FHSAE Voltz N Boltz

The Vandal Hybrid Racing Team is a non-profit organization which advances the education of future engineers by designing and building a vehicle to compete in the annual Formula Hybrid competitions. The mission of the Vandal Hybrid Racing Team is to build the best Formula Hybrid vehicle possible using our acquired engineering and real world skills while having a good time. The Vandal Hybrid Racing Team is a great way for students to gain appreciation for the hands on side of engineering. Many skills used to build the formula hybrid vehicle are not taught in the class, but gained through trial and error along with plenty of practice. Because of the vast range of skills students learn while being a team member, the project produces very well rounded engineers with an appreciable understanding of how to apply engineering principles to every day challenges.

Sub-System Redesigns
Valve Cover

Body


 * Issue: Need a new lightweight body design. We need to figure out how to mold it, how to scale it to fit the vehicle, and make sure the body shape will fit correctly around the frame and components.


 * Solution:
 * Artemio, our Virtual Technology Design major, designed the body in 3DS max.
 * Imported model into CATIA to give the surface a thickness so that the model is a "real" part.


 * Future Work:
 * Scale CAD model to fit our frame and check for unexpected interference's with other components of vehicle so that we can reshape the body shape accordingly.
 * Finalize the CAD model to send into Jason Stirpe at Janicki Industries so that they can shape the mold we will use to lay down the carbon fiber body shape. This also requires a written proposal, and then they will decide if they will help us with the mold.
 * Shape the body (we already have carbon fiber).

Throttle By Wire


 * Issue: Update drive by wire for throttle body system.


 * Solution:
 * Previous iterations of the formula hybrid vehicle have actuated the throttle body by use of a cable attached to the throttle blade.
 * We decided to go to an electrically actuated throttle body because we can have more control of the vehicle not only through use of our ECU but with the addition of our standalone energy management system.


 * Future Considerations:
 * We are currently testing and troubleshooting our test bench setup and starting to incorporate the EMS.

Suspension Redesign of suspension for incorporation of Carbon Fiber A-Arms.

Tractive System Measuring Point (TSMP)

Redesign for Low Voltage Measuring.

Apex Joint

New joint manufactured to reduce steering play.

Pingel Shifter

Issues: Did not shift into some of the gears and sporadic shifting. Mostly Lacks capability to downshift.

Possible Causes: Not enough current to the shifter, too much load from the engine during shifting, shift lever too short, mechanical linkage preventing the Pingel Electric Shifter’s full range of movement. Solution:


 * Contacted Pingel to verify the maximum rated output force from the Pingel Electric Shifter (30-35 lbs.)
 * Pingel Electric Shifter generates the maximum rated output at its full range of movement.
 * Measured the force it takes to shift the engine with a fish scale (pulling on the end of the shift lever), about 30 lbs. maximum.
 * Fabricated jig to measure the output force from the Pingel Electric Shifter
 * Verified the maximum output force from the Pingel Electric Shifter to be about 30 lbs.
 * Lengthened the shift lever to provide more torque from the Pingel Electric Shifter, and to allow the Pingel Electric Shifter to generate the maximum force (full range of movement).

Outcome:


 * Shifts through all gears now
 * Still hesitates now and then, not 100% reliable
 * Ground clearance is restricted from the lengthened shift lever

Future Considerations:


 * Hook up engine ignition kill module to “unload” the engine during shifting
 * Fix the centrifugal clutch to fully disengage at idle (different issue)
 * Higher capacity charging system to prevent voltage drop at low engine rpm and/or during shifting

Staging Clutch
 * Issue:Early in the year we were able to do testing with the 2013 car and noticed some issues that needed improvement. One of the issues was for the need of a staging clutch. This was due to the fact that in events starting from static we would like to have the RPMs high before taking off to achieve as much torque as possible from the beginning. Since our case for our YZ250f is custom machined in house, the manual clutch was taken off and a Rekluse automatic clutch was installed. Although this situation works we felt that the addition of a manual clutch would help increase times in certain events. As mention before the case is custom machined so stock parts could not be added and a custom system was to be designed.


 * Solution:
 * Designing a cam system that will linearly actuate the push rod that will, in turn, separate the clutch plates allowing the car to be in a neutral state and being able to raise the RPMs while remaining static.
 * This cam will be actuated by a clutch cable that is attached to a hand lever on the steering wheel. A scatter shield is also being incorporated to be within regulations of the rules.
 * Solid modeling is still in place and minor details are being figured out. We hope to be starting the manufacturing/installation period soon.

Brakes


 * Issue:
 * Brakes severely drag/lock up when hot
 * Normal brake drag increases rolling resistance
 * Low pressure brake lines were not protected (braided) lines
 * A single hydraulic reservoir was used to supply the front and rear master cylinders with hydraulic fluid
 * Brake over travel switch only momentarily shut down the vehicle.


 * Causes:
 * Air in the brake system?
 * Residual pressure valves need removed?
 * Caliper pistons do not retract
 * Low pressure brake lines are required to be protected
 * There must be at least two separate hydraulic reservoirs to supply hydraulic fluid to the front and rear brake system independently
 * Brake over travel switch must permanently shut down the vehicle in the event that the brake pedal travels too far (such as a hydraulic leak).


