EV Challenge Vehicle Specifications, Rules, and Forms for Competition

January 2012

CONTENTS

Vehicle Specifications 2-21 Program Overview and Rules 23-36 Forms and Additional Information Appendix Technical Inspection Forms: Weight Inspection Electrical Inspection Mechanical Inspection Vehicle Design Score Sheet Oral Presentation Score Sheet Troubleshooting: Pre-post Test Questions Pre-post Test Answers Troubleshooting Board Wiring Diagram Photo of Troubleshooting Board School Initiative Form

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EV Challenge Electric Vehicle Specifications Version 11 – January, 2012

Items highlighted in yellow indicate changes from previous versions.

TABLE OF CONTENTS I. General

A. Purpose of the Specifications B. Compliance with Specifications C. Minimum Vehicle Performance D. State Vehicle Requirements E. Vehicle Selection

II. Vehicle Classes

A. Three Classes B. Design Objective C. Description

III. Electrical

A. Traction Batteries 1. Battery Pack Voltage 2. Battery Type 3. Battery Installation 4. Battery Ventilation 5. Multiple Battery Packs 6. Battery Change-out 7. Battery Disconnect Device 8. Battery Location 9. Battery Fuses

B. Charging 1. General Regulations 2. All Chargers 3. On-board Chargers 4. Off-board Chargers

C. Auxiliary 12 Volts D. Electric Motors E. Controller

IV. Electrical Safety

A. Definitions 1. “Ampacity” 2. “Break-down voltage”

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B. Conductor Rating C. Fuse and Wiring Compatibility D. Conductor Routing E. Quick Disconnects, Plugs, etc. F. Incidental Contact G. Bleed-down Devices H. Warning Signs

V. Mechanical

A. Vehicle Controls B. Running Gear C. Parts to be Removed D. Suspension E. Wheels and Tires

1. General 2. Tire Pressure 3. Tire Modifications 4. Tire Replacement 5. Tire Softeners and Warmers

F. Steering Mechanism G. Brakes

1. General 2. Parking Brake

H. Throttle Return I. Covers and Shields J. Drivetrain Components K. Fasteners

VI. Vehicle Body and Interior

A. Vehicle Appearance B. Vehicle Body C. Decals and Stickers D. Vehicle Structure E. Roll Bars F. Doors G. Hood and Trunk H. Ground Clearance I. Weight

1. Gross Vehicle Weight Rating 2. Maximum Vehicle Weight 3. Weight Bias 4. Vehicle Lean

J. Occupant Visibility K. Windows and Windshield

1. General 2. Window Tinting

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3. Decals L. Mirrors M. External Lighting N. Audible Warnings

1. Horn 2. Backup-alarm

O. Vehicle Interior P. Dashboard Q. Fire Protection R. Seats S. Seat Belt

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SECTION I – GENERAL A. OVERALL OBJECTIVE The purpose of the Vehicle Specifications are to: • Ensure the safe construction and operation of the electric vehicle conversions utilized

in the program. • Maintain a relative equality regarding vehicle performance. • Promote creativity and innovation when possible.

B. COMPLIANCE WITH SPECIFICATIONS All EVs will be inspected for compliance with these vehicle specifications. An event rules committee will be created at each event that is comprised of two teachers and the head of inspections. This three-person committee will be responsible for reviewing any issues of non-compliance arising during technical inspection. If needed, the committee will utilize the input of the executive director to make final decisions. Penalties may be assessed for failing to comply with these specifications. Such penalties will be assessed to allow a vehicle to compete only if event officials feel the safety of participants will not be jeopardized. The vehicle inspection process requires that components be viewed and identified at the competition. Design of vehicles must ensure that all conversion components (batteries, cables, controller, etc.) are accessible allowing inspection and ease of repair. C. MINIMUM VEHICLE PERFORMANCE The organizers reserve the right to intervene or disqualify any vehicle having sub-standard performance, if that vehicle is deemed a hazard to other vehicles, its operators, or to spectators. D. STATE VEHICLE REQUIREMENTS Each vehicle must have a current license tag, appropriate state-required liability insurance, and have passed and display a current state inspection sticker. The inspection sticker must have been obtained after the vehicle was converted to electric power and all other structural and safety modifications were completed. Any subsequent changes to the vehicle which may affect state inspection approval will require re-inspection by an approved state inspection agency. Vehicles that are licensed in a state that does not perform a safety inspection will be subject to an in-depth inspection by event officials and school official (instructor, etc.) verification that the vehicle meets all applicable regulations. E. VEHICLE CONVERSION Vehicles chosen for conversion must have been manufactured by a recognized auto manufacturer and at least 10,000 produced. Rookie schools (schools that are building their first conversion) must first build a vehicle for

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the Car or Truck Class -- see “Section II: Vehicle Classes” to learn more. Schools building a vehicle must inform EV Challenge officials of the vehicle's make and model before beginning the conversion process. This will ensure that the vehicle fits appropriately into the EV Challenge classes and save the school time and money if an inappropriate vehicle is chosen for conversion. Each participating school must enter a vehicle they converted from gasoline to electric power. Vehicles that have previously been converted to electric power by anyone other than the participating school’s students will not be allowed to compete. Vehicles that were built by the manufacturer as an electric vehicle will not be allowed to compete. Schools that utilize vehicles converted by students in a previous year must provide current students with opportunities to rebuild, modify and understand the vehicle.

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SECTION II – VEHICLE CLASSES

A. THREE CLASSES EV Challenge vehicles will be divided into three separate classes: Car, Truck, and Modified. These classes will only apply to the vehicle-specific events: Range, Autocross, Acceleration, and Vehicle Design. B. DESIGN OBJECTIVE It is the design objective of the EV Challenge to have schools build street-legal vehicles that have the same functionality as the original vehicle. C. DESCRIPTION All vehicles must be built according to the EV Challenge Vehicle Specifications. The table below and on the following page illustrates some of the general differences between the classes. Refer to the Specifications for a more thorough description of these and other differences.

Car Truck Modified

Who

Any participating school

Any participating school

Successful Veteran Schools may be

approved by event officials to build a Modified vehicle

Vehicle Type

Any vehicle that doesn't fall into the

Truck class and meets EV Challenge specs.

Open bed pickups only (Chevy S-10, Ford

Ranger, GMC S-15, Toyota Tacoma, etc.)

that meet EV Challenge specs.

No limitation on vehicle type as long as it meets EV Challenge specs.

Gross Vehicle Weight Rating

GVWR of no greater than 3800 lbs.;

converted vehicle must weigh no more

than GVWR

GVWR of 3575 lbs. or

greater; converted vehicle must weigh no more than

GVWR

Converted vehicle must

weigh no more than GVWR

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Voltage 96 volts or less 96 volts or less 156 volts or less

Motor

One DC motor

One DC motor One or more DC motors

Controller

One controller rated at (or programmed to) 600 battery amps or

less

One controller rated at (or programmed to)

600 battery amps or less

One or more controllers rated at (or programmed

to) 1200 battery amps or less

Tires

Standard DOT

approved street tires

Standard DOT approved

street tires

Standard DOT approved street tires or DOT

approved competition tires

Tire Change

Unless damaged, tires cannot be changed at

event

Unless damaged, tires

cannot be changed at event

With limitations, tires may be

changed between events

Interior

Stock

Stock Stock with limited

modifications allowed Exterior

Body/Lights

Stock

Stock Stock with limited

modifications allowed

Battery

Location

Not allowed in front

passenger area

Not allowed in front

passenger area

With limitations, batteries allowed in front passenger area

Battery

Type

Lead-acid

Lead-acid

Any battery chemistry; proof of safety required

Vehicle Production

Original vehicles must have been manufactured by a recognized auto manufacturer and at least 10,000 produced

Wheels All original vehicles must have been designed with a wheel of at least

13 inches. Converted vehicle must have wheel of at least 13 inches.

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SECTION III – ELECTRICAL A. TRACTION BATTERIES 1. Battery Pack Voltage: Maximum battery pack voltage must be 96V or less for vehicles in the Car and Truck Classes. Vehicles entered in the Modified Class will be allowed a maximum battery pack voltage of 156 volts. No restriction is placed on battery capacity (measured in kWh) as long as maximum battery pack voltage is within the above specified voltage. No restrictions are placed on size or number of cells (however, resulting vehicle weight is a restriction; see “Maximum Vehicle Weight”). 2. Battery Type: For Car and Truck classes, battery type must be lead-acid. Modified Class vehicles will be allowed to use any battery chemistry, provided that the school is able to document that they have reasonably investigated the safety of the proposed battery chemistry. Teams will not be allowed to change to a different battery configuration, voltage, or type during the competition. 3. Battery Installation: The battery packs must be supported by a metal frame or metal container that is securely fastened to a frame member or structural load bearing member (unibody) of the vehicle (not thin sheet metal) to prevent movement, spillage, or a dangerous situation in case of collision or rollovers. The battery pack must be fastened in multiple locations so as to distribute the inertial load of the pack. Batteries must be mounted so that terminals always maintain a safe distance from one another, even in the case of severe jarring or vehicle collision. It is recommended that all battery terminals and conductors be individually covered or sealed with insulating material rated for full DC bus voltage. Batteries located in an enclosed area (such as the trunk or passenger area) must be housed in an enclosed container that is constructed and mounted as described above. This container must be vented (see below). Battery pack must be electrically isolated from chassis (a floating ground). 4. Battery Ventilation: Battery containers within enclosed areas (see above) must be equipped with forced-air ventilation to the outside of the vehicle to remove gases and vapors, but not so as to require removal, cutting away or in any way taking out body part(s) that alter the stock appearance. This regulation applies to both sealed and wet- cell batteries. It is recommended that the venting system have the exhaust mounted on the top of the battery enclosure to draw air from the bottom to the top. The fan must be rated at least 10 cfm and be brushless or have an explosion-proof rating such that it does not produce sparks. The fan can draw its power from any power source. It must operate at any time the vehicle is operating and during recharging of the batteries. 5. Multiple Battery Packs: The packs may be contained in any number of battery enclosures, as long as each conforms to the above specifications.

