Formula Hybrid Car (FHSAE) 2015-2016

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The Vandal Hybrid Racing Team is a student organization that produces a hybrid formula car for SAE competition.

Formula Hybrid Vehicle picture from 2015.
Sponsors
Team Name Vandal Hybrid Racing
Duration Summer 2015 - Spring 2016
Faculty Advisers
Mentor
  • Justin Pettingill


Summer/Fall Students
  • Sam Childress
  • Ali Dashti
  • Alberto Garcia
  • Coye Johnson
  • Rick Leathers
  • Mike Marsh
  • James White
Fall/Spring Students
  • Joel Aguilera
  • David Arnett
  • Monte McKinnon
  • Dan Mikkelson
  • Steven Nieuwenhuis
  • Joel Ratcliffe
  • Zach Robertson
  • Matt Sonnen
  • Bryan Tiniakos
  • David Waters
  • James Wilson
Additional members
  • Deryk Ahner

Sub-System Redesigns

Battery Box

DESIGN DEVELOPMENT DESIGN IMPLEMENTATION
ISSUES:
  • Not compliant with current fire safety rules
  • Hard to work on and remove
  • Motor controller mounted on the seat instead with the rest of the electronics.

SOLUTION:

  • New material (Flame retardant Vintec I PVC)
  • New box design
    • Incorporates motor controller
    • Easier access to electronics
    • Better organization
New battery box design.

Powertrain - Exhaust

DESIGN DEVELOPMENT DESIGN IMPLEMENTATION
ISSUES:
  • The vehicles main issue is rule compliance. The Noise level must be less than 110 dBs for an A-type, Fast Weighting Scale test at 8500 rpm. We must create a new high performance silencer that Ensures Vehicle Rule compliancy without sacrificing vehicle performance.

Solution:

  • Investigation of a Two Box Silencer hybrid design muffler with internal Helmholtz resonators is being done to determine if it is a viable solution to the compliance problem.
Two box silencer design.
New exhaust on car
Helmholtz chambers in the new muffler design.

Aerodynamics

DESIGN DEVELOPMENT DESIGN IMPLEMENTATION
ISSUES:
  • There is no aerodynamic part on the car.

Solution:

  • Cutting and mounting the diffuser to improve the down force, make it more stable in turns and improve the grip with the ground.
Render of the diffuser that will be used on the car.

Suspension

DESIGN DEVELOPMENT DESIGN IMPLEMENTATION
ISSUES:
  • High Spring Rates
  • Fatiguing Ball Joint Carriers

Solution:

  • Design, Manufacture, and Install Sway Bar
  • Make New Ball Joint Carriers Out of Titanium
Front Suspension Rocker with Attachment Point for Sway Bar
Lower Ball Joint Carrier
Upper Ball Joint Carrier
Overall Picture of Front Suspension

Chassis

DESIGN DEVELOPMENT DESIGN IMPLEMENTATION
ISSUES:
  • Master Cylinder - Rear wheels do not lock up under braking, this is needed to pass inspection at competition
  • Shifter - Shifter mechanism has undesirable amount of play, making it hard to shift in to gear
  • Frame - The current frame has reached its engineering limits, thus needing a total redesign


Solution:

  • Master Cylinder - Replace master cylinders with ones purchased from Tilton Racing
  • Shifter - Remachine with new materials, and possibly a redesign if necessary
  • Frame - Gather information from other sub systems to aid in new design
Brake master cylinder
Shift lever
Frame

High Voltage System

DESIGN DEVELOPMENT DESIGN IMPLEMENTATION
ISSUES:
  • Poor Wiring, no documentation
  • Unable to run successfully in hybrid mode
  • Battery not successfully constructed
  • Ensure Rules Compliance throughout design

Solution:

  • Utilize PCB design for most of circuit connections
  • Use the schools Power Lab to make hybrid work and extensively test it.
  • Create an efficient battery design with minimal losses
Printed Circuit Board(PCB) design for high voltage control.
Former state of battery box.

