantparts.Markthepartsintherendering,ifnecessary.
2.11HVDisconnect(HVD)
2.11.1Description
DescribeyourconceptoftheHVDandhowitcanbeoperated.
2.11.2Wiring,cables,currentcalculations,connectors
Describewiring,showschematics,describeconnectorsandcables andshowusefuldataregardingthewiring. Include information on the working voltage and current rating of the HVD.
2.11.3Positionincar
ProvideCAD-renderingsshowingallrelevantparts.Markthepartsintherendering,ifnecessary.
2.12Ready-To-Drive-Sound(RTDS)
2.12.1Description
DescribeyourconceptoftheRTDS,howisthesoundproduced,whataretheparametersforactivatingtheRTDS,etc.
2.12.2Wiring,cables,currentcalculations,connectors
Describewiring,showschematics,describeconnectorsandcables andshowusefuldataregardingthewiring.
2.12.3Positionincar
ProvideCAD-renderingsshowingallrelevantparts.Markthepartsintherendering,ifnecessary.
2017 Formula SAE Electric 1
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3Accumulator
3.1Accumulatorpack1
3.1.1Overview/description/parameters
Describeconceptofaccumulatorpack,providetablewithmainparameterslikenumberofcells, cell stacks separated by maintenance plugs,cellconfiguration,resultingvoltages->minimum,maximum,nominal,currents,capacityetc.
Fill out the following table:
Maximum Voltage: / 550VDCNominal Voltage: / 500VDC
Minimum Voltage: / 300VDC
Maximum output current: / 405A for 10s
Maximum nominal current: / 250A
Maximum charging current: / 50A
Total numbers of cells: / 200
Cell configuration: / 100s2p
Total Capacity: / 21.6 MJ
Number of cell stacks < 120VDC / 5
Table 3.1 Main accumulator parameters
3.1.2Celldescription
Describethecelltype usedandthe chemistry,providetablewithmainparameters.
Fill out the following table:
Cell Manufacturer and Type / Kokam XYZCell nominal capacity: / 5.4 Ah
Maximum Voltage: / 4.2 V
Nominal Voltage: / 3.7V
Minimum Voltage: / 2.8V
Maximum output current: / 20C for 10s
Maximum nominal output current: / 15C
Maximum charging current: / 5C
Maximum Cell Temperature (discharging) / 65°C
Maximum Cell Temperature (charging) / 55°C
Cell chemistry: / LiFePO4
Table 3.2 Main cell specification
3.1.3Cellconfiguration
Describe cell configuration, cell interconnect, show schematics of electrical configuration and CAD of connection techniques, cover additional parts like internal cell fuses etc.
3.1.4Celltemperaturemonitoring
Describehowthetemperatureofthecellsismonitored,wherethetemperaturesensorsareplaced,howmanycellsaremonitored,etc.Showschematics,coveradditionalparts,etc.
3.1.5Batterymanagementsystem
DescribetheBMS used including at least the following:
-Sense wiring protection (fusing / fusible link wire used)
-What upper and lower voltage does the BMS react at and how does it react?
-What cell temperature does the BMS react at and how does it react?
-Show tables of operation parameters
-Describe how many cells are sensed by each BMS board, the configuration of the cells, the configuration of the boards and how any comms wiring between boards is protected
-Describe how the BMS is able to open the AIRs if any error is detected
-Describe where galvanic isolation occurs between TS and GLV system connections.
3.1.6Accumulatorindicator
Describetheindicator,showwiring,providetableswithoperation, PCB design,etc.
3.1.7Wiring,cables,currentcalculations,connectors
Describetheinternalwiring,showschematics,providecalculationsforcurrentsandvoltages and showdataregardingthecablesandconnectors used.
Discuss maximum expected current, DC and AC how long will this be provided?
Compare the maximum values to nominal currents
Give a table for each kind of wire in your tractive-system:
Describe your maintenance plugs, providepictures
Use tables like the one shown below:
Wire type / Company A,Continuous current rating: / 150A
Cross-sectional area / 0.205 mm²
Maximum operating voltage: / 800VDC
Temperature rating: / 150 °C
Wire connects the following components: / Cell and BMS
Table 3.3 Wire data of company A, 0.205 mm²
3.1.8Accumulatorinsulationrelays
DescribetheAIRs usedandtheirmainoperationparameters,usetables,etc.