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6. Battery Change-out and Configurations: Changing of batteries, battery type or voltage will not be allowed during the entire event. Individual batteries may be replaced in the event of a battery failure or malfunction (melted post, physical damage, etc.) Batteries discharged during normal use does not constitute failure. Batteries discharged in the course of vehicle operation, but otherwise undamaged, may not be exchanged for fully charged batteries. Event officials must be notified prior to the replacement of any batteries. Batteries may be connected in either a series, parallel, or series/parallel configuration. However, the total battery pack voltage must remain within the limits (96 for car and truck class and 156 for modifieds) and the configuration may not be changed at any point during the event. 7. Battery Disconnect Device: All vehicles must be equipped with a battery disconnect device capable of disrupting full battery current, as would result from a wiring fault or component failure. The disconnect must have two stable states: open and closed. The device must be manually operable from the driver’s seat and installed in the main traction battery cables. While the device must be able to be manually operated by the driver in a belted-in position, the actual disconnect device itself must be located outside of the vehicle cabin (so as to reduce driver/passenger exposure to a potential electrical arc.) Solid-state relays are strictly forbidden. Wiring, linkages, cables, etc., must be located in a manner to minimize damage in the event of an accident. Exposed terminals or contacts are strictly forbidden (see Electrical Safety). The place where the disconnect is located or actuated must be clearly marked as "Battery Disconnect" and be clearly labeled "ON" and "OFF". Letters must be at least 1 inch high and be in a high contrast color. 8. Battery Location: Batteries must be located to maximize safety and vehicle performance. Batteries may but be put in the long, enclosed "drive shaft tunnel" area, only if completely enclosed on all sides and safety sealed off from driver. Batteries may be mounted in rear passenger area if enclosed. For the Modified Class only, batteries may be placed in the front passenger (not driver) area. Modification of the floor and seating area is allowed. However, design must be done in such a way as to maintain the vehicle’s safety and ability to comfortably carry a front passenger. Additionally, modifications must be done in such a way as to not be obvious to the casual observer (i.e. no large battery box simply placed in this area). 9. Battery Fuses: Batteries must be current-limited via at least one fuse (not a circuit breaker) that is installed half-way through the total battery string. The fuse rating must be as follows: 500 amp fuse maximum – for vehicles with motor controller limits of 700 amps 800 amp fuse maximum – for vehicles with motor controller limits of 1200 amps

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B. CHARGING 1. General Regulations: Vehicles should be brought to each event fully charged. Vehicles will operate throughout the day on a single charge. Charging will not be allowed at the location of any competition, except as directed by event officials. (Sections 2-4 below are suggestions only.) 2. All Chargers: Charger AC input and extension cords should be a minimum of two wire and ground, outdoor rated (SO) cord. Minimum wire size should be #12 AWG for 20 ampere service and #8 AWG for 50 ampere service. Cords should be in excellent condition with no splices abrasions or cuts penetrating the outer jacket. Cords should be rated for use at 400 volts or greater. DC to DC connections should either be hard-wired or use a shielded connector that does not allow human contact with the energized terminals. Alligator clips or other temporary connections are not recommended. Charging power should be provided through Ground Fault Current Interrupter Circuit Breakers which will trip free at a ground current (or branch circuit current imbalance) of greater than 5 milliamperes. Chargers should be capable of operation from this source. The charger should be equipped with an output fuse rated for use at 250 volts or greater and an ampacity no greater than 125% of maximum charger DC output. 3. On-board Chargers: Charger connections should be configured to ensure that the frame of the vehicle is grounded to the AC power supply ground (earth ground) whenever the charge connector is inserted into the vehicle. The ground circuit should be a minimum #12 AWG for 20 ampere service and #8 AWG for 50 ampere service. Connectors should be similarly rated. The DC output wires/cord should be rated for at least 125% of the maximum charger output current. 4. Off-board chargers: DC output cord should be rated for at least 125% of the maximum charger output current. The outer jacket of this cord should be rated for outdoor use at a voltage of a least 200% of the charger output. The DC connector to the vehicle should be rated for at least 125% of the maximum charger output current. C. AUXILIARY 12 VOLTS The non-powertrain components may be serviced by an additional, auxiliary battery or small pack, as long as it is isolated from the traction batteries and cannot provide current to the traction motors in any manner. It may be recharged from the traction batteries (i.e., via a DC-DC converter), or from a separate battery charger. D. ELECTRIC MOTORS Propulsion motors must be DC. No restrictions will be placed on motor size, number, or

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power for a Modified Class vehicle. Vehicles in the Car and Truck Classes are limited to one motor, with no size or power restriction. E. CONTROLLER Each vehicle must be equipped with a commercially available controller designed for electric vehicle use with the motor selected. Vehicles in the Car and Truck Classes are limited to a single controller of no greater capacity than (or programmed to) 600 battery amps. Modified Class vehicles can have more than one controller. Modified vehicle controllers may be rated at greater than 600 battery amps and must be no more than (or programmed to) 1200 battery amps. No controller bypass switches, or other means designed to bypass the design capacity of the controller will be allowed.

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SECTION IV – ELECTRICAL SAFETY A. DEFINITIONS 1. “Ampacity" is a value in amperes that expresses the maximum safe current handling value for a particular wire and insulation combination. This value is dependent upon the conductor type, its cross-sectional area, the insulator type and thickness, the desired maximum operating temperature, and the ambient temperature. 2. “Break-down voltage" is the voltage at which the dielectric strength of a wire’s insulation is exceeded and the insulation ceases to be a high-impedance path to the flow of current. B. CONDUCTOR RATING Battery conductors and cables must be sized in such a way that the ampacity of the chosen conductor exceeds the highest operating current expected in that conductor by a factor of at least 25%. As an example, a conductor chosen for a maximum of 200 amps must be able to withstand 250 amps. Conductor insulation must have a breakdown voltage of at least two times the peak ground-reference voltage expected in that conductor. The wiring should be considered with respect to the temperature and conditions of service to which the wiring may be subjected (suggested under vehicle routing be covered with flexible, waterproof electrical conduit). C. FUSE AND WIRING COMPATIBILITY Thought should be given to the fuse and conductor selection. Battery power wiring should be capable of carrying the current of the fuse rating for the time delay experienced by the fuse until it is blown. That is, in the instance of short circuit, battery cables should not fail (melt insulation and/or cause fire) before the fuse has severed. D. CONDUCTOR ROUTING The conductors must be routed such that there can be no inadvertent physical contact with high-voltage electrical equipment or components. All conductors must be securely fastened to minimize movement. When a conductor must pass through a panel or bulkhead, the use of appropriate strain relief’s, grommets, and feed throughways will prevent insulator chafing. E. QUICK DISCONNECTS, PLUGS, ETC. All high-power disconnects must be made through devices rated at greater than 125% of the peak current that is to be conducted through that connector. All disconnects must be made in such a manner that when disjoined, the energized side of the connection has completely shrouded contacts. F. INCIDENTAL CONTACT No exposed conductors carrying voltages in excess of 36 V with respect to the system ground or with respect to other exposed conductors will be allowed. Each separate high voltage terminal must have its’ own, independent, cover. (For example, a series of battery terminals cannot simply be covered by one shield. Each individual terminal must have its own cover/boot.) There will be no metal contacts or wiring of any voltage exposed such that a tool or any metal device may inadvertently fall into or touch to cause a short circuit (even small

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voltages can cause large, dangerous currents through a metal hand tool). All conductors falling into this class must be equipped with insulating shields with sufficient breakdown voltages to prevent shock through incidental contact. This applies to batteries and all other connections above 36V, whether the vehicle is in operation or display. These guidelines are accepted in industry and are given as "working values" only. The vehicle design team is encouraged to research works on human exposure to electrical currents such as the studies conducted by Charles Dalziel (IEEE Publication, Reevaluation of Lethal Electrical Currents, 1970). G. BLEED-DOWN DEVICES Many controllers contain capacitors that can retain a dangerous charge for many minutes after being disconnected from the battery source. As such, it is strongly recommended that a bleed-down procedure be known and followed as necessary. H. WARNING SIGNS Areas of the vehicle that contain conductors or equipment that operate with high current or at a voltage greater than 36 V must be properly insulated and marked with "Warning- High Voltage" signs.