Low Voltage System

DESIGN DEVELOPMENT DESIGN IMPLEMENTATION
ISSUES:
  • Lack of documentation
  • Wiring harness can be improved
  • Unreliable circuitry
  • Lack of data acquisition

Solution:

  • Proper, updated documentation
  • MoTeC and ignition module relocation
  • PCB design
  • Dash Redesign
  • Data acquisition implementation
Latching circuit PCB.
Former state of the low voltage controls.
Hercules Connection Platform PCB.
Former state of the car's dash.

Team Profile

TEAM MEMBER BIOGRAPHY SUB-SYSTEM ASSIGNMENTS & DUTIES
Joel Aguilera, M.E.
agui3216@vandals.uidaho.edu
I am currently a senior in Mechanical Engineering at the University of Idaho. I am interested in courses that deal with fluid dynamics and heat transfer, and Solidwork modeling. Some things that I enjoy to do is travel, and bass fishing on my down time. Aerodynamics
Deryk Ahner, M.E.
ahne5837@vandals.uidaho.edu
I am a freshman studying mechanical engineering at the University of Idaho. I hope to get some hands on experience working on the car while at the university. In my free time I like to fish, and relax with friends. Powertrain

Suspension

David Arnett, E.E.
arne9249@vandals.uidaho.edu
David Arnett is progressing towards a B.S. in Electrical Engineering at the University of Idaho, and will graduate in May of 2016. He worked as an electrical engineering intern on the Formula Hybrid Vehicle for the summer of 2014, and was responsible developing data acquisition on a Max32 platform. He then went on to develop a new more robust data acquisition system and determine the cause of issues in the high voltage system over the summer of 2015. David plans to attend the University of Idaho for a Master’s of Science Degree in Electrical Engineering emphasizing in embedded controls and power electronics. Low-Voltage Electrical
Sam Childress, M.E.
chil6774@vandals.uidaho.edu
I am a senior in Mechanical Engineering graduating in December of 2015. Once graduated I will be looking for jobs in Detroit with my fiance. In my free time I enjoy hiking, biking, rafting, and 3d printing. Battery box

Wiki page

Ali Dashti, M.E.
dash2077@vandals.uidaho.edu
My name is Ali Dashti from Kuwait. One of the reasons I chose to study in Idaho because of its weather, we do not have snow and all the beautiful green views. I am senior in Mechanical Engineering and expecting to graduate in May 2016. In my free time I like to play soccer and video games. Aerodynamics
Alberto Garcia, M.E.
Garc3775@vandals.uidaho.edu
I am currently a senior in Mechanical Engineering and expecting to graduate in May 2016. My areas of interest are material analysis, solid mechanics and a bit of design. During my free time I like to watch documentaries, take my dog out for runs and exploring new things. Suspension
Coye Johnson, M.E.
john5136@vandals.uidaho.edu
I severed 6 years in the navy, got out to go to school. Now I am graduating in Dec. with a BSME and currently looking for a job. Battery box
Mike Marsh, M.E.
Mars9871@vandals.uidaho.edu
I am currently studying mechanical engineering at the University of Idaho where my interests are studying solid mechanics, thermodynamics, and fluids. My expected graduation date is December 2015, I plan on staying in the Northwest.

In my free time I enjoy riding bikes, hiking, playing sports, and listening to music.

