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.

Valve Cover
At the beginning of the year we were only equipped with one valve cover and two engines (one for the dyno and one on the car). This was inconvenient because of the time that it took to switch them out between testing on the dyno and physical testing of the car. To solve this problem a new valve cover was planned to be machined. The solid model was created and sent into Mastercam where a machine plan was made and eventually sent to our HHAAS CNC mill. The part was a five process part with the fifth and final step being on the hand mill for our cam sensor hole. Once completed, the valve cover was placed on the car and used in testing. With the cam sensor working and no leaks the cover was deemed a success.

Body


Problem: New frame requires a new lightweight body. We have a design, however we need to figure out how we will mold it.

-Junior, a VTD major, designed the body in 3DS max. We had some issues importing his model into Catia but we were able to do it.

-The CAD Model needs to be scaled to fit our frame and we need to check for unexpected interferences with items not in the Catia vehicle assembly.

-I spoke to Jason Stirpe, who works at Janicki and they might be able to assist us with the molding. We first need to finalize the CAD model for the body and write a proposal for Janicki.

Throttle By Wire


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.

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:

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 * 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

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Staging Clutch
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. Sing 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 with 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.

Current State: 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.

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>