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SECTION V – MECHANICAL A. VEHICLE CONTROLS All EVs must be equipped with conventional, functioning automotive controls, including steering wheels, brake pedals, accelerator pedal, and parking brake. B. RUNNING GEAR All vehicles must have four wheels. Vehicle must be propelled by the wheels. Two-wheel drive, 2- wheel front drive, or 4x4 vehicle must remain as such as originally produced or sold. Examples: Pontiac Fiero must remain mid-engine, 2-wheel drive; Ford Escort must remain front-engine, 2-wheel drive, and AMC Eagle 4WD must remain front engine, 4-wheel drive. C. PARTS TO BE REMOVED The following parts should be removed when the vehicle is converted to an electric vehicle: internal combustion engine and attached units, radiator and catch tank, fuel tank, fuel lines, canisters (anything that held or could hold fuel and or liquids non-essential to the electric car), and exhaust system. It is recommended that the vehicle retain components such as the hubcaps, trim rings, jack, spare tire, and necessary tire changing tools. Any loose items (spare tire, jack, etc.) should be removed from the vehicle or securely tied down before the autocross and after it has completed technical inspection and the vehicle design event. D. SUSPENSION Suspension must remain stock for the vehicle with the following exceptions: springs and shocks which may be reinforced or replaced with heavier duty units if mounting points remain in their stock location. Coil-over shocks are permitted if the mounting location is retained. Suspension load areas, mounting points, may be reinforced. Use of air-assisted suspension components (bags, sleeves, shocks) is permitted as long as other specifications within this section are followed. Suspension adjustments for camber are allowed to compensate for changes in front or rear ride height caused by battery weight. Stiffening or softening of chassis can be accomplished by using larger or smaller diameter anti-roll/sway bars as are used on many passenger cars, or by adjusting "pre-load" on anti-roll/sway bars by adjusting length of vertical links such as those attaching A-frame to sway bar. Vehicle may have "sway bars" on front and rear, even if it did not come so equipped when produced. After-market sway bars are permitted if they do no go outside the spirit of these stock vehicle rules. Stock links may be replaced with spherical rod-end style links. No cockpit operated suspension adjusters allowed. E. WHEELS AND TIRES

1. General: All vehicles must have four wheels. A spare must be available at all times. Tires

must be DOT approved, 13-in wheel diameter or greater. Original vehicles must have been designed with a wheel of at least 13 inches in diameter. Vehicles in the Car and Truck Classes must use a DOT approved stock type street tire with a treadware rating of 140 or higher. Modified Class vehicles may use either DOT approved stock type street tires or DOT approved competition tires. The total load rating of the tires must be greater than the weight of the fully loaded vehicle, including occupants, cargo, and batteries. If non-production wheels

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are used, the team must ensure that the wheel is capable of withstanding the expected loads as well as a reasonable amount of road abuse. Tires and wheels must have compatible rim widths. Each vehicle should have available an appropriate spare tire/wheel and equipment necessary to change that tire/wheel (see Parts to be Removed).

2. Tire Pressure: Tire pressures must be within the range stated on the tire or as directed by event officials. 3. Tire Modifications: Tire tread depth cannot be less than 4mm (5/32 in.) at the start of any event. Manufacturer markings on the tire sidewalls may not be altered or removed. Tires may not be re-grooved or altered in any way, other than tread shaving or truing. 4. Tire Replacement: Vehicles in the Car and Truck Classes may not change wheels and tires during the event. If a change is necessary due to failure or excessive wear, replacement(s) should be identical to the wheel or tire being replaced, and any replacement tire must be inspected and approved by event officials.

The wheels/tires on a Modified Class vehicle may be changed between events. This will allow vehicles in the Modified Class to use competition tires for the autocross and street tires for the range event. In the event of inclement weather, EV Challenge officials may decide that competition tires are unsafe and a school will be required to use standard street tires due to wet track/road conditions. 5. Tire Softeners and Warmers: Teams may not use tires that have been subjected to liquids or chemical compounds that soften the tire or change its composition. Tire warmers may not be used. Section V.E.6, Age of Tires, will be implemented next year during the 2012-13 school year. 6. Age of Tires: Given the competitive stresses put upon the vehicle’s tires, tires must be no older than 6 years, as indicated by the date stamp on the tire. How to Read a Tire Date Stamp: : http://www.ehow.com/how_4778981_read-tire-date-stamp.html Here are a couple of resources regarding dangers of old tires: http://abcnews.go.com/Video/playerIndex?id=4826897 (a video) and http://www.aa1car.com/library/tire_expire.htm F. STEERING MECHANISM Must remain stock OEM steering mechanism. Some rack & pinion systems may be modified with permission of the Challenge Technical Manager. Steering mechanism must work freely with no binding or wheel/body contact. No steer by wire systems are permitted.

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G. BRAKES 1. General: All vehicles must have an operating brake system. If power brakes were originally equipped on the vehicle, they must be retained (suggest an electric vacuum pump w/ reservoir). Regenerative braking systems will be allowed, but cannot be employed as the primary braking system. (Note: this specification will continue to be in effect for 2011-12 school year but it is being reviewed.) 2. Parking Brake: All vehicles must have an operating manual parking brake capable of holding the vehicle’s weight (with the extra battery weight) at rest on a grade. H. THROTTLE RETURN The throttle on all vehicles must be free moving and, when released, must return to the zero-current position on the electric motor. If cruise control is used, it must be deactivated when the brake pedal is depressed. I. COVERS AND SHIELDS Any exposed drivetrain, suspension, and steering components must be shielded from the occupants. Series-wound DC motors, upon being disconnected from the drive system, can free-rev and explode in just a few seconds. Vehicles must include safety provisions to ensure that motors cannot free-rev or have appropriate shielding so that if motor or armature would disintegrate, that driver, spectators, or anyone else cannot be harmed. High-speed (greater than 1000 rpm) components (flywheels, clutches, belt drives, chain drives, and torque converters) that are not appropriately shielded must have a scattershield constructed of at least 12 gauge mild steel or documented equivalent. Finger guards made of expanded metal or heavy screen may be used to shield low-speed components if cooling air-flow is required. J. DRIVETRAIN COMPARTMENTS The motor and battery compartments must be separate and isolated from the passenger compartment by bulkheads or securely fastened and sealed covers to protect the occupants from mechanical failure, fluids, and fumes. K. FASTENERS It is recommended that all fasteners on critical vehicle components such as suspension, steering, brakes, battery containment, seat belts, ballast carrier, and drivetrain be stock configuration or be secured with lock nuts, double nuts, nuts secured by safety wires, or cotter pins. If the location precludes the use of one of these devices, products such as Loctite may be used.

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SECTION VI – VEHICLE BODY AND INTERIOR A. VEHICLE APPEARANCE It is a primary design objective for the vehicle to remain as functional and safe as possible, in a way that is similar to the how the original manufacturer intended. B. VEHICLE BODY The original body panels may be modified or replaced in an effort to improve vehicle performance. These modifications must not be made in a way that interfere with safety of the participants or spectators or reduce the structural integrity of the vehicle. Belly pans may be used to smooth airflow under the vehicle and must not impair vehicle operation (suspension movement, steering, etc. It is the school’s responsibility to ensure that all vehicle components are weatherproof in case of inclement weather. C. DECALS AND STICKERS An area 9” wide X 12” tall must be left vacant on the bottom rear of each front fender OR on the bottom front of each passenger door. An event specific sticker will be provided for placement in this area. Additional sponsor stickers may be provided by event officials. Although Challenge officials request that these additional stickers be placed on the front fenders, the final decision is up to the school’s individual vehicle design team. Additional stickers may be placed on vehicles by the school team. D. VEHICLE STRUCTURE If modifications are made to a vehicle’s structure, it is the team’s responsibility to ensure that the safety of the vehicle has not been compromised through appropriate calculations or testing. E. ROLL BARS The EV Challenge does not require roll bars except in the case of convertibles or open cockpit vehicles. Convertibles or open cockpit vehicles must have a roll bar installed to provide driver protection in the event of the vehicle turning over. Closed cars may install roll bars if school officials feel it is advisable. When installing roll bars, the requirement contained in the section “Vehicle Interiors” must be observed. F. DOORS Doors must perform flawlessly and latch securely. Manufacturer’s latch and release mechanisms should be used where appropriate. Modified Class vehicles may seal doors shut provided they can demonstrate a quick vehicle operator access and egress.

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G. HOOD AND TRUNK Hoods and trunk must be secured. This may be done by using the original manufacturer’s latching mechanism or properly installed hood/trunk pins. H. GROUND CLEARANCE During the vehicle design process, students must weigh the vehicle performance trade-offs when considering low ground clearance, aerodynamics, and suspension travel. Ground clearance must be a minimum of 4.0”. If the original vehicle had less than 4.0 inches ground clearance, documented measurements taken prior to conversion must be provided to event officials. I. WEIGHT 1. Gross Vehicle Weight Rating: The GVWR is the maximum amount of weight that a vehicle can carry, as stated by the vehicle manufacturer. This weight is normally found on a metal plate on one of the door pillars. All Car Class vehicles must have a GVWR of no greater than 3800 pounds. All Truck Class vehicles must have a minimum GVWR of 3575 pounds. There are no GVWR restrictions for the Modified Class other requiring the vehicle to weigh less than the manufacturers GVWR (see Maximum Vehicle weight). 2. Maximum Vehicle Weight: The weight of a conversion vehicle may not exceed the production Gross Vehicle Weight Rating (GVWR) as indicated on the vehicle’s manufacturer’s identification plate (in competition-ready configuration; excluding driver). Tampering of the manufacturer’s identification plate will not be permitted. If a manufacturer’s identification plate is not available, suitable documentation to indicate the production GVWR may be accepted by event officials. 3. Weight Bias: It is recommended that right-to-left weight bias, as measured at the wheels, be within 5%. Teams should also consider the effect of the front/rear weight bias on the handling and stability of the vehicle. 4. Vehicle Lean: It is recommended that the vehicle stay neutral with respect to front to back (and left to right) sag. The extra weight of the batteries should be considered and measures taken to prevent the vehicle from unequal suspension deflection. Suspension geometries can be severely affected by unequal sag and give the vehicle unsafe driving characteristics. Any vehicle that event officials feel will be unsafe to drive will not be allowed to compete in dynamic events. J. OCCUPANT VISIBILITY Visibility must not be obstructed by any vehicle modifications or additional hardware. K. WINDOWS AND WINDSHIELD 1. General: All vehicles must have a windshield, with functional windshield wiper(s) to mechanically clear the windshield of rain. The original safety-glass windshield in stock location/angle with original molding must be used. Car and Truck Class vehicles must keep the rear window and all side windows in place and operational as designed by the