Suspention

Budget Manager

Monte McKinnon, E.E.
2015FHSAEMcKinnon.jpeg
Monte McKinnon is progressing towards a B.S. in Electrical Engineering at the University of Idaho, and will graduate in May of 2016. He worked as an electrical engineering intern at Esterline Advanced Input Systems for the summer of 2014, and was responsible for managing multiple projects relating to switch bounce and switch contact degradation. He is currently employed by the United States Air Force and works with the FHSAE electrical design team. Low Voltage Electrical
Dan Mikkelson, M.E.
mikk0195@vandals.uidaho.edu
I am a senior studying Mechanical Engineering here at the University of Idaho. I will be graduating in the fall of 2016. I am most interested in mechanics of materials and working with different materials. In my free time I like to mountain bike and ski. Suspension
Steven Nieuwenhuis, M.E.
niue9100@vandals.uidaho.edu
Hello, my name is Steven and I am senior in the mechanical engineering department at the University of Idaho. I am interested in mechanics of materials, which is why I wanted to be a part of the chassis sub system. In my free time, I like to play ice hockey. Chassis
Joel Ratcliffe, E.E.
ratc3488@vandals.uidaho.edu
valign="top"Joel Ratcliffe is a senior in the Electrical Engineering program at the University of Idaho. He will be graduating in the spring of 2016. Joel has a lot of passion in power, signals and systems, and electromagnetics. He hopes to find a job with a lot of hands on work in either power or signal analysis. High Voltage Electrical
Zach Robertson, M.E.
robe3264@vandals.uidaho.edu
I grew up in Miami, FL for most of my childhood. When I was 14 I moved up to Seattle to go to high school and always maintained a passion for design and inventions. At 18 I moved to Pullman, WA to go to WSU for undergraduate studies in Architecture; I discovered it wasn’t what I wanted to do and browsed around majors for a while before settling in on Mechanical Engineering. The program at WSU was overcrowded and I transferred over to the University of Idaho and quickly fit in. Have loved it ever since and am learning tons of things I never thought I would be able to do. I’m in charge of the design and manufacture of the new intake manifold for the Formula Hybrid Car. Powertrain
Matt Sonnen, M.E.
Sonn1237@vandals.uidaho.edu
My name is Matthew Sonnen. I grew up in Middleton, Idaho. I am currently a senior mechanical engineering student at the University of Idaho. I will be graduating in May, 2016. I plan on going into the aerospace industry after graduation. In my free time I enjoy practicing martial arts, playing video games, and skiing. Aerodynamics
Bryan Tiniakos, M.E.
tini0211@vandals.uidaho.edu
: I’m a senior mechanical engineering student here at the University of Idaho. I have been a part of the team since fall 2012. During my time as an undergrad I worked, tuned, and manufactured various pieces on todays and previous cars and all the subsystems besides the battery box. Outside of relations towards school, I work part time, I am an NPC certified bodybuilding athlete, avid downhill/enduro mountain biker, snowboard quite often, and just about try anything that is regarding to sports. Other hobbies are working on cars, either maintaining, upgrading, or racing whenever I have the privilege to. At this point I only participate in Drag racing events but, look forward to working my way towards circuit racing. Additional, I lived internationally for about four years of my life in Maracaibo, Venezuela when I was younger. Suspension
David Waters, M.E.
elde1366@vandals.uidaho.edu
Hello, my name is David Elder Waters and I am a senior in mechanical engineering at the University of Idaho. I am set to graduate in the Fall of 2016. I have always liked cars, especially fast ones, so what better place than the Formula Hybrid SAE Team to work on fast cars. In my free time, I enjoy a good conversation with my friends, eating, and snowboarding. Chassis
James White, M.E.
whit5979@vandals.uidaho.edu
I came to the University of Idaho because of its location near my hometown and because of the quality of the Mechanical Engineering program. In my spare time I enjoy building robots and other microcontroller projects, hiking, and weightlifting. Suspension
James Wilson, M.E.
wils6484@vandals.uidaho.edu
I am a senior in Electrical Engineering. I have worked previously in the pulse power industry measuring radiation doses from a dense plasma focus. I will be graduating in the spring of 2016. I have a passion for hybrid systems, specifically the electrical motor, its control systems, and regenerative 3-phase braking. I hope to find a job in the auto industry pursuing this passion. High Voltage Electrical