Additionally, fill out the following table:
Relay Type: / ABC RelayContact arragment: / SPST
Continous DC current rating: / 100A
Overload DC current rating: / 200A for 10sec
Maximum operation voltage: / 800VDC
Nominal coil voltage: / 24VDC
Normal Load switching: / Make and break up to 300A
Maximum Load switching / 10 times at 1500A
Table 3.4 Basic AIR data
3.1.9Fusing
Describethefuses used andtheirmainoperationparameters,usetables,etc.
Additionally, fill out the following table for each fuse type used:
Fuse manufacturer and type: / ABC Fuse company, MNO FuseContinous current rating: / 150A
Maximum operating voltage / 500VDC
Type of fuse: / High speed
I2t rating: / 1500A2s at 450VDC
Interrupt Current (maximum current at which the fuse can interrupt the current) / 10000A
Table 3.5 Basic fuse data
Create a table with components and wires protected by the fuse(s) and the according continuous current rating, below is an example table with some potential entries. Complete this table with information for your design and add/remove additional locations as applicable. Ensure that the rating of all the components is greater than the rating of the fuse such that none of the other components become the fuse.
Location / Wire Size / Wire Ampacity / Fuse type / Fuse ratingCells to AIRs / 2 AWG / XXX / MNO Fuse / XXX
AIR to Motor controller / 0 AWG / XXX / 2x MNO Fuse / XXX
AIR to TSAL / 20 AWG / XXX / EFG Fuse / XXX
Accumulator output connector / 2 AWG / XXX
Cells to BMS
Table 3.6 Fuse Protection Table
3.1.10Charging
Describehowtheaccumulatorwillbecharged.Howwillthechargerbeconnected?Howwilltheaccumulatorbesupervisedduringcharging?Showschematics,CAD-Renderings,etc.,ifneeded
Additionally, fill out the table:
Charger Type: / ABC ChargerMaximum charging power: / 3kW
Maximum charging voltage: / 550V
Maximum charging current: / 20A
Interface with accumulator / CAN-Bus, proprietary, serial communication...
Input voltage: / 230 VAC
Input current: / 16A
Table 3.7 General charger data
3.1.11MechanicalConfiguration/materials
Describetheconceptofthecontainer,showhowthecellsaremounted,useCAD-Renderings,showdataregardingmaterials used,etc.
3.1.12Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary. Ensure that the required mechanical structure to protect the accumulator and other electrical components is clearly identified.
3.2Accumulatorpack2
…
Ifidenticalpartsareused,justrefertothecorrespondingsections,don’tcopyandpaste.
2017 Formula SAE Electric1
UniversityName,CarNumber
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4Energymetermounting
4.1Description
Describewheretheenergymeterismountedandhow,etc.
4.2Wiring,cables,currentcalculations,connectors
Describethewiring,showschematics,providecalculationsforcurrentsandvoltages,andshowdataregardingthecablesandconnectors used.
4.3Positionincar
ProvideCAD-renderingsshowingallrelevantparts.Markthepartsintherendering,ifnecessary.
2017 Formula SAE Electric1
UniversityName,CarNumber
______
5Motorcontroller
5.1Motorcontroller1
5.1.1Description,type,operationparameters
Describeimportantfunctions;providetablewithmainparameterslikeresultingvoltages->minimum,maximum,nominal,currentsetc.
Fill out the following table:
Motor controller type: / ABC ControllerMaximum continous power: / 60kW
Maximum peak power: / 75kW for 10s
Maximum Input voltage: / 600VDC
Output voltage: / 250VAC
Maximum continuous output current: / 100A
Maximum peak current: / 200A for 5s
Control method: / PWM, analog signal...
Cooling method: / Air, water, oil...
Auxiliary supply voltage: / 24VDC
Table 5.1 General motor controller data
5.1.2Wiring,cables,currentcalculations,connectors
Describethewiring,showschematics,providecalculationsforcurrentsandvoltages andshowdataregardingthecablesandconnectors used.
Additionally, fill out table:
Wire type: / Company A, 0.205 mm²Current rating: / 150A
Maximum operating voltage: / 800V
Temperature rating: / 150 °C
Table 5.2Wire data of company A, 0.205 mm²
5.1.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
5.2Motorcontroller2
…
Ifidenticalpartsareused,justrefertothecorrespondingsections,don’tcopyandpaste.
.
2017 Formula SAE Electric1
UniversityName,CarNumber
______
6Motors
6.1Motor1
6.1.1Description,type,operatingparameters
Describethemotor used,providetablewithmainparameterslikeresultingvoltages->minimum,maximum,nominal,currents,resultingmotorpower,usefigurestoshowimportantcharacteristics.