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vehicle manufacturer. 2. Window Tinting: Tinting, shading, or any process that alters the transmission of light through the glass must meet all applicable state laws. 3. Decals: Decals, graphics, or lettering must not be placed on windows in such a manner as to impair a driver’s visibility. L. MIRRORS All vehicles must have appropriate mirrors. M. EXTERNAL LIGHTING Car and Truck Class vehicles are required to have all of the original functioning equipment exterior vehicle lighting. Modified Class vehicles must have functional lighting required by state safety inspection. N. AUDIBLE WARNINGS 1. Horn: All vehicles must be equipped with a functioning production type electric automotive horn. 2. Backup Alarm: All vehicles must be equipped with a backup alarm that operates whenever the vehicle is placed into reverse. O. VEHICLE INTERIOR 1. Car and Truck Classes: It should be a primary design objective of each team to ensure that vehicle appearance remains as close to the original vehicle design as is reasonably achievable. In addition to the additional interior specifications, vehicles should keep carpet, headliner, and interior panels in place. 2. Modified Class: As stated in Section II.B, it is the design objective of the EV Challenge to have schools build street-legal vehicles that adhere to the functional and stock design objectives of the original vehicle. However, if a Veteran school wishes to enter a vehicle in the Modified Class, the school has the option of modifying the vehicle’s interior in such a way as to possibly improve vehicle performance or safety. 3. General: If it is necessary to remove interior materials to facilitate installation of battery boxes, safety equipment, or other items necessary for the conversion to electric power or to enhance safety, care must be taken to eliminate sharp edges or protrusions. The metal structure of a vehicle, unibody panels, floor, etc., may be removed only as necessary to install safety equipment, electric motor or batteries. Vehicles must have a separate passenger compartment such that bulkheads or firewalls separate occupants from drivetrain components, etc., and have a solid panel floor closeout separating the occupants from the road. P. DASHBOARD

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All vehicles must have a functioning speedometer. Car and Truck Class vehicles must have a completely stock dash, except for minor modifications necessary to install gauges necessary for an electric vehicle. Modified Class vehicles may modify the dashboard to enhance vehicle operation or safety. Q. FIRE PROTECTION Vehicles must be equipped with a 5-pound minimum class ABC fire extinguisher. It must be readily accessible to a belted-in driver and securely mounted on the transmission tunnel (rear wheel drive) or on floor without interfering with driver controls. Mounting brackets must be provided of sufficient strength such that the extinguisher is retained in the even of a collision. R. SEATS For all classes: Only a front driver seat is required. Teams may use production, after-market, or original design seats. The seats must be firmly connected to the chassis. (Note: As stated in Section IIA, the design intent of the EV Challenge is to build vehicles that retain the functionality of the original vehicle. This applies to all vehicle classes. Vehicles retaining only the driver seat will likely not score as high in the “functionality” section of the design competition. S. SEAT BELTS The driver and passenger seats must be properly equipped with lap belts and shoulder harnesses that meet or exceed OEM specifications. "Y" type OEM lap belt/shoulder harness combinations are permitted. Strap materials must be Nylon or Dacron polyester or materials meeting OEM, SCCA, NHRA, or NASCAR specifications. Straps materials must be in new or perfect condition. Buckles must be metal to metal quick release type. The shoulder harness must be mounted at the OEM location or behind the driver and above a line drawn downward from the shoulder point at an angle of forty (40) degrees with the horizontal. Mounting of all belts and harness must be with SAE Grade 8 bolts or with OEM hardware. OEM mounting fixtures must be used or mounting should include large diameter washer or equivalent to spread the load. Any design documentation should address lap and shoulder harness mountings and should document the adequacy of any modifications.

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EV Challenge Program Overview and Rules Version 4, January, 2012

Items highlighted in yellow indicate changes from previous versions.

TABLE OF CONTENTS

I. Introduction II. General Vehicle Rules III. Vehicle Drivers IV. Insurance Waivers V. School Classification and Vehicle Classes VI. Events VII. Troubleshooting VIII. Jeopardy IX. Autocross X. Range XI. Vehicle Design XII. School Initiative XIII. Scoring and Awards

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SECTION I – INTRODUCTION

A. Mission of the EV Challenge The EV Challenge is the educational program of the nonprofit Carolina Electric Vehicle Coalition, Inc. The mission of the program is:

To inspire high school students about education, the environment and their future by providing them with practical interdisciplinary skills to design, construct, operate and educate the public about innovative street-legal electric vehicles.

B. Program Objectives In support of the mission, above, the EV Challenge is designed to: 1. Be a yearlong educational program and competition implemented by each school (not simply an event). This objective is ideally met by schools forming an electric vehicle club or team and/or by integrating the program into the school’s curriculum. 2. Be interdisciplinary, involving a maximum number of students from a variety of disciplines. 3. Be safe. 4. Be innovative. 5. Provide opportunities for students to educate the public about electric vehicles.

C. Final Interpretation of the Rules EV Challenge personnel shall have the final interpretation of these rules.

SECTION II – GENERAL VEHICLE RULES

A. All vehicles shall be built (and will be inspected) in compliance with the “EV Challenge Electric Vehicle Specifications."

B. Vehicles shall be operated in a safe and legal manner at all times. Unsafe or reckless operation of vehicles, speeding, or failing to comply explicitly with traffic laws will result in penalty and/or disqualification.

SECTION III – VEHICLE DRIVERS

A. All driving events require high school student drivers.

B. Vehicle drivers shall have a valid driver’s license. Students with learner’s permits will not be allowed to drive in the events.

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SECTION IV – INSURANCE WAIVERS All school participants are required to sign/complete the required insurance waivers provided as part of the registration materials for each event. Typically, this includes “Parental Consent” and “Minor’s Assumption of Risk” forms for minors and general liability waivers for adults.

SECTION V – SCHOOL CLASSIFICATION AND VEHICLE CLASSES A. School Classification Participating schools that are building their first conversion vehicle will be classified as “Rookie Schools.” “Veteran Schools” are those schools that have built a conversion vehicle in a prior year.

These classifications are mainly used as a way to help organize the program. All schools compete against one another in the overall program, regardless of classification.

1. Rookie Schools must enter the Car or Truck Class.

2. For the School Initiative event ONLY, schools must participate in activities that

correspond to their classification. See the School Initiative Activity Form for details.

3. A Rookie-of-the-Year trophy will be awarded to the overall top Rookie School.

B. Multiple Teams from One School A school may only enter up to two teams in the EV Challenge. However, each team must have their own separate:

• Troubleshooting team • Oral presentation • Jeopardy team • Vehicle for the Autocross, Acceleration, Range and Vehicle Design Events

A school must use the same score for each of its teams for the School Initiative event and Web Site Competition. Schools should be prepared for competition events to be run concurrently, and may want to have different students identified for each competition event.

C. Vehicle Classes For the vehicle-specific events such as Autocross, Range, Acceleration, and Vehicle Design, vehicles will be divided into three separate classes – Car, Truck, and Modified. These vehicle classes will ONLY apply to the vehicle-specific events. See Section II of the “EV Challenge Vehicle Specifications” for technical details.

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The Car and Truck Classes are intended to provide all schools with a solid platform upon which to build a totally stock vehicle and learn basic electric vehicle technology. The Modified Class is designed to provide successful Veteran schools with an opportunity to expand their program by building a more technically sophisticated vehicle. After Rookie schools have successfully built a Car or Truck Class vehicle during their first year, they may seek Challenge approval to build and enter a Modified vehicle for the Challenge program in subsequent years. There must be at least four vehicles to constitute a class. If there are less than four vehicles in a class, the vehicles will be moved to another class at the discretion of EV Challenge officials.

SECTION VI – EVENTS

The EV Challenge competition consists of the following seven events. Each event counts toward the schools overall score. Events and how they count on the overall score are listed below: A. Trouble-shooting; 10%; students complete a written technical test and diagnose electrical

and mechanical faults in a troubleshooting board.

B. Jeopardy; 10%; students respond to live electric vehicle-related questions in a race against other teams.

C. Oral Presentation; 10%; students prepare a presentation that is given in a live oral competition that addresses a unique topic and summarizes the school’s program.

D. Autocross; 10%; students drive vehicles through a slalom course in a timed event.

E. Range; 20%; students drive the vehicle as far as it will go. E. Acceleration; 10%; students accelerate vehicles as fast as they will go in 1/8-mile.