 * Solutions:
 * Found self-retracting calipers from Wilwood
 * Created math model to calculate the required input force from the driver to lock up the wheels
 * Decided to increase the brake rotor diameter to increase the braking power
 * Determined that the self-retracting calipers will work
 * Designed a new mounting bracket for the calipers
 * Sourced and installed braided stainless steel lines for the low pressure brake lines
 * Designed and fabricated a new mount to include two hydraulic reservoirs instead of one
 * Installed single pole, single through toggle switch to act as a brake over travel switch


 * Outcome:
 * Brake system meets all requirements
 * Mounting parts for the new Wilwood calipers have been ordered
 * The rolling resistance should be decreased


 * Future Considerations:
 * Finish installing the new Wilwood calipers
 * Test the brake system to ensure that all four wheels can be locked up
 * Verify that the rolling resistance has been reduced

Engine Maintenance

Jordan Anderson
B.S.M.E., Expected May 2014

Sub-System: Throttle By Wire

Duties: Team Captain, Engine Management

Bio: Interest in machine design and CFD/FEA modeling and optimization. Deans list fall 2013.

Email: ande0878@vandals.uidaho.edu

Jonathan Andring
B.S.M.E., Expected May 2014

Sub-System: Brake System, Pingel Shifter

Duties: Chief Engineer...

Bio: I am a senior mechanical engineering student at the University of Idaho. I grew up most of my life in northern Idaho and enjoy many outdoor activities including, skiing, hunting, fishing, snowmobiling, and ATV riding. I also enjoy engine rebuilding and tinkering on various mechanical systems. When I graduated from high school, I went to North Idaho College for the Welding Technology program. After graduating from this program, I went to work for Diedrich Manufacturing, a manufacturer of high end coffee roasters. My work at Diedrich Manufacturing included fabricating/welding tubular and sheet metals parts, many of which were labor intensive and detailed. I also worked on many new designs/prototypes. After about three and a half years, I came to the conclusion that I wanted to go back to school for mechanical engineering. Now, four and a half years later, I am on the hybrid formula car SAE design team, and will be graduating in May of 2014 with my B.S.M.E.

Email: andr8464@vandals.uidaho.edu

Derek Arrotta
B.S.M.E., Expected May 2014

Sub-System: Engine Management</li>

Duties: Wiki Manager, Pingel Shifter fix, Rules and Safety Officer, ESAC funding, CATIA manager, helped with making Body.</li>

Bio: I grew up in Spokane, WA and have done most of my higher education in Idaho. I've continuously been on the deans list and honor roll the past two years at the University of Idaho, passed the FE exam, and currently have a 3.52 GPA. I'm a huge fan of music, I play the guitar, love to play basketball and soccer, rock climb, and hike in my free time. So far I've been interested in creative design (Solidworks and CATIA) and the dynamics of project management. Although career-wise I am open to all forms of engineering and am eager to learn more.</li>

Email: arro6582@vandals.uidaho.edu</li>

Amos Bartlow
B.S.E.E. with Aerospace Studies Minor, Expected May 2014

Sub-System: Energy Management, Low Voltage Controls, High Voltage Tractive System</li>

Duties:

Bio: Emphasis in micro-controllers and HF circuits. A part of AFROTC, FHSAE, and the clean snowmobile team. Achievements include UI deans list and honor roll.</li>

Email: bart9078@gmail.com</li>



Adam Bunch
B.S.M.E., Expected May 2014

Sub-System: Frame, Impact Intennuator</li>

Duties:</li>

Bio: I am a Mechanical Engineer at the University of Idaho and will be graduating May 2014. I chose engineering because of my passion for racing and always trying to achieve top performance on whatever I was racing. I have been racing since I was of age to do so and because of that I joined the FHSAE team for senior design. I am currently assigned to the frame, impact int. and a redesign of a staging clutch for the car. Aside from engineering I am a member of Sigma Alpha Epsilon fraternity and ran track for the University for two years.</li>

Email: bunc4650@vandals.uidaho.edu</li>

Ignacio Lopez
B.S.M.E., Expected May 2014

Sub-System: Body, Ergonomics, Future Re-gen</li>

Duties:</li>

Bio: A part of society of hispanic professional engineers, dean's list.</li>

Email: lope0093@vandals.uidaho.edu

Nathan Peterson
B.S.M.E., Expected May 2014

<li>Sub-System: Suspension, Tractive System Measurement Point (TSMP), Apex Joint.</li>

<li>Duties:</li>

<li>Bio: A part of SAE, theta chi fraternity, and resonate church. Achievements include dean's list (fall 2013 and spring 2012) and center for advanced energy studies (CASE) scholar.</li>

<li>Email: pete9356@vandals.uidaho.edu</li>

Artemio Ambriz
VIrtual Technology and Design Major

<li>Sub-System: Body.</li>

<li>Duties: Design the new body shape.</li>

<li>Bio: I am a part of aerospace and augmented reality senior capstone group. This project was a great opportunity to advance my skills in virtual design and was a pleasure to work on. </li>

<li>Email: ambr5358@vandals.uidaho.edu</li>