Additionally, fill out table:
Motor Manufacturer and Type: / ABC MotorMotor principle / Asynchronous, permanently excitated
Maximum continuous power: / 25kW
Peak power: / 70kW for 5s
Input voltage: / 250VAC
Nominal current: / 50A
Peak current: / 70A
Maximum torque: / 60Nm
Nominal torque: / 20Nm
Cooling method: / Water, oil, air,...
Table 6.1 General motor data
Give a plot of power vs. Rpm including a line for nominal and maximum power
give a plot of torque vs. rpm including a line for nominal and maximum torque
6.1.2Wiring,cables,currentcalculations,connectors
Describethewiring,showschematics,providecalculationsforcurrentsandvoltages andshowdataregardingthecablesandconnectors used.
6.1.3Positionincar
ProvideCAD-renderingsshowingallrelevantparts.Markthepartsintherendering,ifnecessary and clearly identify the structure used to protect all relevant parts.
6.2Motor2
…
Ifidenticalpartsareused,justrefertothecorrespondingsections,don’tcopyandpaste.
2017 Formula SAE Electric 1
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______
7Torqueencoder
7.1Description/additionalcircuitry
Describethetypeofthetorqueencoder(s) used,providetableswithmainoperationparameters,anddescribeadditionalcircuitryusedtocheckormanipulatethesignalgoingtothemotorcontroller.Describehowthesystemreactsifanimplausibilityorerror (e.g. short circuit or open circuit or equivalent)isdetected.
Torque encoder manufacturer and type: / ABC EncoderTorque encoder principle: / potentiometer
Supply voltage: / 5V
Maximum supply current: / 20mA
Operating temperature: / -20..180 °C
Used output: / 0-5V
Table 7.1 Torque encoder data
7.2Torque Encoder Plausibility Check
Describe additional circuitry used to check or manipulate the signal going to the motor controller. Describe how failures (e.g. Implausibility, short circuit or open circuit or equivalent) are detected and how the system reacts if an implausibility or errors is detected.
7.3Wiring
Describethewiring,showschematics,showdataregardingthecablesandconnectors used.
7.4Positionincar/mechanicalfastening/mechanicalconnection
ProvideCAD-renderingsshowingallrelevantparts anddiscussthemechanicalconnectionofthesensorstothepedalassembly.Markthepartsintherendering,ifnecessary.
2017 Formula SAE Electric 1
UniversityName,CarNumber
______
8AdditionalLV-partsinterferingwiththetractivesystem
8.1LVpart1
Describethosepartsherewhichinterfereorinfluencethetractivesystem,forexampleacontrollingunitthatmeasureswheelspeedsandsteeringangleandcalculatesatargettorqueforeachmotororaDC/DC-ConverterprovidingpowerfortheLV-systemfromtheHV-system,etc.
8.1.1Description
Describetheparts usedandtheircircuitry,andprovidemainoperationparameters,usetablesorfigures,etc.
8.1.2Wiring,cables,
Describethewiring,showschematics,etc.
8.1.3Positionincar
ProvideCAD-renderingsshowingtherelevantparts.Markthepartsintherendering,ifnecessary.
8.2LVpart2
…
2017 Formula SAE Electric1
UniversityName,CarNumber
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9Overall Grounding Concept
9.1Description of the Grounding Concept
Describehow you intend to achieve the resistances between components at the required levels as defined in EV4.3.
9.2Grounding Measurements
Describe which measurements you will take to ensure that EV4.3 is achieved
2017 Formula SAE Electric1
UniversityName,CarNumber
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10Firewall(s)
10.1Firewall1
10.1.1Description/materials
Describetheconcept,layerstructureandthematerialsused forthefirewall.ShowhowthelowresistanceControlSystemgroundconnectionisachieved.
10.1.2Positionincar
ProvideCAD-renderingsshowingallrelevantparts.Markthepartsintherendering,ifnecessary.
10.2Firewall2
2017 Formula SAE Electric 1
UniversityName,CarNumber 11
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11Appendix
Numberingaccordingtochapter1to10
Adatasheetformotorcontrolleroneforexamplehastohavethenumbering11.10.5
Example appendix entry:
11.2.2 – Bender IR155-3203 IMD ratings
Referred from 2.1.1.
Complete data sheet located at:
2017 Formula SAE Electric1