F. Vehicle Design; 10%; judges assess the design of vehicles.

G. School Initiative; 20%; teams are rewarded for participating in a wide variety of events and activities throughout the year

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SECTION VII – TROUBLESHOOTING A. The troubleshooting event is intended to test students’ electric vehicle troubleshooting skills and general electric vehicle knowledge. B. Overview

1. Each school team shall form a troubleshooting team of 2 students. 2. Two parts to the event:

a. Part 1 – Written Assessment – 7 minutes b. Part 2 – Identify Faults on Troubleshooting Board – 7 minutes

C. Part 1 – Written Assessment

1. Students will be given a written assessment that contains 21 questions. The 21 questions will be made up of 20 multiple-choice questions and 1 short answer question. No notes, scratch paper, or other aids will be provided or allowed.

2. The two students will work on the assessment together. They may wish to divide up the questions in an effort to answer all 21 questions in the 7-minute time period.

3. The assessment will test the students’ general knowledge of electric vehicle troubleshooting and electric vehicle components.

4. Students may prepare for the assessment by reviewing the EV Technology Pre- and Post-Test and the “Troubleshooting an EV” lessons in the EV Challenge Curriculum.

D. Part 2 – Identify and Fix Faults on a Troubleshooting Board

Part 2 of the event will utilize a specially designed “Troubleshooting Board.” The students’ goal is to identify and fix 2 electrical faults placed in the troubleshooting board in the least possible time. 1. Students will be given 7 minutes to identify and fix the 2 faults. If students

correct both faults in less than 7 minutes, the time will be recorded and used for tie-breaking purposes only.

2. Students will be able to use a multi-meter, the board’s wiring diagram, and a pen/pencil/paper (if needed). The wiring diagram is available in the “for schools” section of the EV Challenge web site.

3. Use of a multi-meter is the primary way that students will be able to correctly identify the faults.

4. Students will be required to diagnose and “fix” the faults by replacing faulty components or wiring. Appropriate components and wiring will be provided. Tools will not be needed to replace or fix the faults.

5. Although an EV Challenge multi-meter will be available, students are strongly encouraged to bring their own multi-meter to the event.

6. Safety glasses are required. Although EV Challenge safety glasses will be available, students are strongly encouraged to bring their own safety glasses to the event.

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E. Scoring 1. Part 1 – Written Assessment – 50%; (10 points for short answer, 40 points for

multiple choice) 50 points total. 2. Part 2 – Troubleshooting Board – 50%; (25 points for correctly fixing each

fault) 50 points total. 3. 100 points total for entire event. 4. The winner of the event will be the team with the highest combined score

from Parts 1 and 2. 5. Ties will be broken using the following:

a. The shortest time used to fix both faults on the Troubleshooting board. b. The highest score on the written assessment. c. The highest score on the short answer section of the written

assessment. F. Troubleshooting Board Description

1. The EV Challenge Troubleshooting Board has been specially designed for the Troubleshooting event. The board fits on a tabletop and simulates the operation of the electrical system in a typical EV Challenge vehicle. The board utilizes a 36-volt high voltage system and a 12- volt low voltage system.

2. The board is equipped with the following components: a. 36-volt Curtis controller b. Curtis 0 – 5000 ohm pot box (potentiometer) c. 3 12-volt sealed batteries that make up a 36-volt battery pack d. A sealed 12-volt auxiliary battery e. DC permanent magnet motor f. Albright main contactor g. On/off key switch h. High voltage main disconnect i. High voltage main fuse j. 2 12-volt fuses k. “Test-points” that correspond to the numbers on the wiring diagram l. Jumper wires and spare components will also be provided

3. The board operates as follows: a. Step 1: Make sure that the main disconnect is closed b. Step 2: Turn key switch on c. Step 3: Move lever on potentiometer. Motor should rotate.

4. How the Troubleshooting board will be used during the event: a. Step 1: Students will be given a wiring diagram of the troubleshooting

board and presented with a brief video of the troubleshooting board’s operation. Students will be provided with 10 minutes to review these materials. Students will not be able to view the actual board during this time.

b. Step 2: Students will then be taken to a separate room where the troubleshooting board will be located. Students will be given a one- minute overview of the board. After the overview, students will be given 7 minutes to find and fix the faults.

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c. The faults may be fixed by using jumper wires or by replacing a faulty component(s). The jumper wires and components will be provided. No tools will be necessary.

SECTION VIII – JEOPARDY A. Primary Objective

To strengthen the interdisciplinary nature of the EV Challenge with an academic event.

B. Event information and resources forthcoming.

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SECTION IX – ORAL PRESENTATION

A. The oral presentation is designed to test students’ professional oral presentation/speaking skills only. As such, no slides, overheads, pictures, props, PowerPoint systems or other hand-held presentation devices may be used.

B. The Oral Presentations will be five-seven minutes only. Unlike past years, only one presentation will be given.

C. Oral Presentation Guidelines

The presentation must follow these guidelines and the Oral Presentation Judging Form. 1. Provide an overview of a school’s electric vehicle program. This shall

include a description of your program’s vehicles, what classes are involved, a list of your community sponsors, a history of your program, the successes and challenges, how obstacles have been overcome, the importance of teamwork, what has been learned, interesting stories, etc.

2. Give a thorough and accurate explanation based on oratorical prompt provided by program officials. a. Presenters shall provide accurate information and demonstrate a thorough

understanding of the issues associated with the prompt given. b. At least two professional sources must be cited to support the information

presented. These sources may be a professional journal, a business/industry report, or information from a government agency. (Newspapers are not considered a professional source, although newspapers can often lead you to a good professional source of information.)

3. Up to two people can participate in the oral presentations. 4. Students may wear attire that they deem appropriate. 5. Presentation will be given at a podium before a live audience. 6. Skits are not acceptable. Characterization, costumes and/or props must be

avoided. 7. The presentation will be judged by a panel of at least three official judges. 8. The presentation will be scored using the Oral Presentation Judging Form

found in the “for schools” section of the EV Challenge website. Use this form to guide the development and rehearsal of your presentation!

9. If a school has two participating teams, each team shall separately participate in the Oral Presentation.

10. Each presentation must be completed within the time provided. Presentations will be stopped at the seven-minute mark.

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SECTION X – AUTOCROSS A. The autocross will be conducted under the direction of the Tarheel Sports Car Club.

B. Each team will be allowed a specified number of official timed runs (typically 6). These runs may be taken by the same driver or by different drivers. All runs must be completed within the time period specified by event officials. Time permitting, “fun runs” will be allowed after the completion of the official timed runs.

C. Runs are timed to the nearest 0.001 second. In the event that two or more teams’ selected run is equal to the nearest 0.001 sec, the tie will be broken using the team’s best remaining run.

D. If a driver fails to make all gates marking the course, the run will be marked as a DNF (Did Not Finish) and no time will be awarded.

E. A 2 second per cone penalty will be assessed for each cone hit resulting in the following:

1. Any cone knocked over 2. Any cone knocked out of the marks by the base of the cone, even if the cone is

still standing. F. A cone penalty is not assessed if a cone is bumped, remains standing, and any portion of the base of the cone remains inside the marks by the base of the cone.

G. If you notice a cone out of place during your run, you have the option to stop and point the cone out to a course worker. If the cone is out of place, you will be given a re- run.

H. All drivers must wear helmets and use their seat belts.

I. All vehicles must pass a technical inspection by Tarheel Sports Car Club and EV Challenge personnel. Particular attention will be paid to tire pressures. No loose objects will be allowed in the car. Only Modified Class vehicles may be allowed to use a DOT-approved competition tire. Car and Truck Class vehicles must use the same tires and wheels used in the range event.

J. Event officials will conduct a walk-through of the course prior to the event. Drivers are required to participate in this walk-through. All students and instructors are welcome to walk the course at the same time as long as they don’t interfere with the drivers’ walk-through. Bicycles or other such forms of transportation may not be used to see the course.

K. At a minimum the driver’s window must be all the way down. Having both sides down is preferred.

L. One passenger per run is allowed.

M. The driver must keep his/her arms inside the vehicle at all times while on course.

N. If you are red-flagged, come to a complete stop and follow the instructions of the

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course worker. O. Striking any timing equipment or the large cones marking the timing equipment will result in an automatic DNF.

P. A car that starts its run but is unable to complete the run for mechanical reasons will be given a DNF for that run.

Q. In the event of timer malfunction, the car(s) involved will receive a re-run.

R. If a car is red-flagged for something that is not the responsibility of the driver (e.g., an animal wanders on course) the driver will receive a re-run.

S. Teams will run in the order designated by event officials. After completing a run, a team must return to the end of the line unless directed to do otherwise by event officials.

T. Teams that are not in place and ready to begin their run when it is their turn will forfeit that run.

SECTION XI -- RANGE A. Each vehicle must follow the pace car. Vehicles that pass the pace car will be subject to disqualification.

B. Teams will be allowed to pass other team vehicles only if necessary to maintain the pace set by the pace car. The pass should be completed safely and in compliance with applicable laws and regulations. Passing in an unsafe or illegal manner will result in disqualification.

C. Vehicles that are unable to proceed at a safe speed must pull completely off the road as soon as it is safe to do so. If the pace vehicle pulls up behind a vehicle and flashes its lights, blows its horn, or otherwise signals to the driver, the vehicles must pull completely off the road as soon as it is safe to do so. Team members should remain with their vehicle, unless doing so presents a hazard, and then they shall exercise judgment that will minimize the risk to themselves and to others.

D. Teams that experience vehicle failure shall ensure that their vehicle is parked safely off the road and out of the flow of traffic. Team members should remain with their vehicle, unless doing so presents a hazard, and then they shall exercise judgment which will minimize the risk to themselves and to others.

E. Any vehicle that is passed by the pace car shall pull off the road as soon as it is safe to do so. Team members should remain with their vehicle, unless doing so presents a hazard, and then they shall exercise judgment that will minimize the risk to themselves and to others.

F. At the point the pace car passes a vehicle, mileage is marked and the vehicle passed is retired from the event.

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G. Mileage calculations are performed by event officials and their decision is final. H. One passenger/vehicle is allowed. I. Depending upon the course used, the event may include a stop-and-go portion and an option for multiple drivers. I. Drivers may not use cell phones. Passengers may use a cell phone. Drivers may use hands-free two-way radios.

SECTION XII – VEHICLE DESIGN A. Refer to EV Challenge Vehicle Specifications regarding the design objectives for EV Challenge vehicles.

B. Vehicle design will be judged according to a design competition score sheet found in the “for schools” section of the EV Challenge web site.

C. A minimum of three design judges will score the vehicles and the results of all the judges will be combined to determine each vehicle score.

D. Each design judge will be required to judge all the participating vehicles.

E. During the design competition, a student must be with the vehicle to answer any questions that the design judges might ask. 50% of the vehicle design score will be attributed to student responses and knowledge of the vehicle. As noted on the vehicle design score sheet, at least one student is required to be with the vehicle during the entire vehicle design process. The student should be able to competently and knowledgably walk the judges through the six sections of the vehicle design score sheet.

SECTION XIII – SCHOOL INITIATIVE A. The School Initiative category awards points to schools for participating in a wide range of activities throughout the year.

B. Schools are rewarded for participation only. Any school that earns 175 or more points will be awarded first place EV Challenge points for this event. The top three scoring schools will receive trophies. Specifics of the scoring system can be viewed in Section XIV.B.

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C. Once a school has determined its Rookie or Veteran standing (see Section V), the school will begin completing activities from the appropriate section of the School Initiative Activity Form. This form is available in the “for schools” section of the EV Challenge web site.

D. All activities must be recorded on the School Initiative Activity Form. This form must be brought to the EV Challenge Final Event, including any supporting documents as required on the School Initiative form.

E. This event will be judged on the honor system. An honest accounting of what activities a school participated in is required. F. All school initiative activities must have taken place between the 2011 Final Event and April 18, 2012.

SECTION XIV – SCORING AND AWARDS A. Overall Scoring EV Challenge points for each event will be added together to obtain an overall score. Lowest overall score wins the EV Challenge. EV Challenge points are awarded based upon where a team places in each particular event. For example, if a team places 3rd in the troubleshooting competition, that team earns 3 EV Challenge points. If a team places 7th in the autocross, that team earns 4 EV Challenge points. See the table on the next page to see how specific points are allocated for each event.

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Points Allocated per Event

Place in Event

School

Initiative 20%

Trouble-shooting

10%

Jeopardy 10%

Oral

Presentation 10%

Autocross*

10%

Acceleration*

10%

Range*

20%

Vehicle Design*

10%

1st 2 1 1 1 1 1 2 1

2nd 4 2 2 2 2 2 4 2

3rd 6 3 3 3 3 3 6 3

4th 8 4 4 4 4 4 8 4

5th 10 5 5 5 4 4 8 4

6th 12 6 6 6 4 4 8 4

7th 14 7 7 7 4 4 8 4

8th 16 8 8 8 4 4 8 4

9th 18 9 9 9 4 4 8 4

10th 20 10 10 10 4 4 8 4

11th or Greater

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11

11

11

4

4

8

4

DNE** 50 20 20 20 10 10 20 10

*Autocross/Range/Acceleration/Vehicle Design – The Car, Truck, and Modified classes will be scored separately for these three events. **DNE – Did not enter B. Scoring for the School Initiative activity As indicated in Section VI, the School Initiative activity is worth 20% and thus schools will earn three times as many points in this event.

School Initiative Score EV Challenge Points

175 or greater 2

164-174 4 153-163 6 142-152 8 131-141 10 119-130 12 106-118 14 91-105 16 76-90 18 61-75 20

Below 60 25

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C. Tie-Breakers The first tie-breaker will be a school’s total score in the School Initiative activity. The second tie-breaker will be the school’s Jeopardy score.

D. Penalties

1. In the event that vehicles do not explicitly meet the rules of the competition but are still allowed to participate in events, penalties may be assessed to scores and/or event rankings.

E. Awards 1. Trophies will be awarded for: · First in each event · First – Third Overall · Rookie of the Year

2. Prize Money

The EV Challenge will distribute, equally, a fixed sum of money to each of the teams participating in all events.

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Appendix:

Forms and Additional Information

EV Challenge Weight Inspection

Vehicle # __________ School Name _____________________ Vehicle Make ___________ Model ____________ Year _______ GVWR: ______ Proof of Vehicle GVWR: Yes No Vehicle Weight Under GVWR: Yes No

Left Front Right Front Weight______ Weight_____ % __________ % _________

Left Rear Right Rear Weight______ Weight_____ % __________ % _________ Total Weight ________ Left Side Weight _______

Left Side % __________

EV Challenge Electrical Inspection

Vehicle # __________ School Name ___________________________

Notes and Explanations for Any “No” Circled Above

)_______

# Inspection Item Specification Reference

Circle Yes / No / N/A

1 Max. Battery Pack Voltage -- Car/Truck -- 96; Modified -- 156 III.A.1-2 Yes No

2 Battery Type – Lead Acid only for Car/Truck; Modified Any Battery III.A.2 Yes No

3 Battery Frames/Containers Appropriate III.A.3 Yes No

4 Battery Ventilation Operates When Necessary (if Applicable) III.A.4. Yes / No / N/A

5 Battery Disconnect Operable, Labeled Properly, and Accessible To Driver III.A.7. Yes No

6 Car/Truck Only -- No Batteries in Front Passenger Area III.A.8. Yes / No / N/A

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Battery Fuse is Correct Rating and In Correct Location (500 amp max fuse for vehicles with controllers up to 700 amps; 800 amp max fuse for vehicles with controllers up to 1200 amps; fuse located near middle of battery pack)

III.A.9. Yes No

8 DC Motor; Multiple Motors Allowed in Modified Only III.D. Yes No

9 Car/Truck -- 600 Amp Controller Max (or programmed to 600); Modified -- 1200 Amp Controller Max (or programmed to 1200); No Controller Bypass Allowed in Any Class

III.E. Yes No

10 Electrical Conductors Sized and Shielded Properly IV.B, C, E Yes No

11 Electrical Conductors Routed Properly IV.D. Yes No

12 All Appropriate Electrical Terminals Properly Insulated IV.F. Yes No

13 High Voltage Signs Used Where Appropriate IV.H. Yes No

EV Challenge Mechanical Inspection Vehicle # __________ School Name ___________________________ Tire Make and Size:_________________________________________

Notes and Explanation for Any "No" Circled Above:

# Inspection Item Specification Reference

Circle Yes / No/ N/A

1 Current State Inspection Sticker I.D. Yes / No/ N/A 2 Vehicle Controls and Running Gear are Appropriate V. A-B Yes No 3 Suspension is Stock (Appropriate Modifications Allowed) V.D. Yes No 4 DOT-Approved Tires (Modified -- DOT approved competition tire ok) V.E.1. Yes No 5 Tire Load Rating Adequate V.E.1. Yes No 6 Tire Pressure Correct V.E.2. Yes No 7 Tire Pressure, Tread, Compostion Appropriate V.E.2, 3, 5 Yes No 8 Steering Mechanism Stock and Functions Properly V.F. Yes No 9 Brake Pedal and Design Appropriate V.G.1. Yes No

10 Parking Brake Operative V.G.2. Yes No 11 Throttle is Free-Moving V.H. Yes No 12 High Speed Components Shielded as Necessary V.I. Yes No 13 Drivetrain Compartments Separate and Isolated V.J. Yes No 14 Roll Bar Installed in Convertible or Open Cockpit Vehicle VI.E. Yes / No/ N/A

15 Doors, Trunk, Hood Latches Operative (Modified Class doors sealed ok) VI.F-G. Yes No

16 4" Minimum Ground Clearance (or documentation for otherwise) VI.H. Yes No 17 Driver Visibility Adequate VI.J. Yes No 18 Windows Appropriate for Class; Functional Windshield Wipers VI.K. Yes No 19 Appropriate Mirrors Present VI.L. Yes No 20 Appropriate Lights for Class VI.M. Yes No 21 Horn Functioning VI.N.1. Yes No 22 Backup Alarm Functions VI.N.2. Yes No 23 Speedometer Functions; Dash Stock (Modified -- may be altered) VI. P. Yes No 24 Minimum 5 Pound ABC Fire Extinguisher Secured and Charged VI.Q. Yes No 25 Lap and Shoulder Belts Appropriate and Function Correctly VI.S. Yes No

EV Challenge Vehicle Design Competition Score Sheet Vehicle # ______ School Name _________________________ Vehicle Make, Model and Year _________________________________ As stated in the rules, Section XII.F., for the design competition, vehicles will only compete against other vehicles within their class: car vs. car, truck vs. truck, modified vs. modified. Additional Vehicle Design rules may be found in Section XII of the SMARTT Challenge Rules of Competition. Each judge will assign a score from 0-10 for each section and these scores will be totaled. The total possible is 200. Ties will be broken using the Functionality score.

SCALE: 10 – Excellent 8 – Good 6 – Average 4 – Below Average 2 – Poor 0 – Not Available

CATEGORY % SCORE FACTOR TOTAL SCORE

1. Functionality As stated in Section IIB of the Vehicle Specifications, it is the design objective of the SMARTT Challenge to have schools build

street-legal vehicles that have the same functionality as the original vehicle. Examples of items the judges may consider: Does the vehicle conversion meet the original manufacturer’s mission (carrying two or

four passengers, a payload, trunk space, etc.)? Will the vehicle meet the needs of a consumer?

15% X 3

2. Technical Innovation

Are there examples of technical innovation throughout the vehicle?

Examples of items the judges may consider: Is there a unique ways that the motor is mounted and/or connected to the transaxle? Is there a unique cooling system employed? Are there innovative battery monitoring and/or heating systems? Is a regenerative braking system

employed? Are there unique ways of accessing and displaying components? Is there a tachometer that limits the motor from over-revving? Are components used in an innovative way? Are unique or innovative components used?

10% X 2

3. Electrical Workmanship

Is there a high quality of electrical workmanship?

Examples of items the judges may consider: Are electrical items laid-out in a neat and clean fashion? Are wires and cables neatly secured and/or bundled? Are electrical items readily accessible? Are colors and/or labels used appropriately to classify wires and cables?

10% X 2

4. Mechanical Workmanship

Is there a high quality of mechanical workmanship?

Examples of items the judges may consider: Are boxes and racks welded and/or riveted neatly? Are motor mounts neatly designed and

installed? Are components mounted in such a way that they are easily accessible? Are brackets, racks, and boxes well-painted?

5% X 1

5. Safety

Does the vehicle design indicate an attention to safety?

The SMARTT Challenge Vehicle Specifications contain numerous safety requirements: a fire extinguisher, isolated electrical terminals, a high-voltage disconnect, batteries secured, etc. In addition to these required items, examples of safety items that the judges may consider are:

Are there are any sharp edges on machined parts that could cause injury? Are colors or labels used to indicate wiring or components? Do lids, beds, etc. stay securely open when lifted? Are there any clear safety hazards that may have been overlooked?

5% X 1

6. Overall Appearance

Does the overall vehicle have an excellent appearance?

Examples of items that the judges may consider: Does the vehicle have a nice paint job? Have decals been applied in an organized and neat fashion? Is the vehicle clean and polished: inside, outside, underneath? Are the wheels/tires clean?

5% X 1

7. Student Knowledge

At least one student is required to be with the vehicle during the entire vehicle design process. Can the student competently and knowledgably walk the judges through this form (in particular, each of the six sections above and on the prior page)?

50% X 10

Overall Total Design Score

NOTES and SUGGESTIONS (Judges: Write notes and suggestions here. These notes will be provided to the schools after the event.)

EV Challenge Oral Presentation Judging Sheet

School Name: Vehicle:

Student Name(s):

Presentation Area

Topic

Excellent – 10 Points

Good – 7 Points

Fair – 4 Points

Poor – 1 Point

Score

CONTENT

50 POINTS POSSIBLE

A. Brief EV

Program Overview

Includes at least: 1. Program history 2. Classes involved 3. Community sponsors 4. What students have learned

Includes three of the four items in box at left.

Includes two of four items in box at left.

Includes one of four items in box at left. X 2*

B. Oratorical Prompt – To Be

Determined

Includes: 1. Logic is excellent with sound

justification and 2. Uses concepts of inertia and

battery energy density to describe how lead-acid and lithium-ion batteries affect vehicle performance.

Includes: 1. Logic is good and 2. Uses concepts of

inertia and battery energy density to describe how lead-acid and lithium-ion batteries affect vehicle performance.

Includes: 1. Logic is average

or 2. Addresses

only inertia or battery energy density.

Presentation does not discuss this topic or there are major flaws in the logic.

X 2*

C. Citation of Sources

Two or more professional sources are cited in support of the topic in row B above. The citations are accurate and fit well in the flow of the presentation.

The presentation cites two sources, but they are not accurate or they do not fit well into the flow of the presentation.

Only one professional citation.

No citations.

Presentation Area

Topic

Excellent – 10 Points

Good – 7 Points

Fair –4 Points

Poor – 1 Point

Score

SPEAKING SKILLS

40 POINTS POSSIBLE

A. Structure

Includes: 1. Excellent introduction 2. Excellent conclusion 3. Smooth transitions 4. Very minimal use

of notes

Includes: 1. Good introduction 2. Good conclusion 3. Good transitions but

could be better 4. Some use of notes

Includes: 1. Fair introduction 2. Fair conclusion 3. Transitions are

awkward 4. Over-reliance on

notes

Presentation is generally poor in structure with little evidence that it was ever rehearsed.

X 2*

B. Physical Presence and Style

Includes: 1. Excellent eye contact 2. Excellent voice

modulation (excellent volume, projection, speed, and inflection)

3. Extremely poised and relaxed (minimal fidgeting and distracting gestures)

Includes: 1. Good eye contact 2. Good voice

modulation 3. Fairly well-poised

Includes: 1. Doesn’t often

look up from notes

2. Fair voice modulation

3. Not very poised

Presenters have generally poor presence and speaking style.

X 2*

LENGTH OF PRESENTATION

10 POINTS POSSIBLE

B. Length of Presentation

Presentation is completed within 5-7 minutes.

X

X Presentation clearly does not fall within the specified timeframe.

Total Score =

*2 – Points for these categories are doubled for a total of 20 possible points.

Notes:

Electric Vehicle Technology #7409

Pre- and Post-test

The pre-test consists of 40 of these questions selected at random. The post-test consists of all 100 questions.

1. What are the electrical units for current? A. Amperes B. Watts C. Joules D. Volts 2. An electric vehicle charging system converts _____________ into _____________ to charge

the batteries. A. gas; chemicals B. electrons; protons C. volts; amps D. AC; DC 3. A 96-volt battery pack produces 24 amps of current in a simple circuit. What is the

resistance in the circuit? A. 72 ohms B. 4 ohms C. 120 ohms D. 2304 ohms 4. A fuse: A. is a device that trips when there is too much voltage. B. usually contains a short piece of metal that melts from the heating effect of too much current. C. usually contains a short piece of metal that melts from the heating effect of too much

voltage. D. is a device that turns on when there is too much current.

5. The percentage of a lead-acid battery that can be recycled is closest to: A. 70%. B. 45% C. 35% D. 95%

6. Mosfets and IGBTs are solid-state devices that ______________________. A. produce a high voltage. B. are commonly found in dc motors. C. conduct large amounts of current. D. create electricity. 7. What does this symbol represent in a wiring diagram? A. A battery B. Electricity C. A diode D. A resistor 8. A specific electric motor has a one-hour thermal rating of 150 amps. This means that: A. the motor can safely run for one hour at 150 degrees. B. the motor can safely produce 150 amps at 150 degrees. C. the motor can safely run on 150 amps for one hour. D. the motor gets too cold to use after running for one hour at 150 amps. 9. Which tool can be used to accurately check the specific gravity of a lead-acid battery? A. Voltmeter B. Hydrometer C. Thermometer D. Test light

10. An electric vehicle uses 5 kilowatt-hours of energy to travel 20 miles. What is the vehicle’s

average rate of energy consumption per mile? A. .25 kilowatt-hours per mile B. .15 kilowatt-hours per mile C. 5 kilowatt-hours per mile D. 20 kilowatt-hours per mile

11. When direct current is supplied to the field coil of a series-wound DC electric motor, the

field coil: A. begins to rotate. B. becomes an electromagnet. C. spins around the brushes. D. conducts current to the battery. 12. A 12-volt test light is a handy tool that is normally used to: A. check the voltage of the main battery pack in an electric vehicle. B. measure the resistance in a light bulb. C. measure the voltage of 12-volt battery. D. inspect a 12-volt electrical system.

13. What type of battery is most commonly used as a starter battery in automobiles? A. Lead-acid B. Nickel-metal hydride C. Lithium ion D. Nickel cadmium 14. When working on the batteries of a full-size electric vehicle, you should make sure that A. the emergency brake is off. B. all of the battery posts are exposed. C. the high voltage system is disconnected. D. both A and B 15. An electric vehicle travels 15 miles in 30 minutes. What is the average speed of the vehicle? A. 15 miles per hour B. 60 miles per hour C. 45 miles per hour D. 30 miles per hour

16. A potentiometer is a type of ___________ resistor. A. potential B. solid-state C. variable D. fixed 17. When a lead-acid battery is discharged, ___________________ reaction is occurring. A. an oxidation-reduction B. a combustion C. a synthesis D. a decomposition 18. Which of the following is generally not considered an alternative vehicle fuel? A. Diesel B. Ethanol C. Methanol D. Natural gas 19. Electric potential is measured in: A. watts. B. amperes. C. volts. D. ohms.

20. Which of the following is most effectively used to neutralize an acid spill from a lead-acid

battery? A. Gasoline B. Sulfuric acid C. Baking soda D. Hydrogen gas

21. If you are using a power tool and the circuit breaker trips, you should first: A. reset the circuit breaker. B. unplug your tool and use another circuit. C. use another tool. D. tell your instructor.

22. When performing work on batteries, be sure to wear: A. eye protection. B. an apron. C. gloves. D. all of these.

23. Electric power can be calculated by multiplying: A. watts X volts. B. watts X amps. C. volts X amps. D. amps X ohms. 24. Which of the following is not controlled by the 12-volt system of an electric vehicle? A. Headlights B. Windshield wipers C. Main contactor D. Main motor 25. Using insulated tools is especially important when you are working on or near: A. a brake system. B. tires. C. batteries. D. a transmission. 26. Which of the following gases is not normally a component of exhaust from a gasoline

engine? A. Carbon dioxide B. Chlorine C. Water D. Carbon monoxide

27. If you want to measure the voltage of a six-volt battery, what scale on a multimeter would provide you with the most precise measurement?

A. 0-1 volts B. 0-10 volts C. 0-100 volts D. 0-1 amps 28. When you first turn on an electric car, you may hear ______________________. A. the main motor spin. B. the potentiometer move. C. the main contacts close. D. the battery current. 29. In a 12-volt automotive circuit, a red wire frequently indicates __________ and a black wire

frequently indicates ____________. A. positive; ground B. ground; negative C. negative; positive D. neutral; negative 30. The federal Clean Air Act Amendments of 1990 and the Energy Policy Act of 1992

required: A. that many fleet operators begin using alternative fueled vehicles in their fleets. B. that 25% of the American public must purchase electric vehicles as soon as possible. C. that the United States Post Office convert 15% of its delivery trucks to electric by the year

2000. D. that cities of over 1 million people must reduce air pollution by 25% by 2010. 31. During the last thirty years, the rapid development of _______________ has contributed the

most to the resurgence of electric vehicles. A. solid-state electronics B. lead-acid batteries C. dc motors D. tire technology 32. The _____________ energy stored within an electric vehicle’s batteries is first converted to

____________ energy before it can be converted to ___________ energy by the motor to move the vehicle.

A. kinetic; potential; electrical B. potential; kinetic; electrical C. chemical; mechanical; electrical D. chemical; electrical; mechanical

33. The earliest electric vehicle was built around: A. 1715 B. 1835 C. 1895 D. 1955 34. When operating a power tool you should always: A. wear loose clothing. B. use water to cool the tool. C. remove your jewelry. D. Both A and C 35. A series of cells connected together is called: A. an electrode. B. a battery. C. an electrolyte. D. direct current. 36. Before using a tool or machine which can cause injury you should always: A. review the appropriate safety manual. B. ask your teacher for permission. C. ask a friend for help. D. Both A and B 37. A gear ratio indicates the ____________________. A. speed of a gear. B. distance between gears. C. amount of torque multiplication between gears. D. number of teeth on a gear. 38. An effective public speaker usually: A. practices their presentation. B. looks at the ground when speaking. C. reads the presentation to the audience. D. speaks softly. 39. You are driving your electric vehicle at night with the lights on. You notice that your

headlights are beginning to become dim. Soon your main contactor opens up and your car coasts to a stop. What is the likely cause of this scenario?

A. The 12-volt system is discharged. B. The main motor overheated. C. The main contactor malfunctioned. D. The potentiometer malfunctioned.

40. During the late 1990’s, most commercial electric vehicles used either ________________ or ______________ batteries.

A. nickel-metal hydride; nickel-cadmium B. lead-acid; nickel-metal hydride C. lead-acid; nickel-cadmium D. sodium-sulfur; nickel-cadmium 41. A “Class A” fire is when ________________ is burning. A. a battery B. gasoline or oil C. an armature D. wood or paper 42. The main rotating part of a DC motor is called the: A. brush. B. armature. C. rotator. D. stator. 43. When electrical current is flowing through a wire, a _________________ can be found

around the wire. A. vacuum B. battery C. magnetic field D. higher pressure 44. Which of the following is most true: One of the main differences between an electric motor

and an internal combustion engine is that ________________________. A. an electric motor is complex and has many moving parts. B. an electric motor has very little torque when it first starts to rotate. C. an internal combustion engine is more efficient than an electric motor. D. an internal combustion engine has many moving parts. 45. An electric vehicle is driven at 40 miles per hour for 30 minutes. The driver then increases

the vehicle’s speed to 60 miles per hour and drives for another 15 minutes. What is the approximate distance that the vehicle traveled?

A. 25 miles B. 35 miles C. 40 miles D. 45 miles 46. In general, when is a cutting tool safest to use? A. When the cutting edge is dull. B. When the cutting edge is sharp. C. When the cutting edge is hot. D. When the cutting edge is loose.

47. Which wire has the largest diameter? A. # 1/0 B. # 22 C. # 10 D. # 2/0 48. A hacksaw: A. is best used to cut wood. B. cuts on the forward stroke. C. is better than a reciprocating saw. D. cannot be used to cut plastic. 49. What statement best describes electricity? A. The movement of charged particles B. The ability to produce work C. A measure of current D. All of the above 50. In a DC motor, the brushes: A. keep the stator clean. B. rotate around the field coil. C. make contact with the commutator. D. never need replacing. 51. When an electric vehicle is in regenerative braking mode, which of the following is normally

occurring? A. The vehicle is downshifting. B. The vehicle is speeding up. C. Current is going to the motor. D. Current is going to the batteries. 52. What is the one of the main benefits of a fuel cell? A. It is simple to manufacture. B. Water is a product of a fuel cell’s operation. C. It is inexpensive. D. All of these. 53. A pulse-width modulated controller in an electric vehicle: A. sends wide pulses to the batteries. B. sends pulses of current to the motor. C. controls the modules. D. pulses the modules with a wide controller.

54. A “Class B” fire is best put out by _______________ the flames. A. cooling B. fanning C. blowing on D. smothering 55. What EV component has been most improved by solid-state electronics? A. Contactor B. Motor C. Main fuse D. Controller 56. One of the main advantages of most full-size electric vehicles is their: A. fifteen-minute recharge time. B. efficient use of energy. C. lightweight battery pack. D. availability to the general public. 57. What is specific gravity? A. How specific an object’s gravity is. B. The specific weight of an object. C. The height of acid in a battery. D. The density of a substance compared to water. 58. When a lead-acid battery is recharged, sulfate crystals are: A. deposited onto the lead plates. B. created once again. C. removed from the lead plates. D. both A and B 59. An emergency manual disconnect switch in an EV usually allows the operator to: A. shut off the 12-volt system. B. disable the high voltage system. C. rapidly discharge the batteries. D. disconnect the accelerator cable from the potentiometer. 60. A capacitor stores: A. electrical charge. B. momentum. C. rotational energy. D. light capacity.

61. Safety glasses must be worn: A. only when working on batteries. B. whenever one is in the lab or shop. C. only when working with power tools. D. both A and C 62. When one gallon of gasoline is completely burned, approximately _________ of carbon

dioxide gas are produced. A. 10 gallons B. 50 gallons C. 100 gallons D. 1000 gallons 63. In 1900, what were the two main types of automobiles? A. Electric and internal combustion B. Steam and electric C. Internal combustion and steam D. There weren’t any automobiles in 1900 64. What is the electrical unit for power? A. Watt B. Volt C. Ampere D. Ohm 65. What is one way that a deep-cycle lead-acid battery is usually different from a lead-acid

starting battery? A. The deep-cycle battery has thicker lead plates. B. The deep cycle battery has thinner lead plates. C. The deep-cycle battery produces more cold-cranking amps. D. Both A and C 66. A flywheel-powered vehicle relies on what physical phenomenon? A. Angular momentum B. Rotational inertia C. Conservation of momentum D. All of the above 67. A standard lead-acid battery has a twenty-hour capacity of 100 amp-hours. However, this

same battery only has a one-hour capacity of 65 amp-hours. Why does this battery have a lower one-hour capacity rating?

A. Batteries generally have less capacity when discharged at a faster rate. B. When discharged for twenty hours, the battery increased its voltage. C. This battery is probably defective. D. When discharged for one hour, the electrolyte in the battery became colder.

68. In many gasoline-powered vehicles, the brakes are assisted by the ___________ that is produced by the engine. A. exhaust B. vacuum C. spark D. torque 69. When lifting a heavy object such as a battery, it is best to: A. drag it across the floor to where you want it. B. lift it primarily with your back and not your legs. C. lift it primarily with your legs and not your back. D. lift it primarily with your arms. 70. When designing an electric vehicle, it is important to consider the: A. battery weight. B. driver location. C. vehicle’s center of gravity. D. all of these. 71. What does this symbol represent in a wiring diagram? A. A switch B. A ground C. A diode D. A capacitor 72. When a converted electric vehicle’s 12-volt start switch is turned on by the vehicle’s driver,

which of the following usually happens? A. The potentiometer sends current to the controller. B. The motor brushes are pre-heated. C. The controller sends current to the motor. D. A contactor closes. 73. A vehicle has 10 kilowatt-hours of energy within its battery pack (at a one-hour discharge

rate). In order to travel 50 miles in one hour, what is the approximate discharge rate that the vehicle must be driven at?

A. .2 kilowatt-hours per mile B. .5 kilowatt-hours per mile C. 1 kilowatt-hours per mile D. 5 kilowatt-hours per mile 74. The potbox in an electric vehicle sends a signal to the: A. controller. B. DC/DC converter. C. motor. D. potentiometer.

75. When working on the high voltage system of an electric vehicle, you should: A. wear loose fitting clothing. B. wear rubber gloves. C. use uninsulated tools. D. expose all of the high voltage connections. 76. A diode is primarily designed to: A. conduct current in two directions. B. store current better than capacitors. C. conduct current in one direction. D. vary resistance. 77. In 1912, Charles Kettering installed the first _____________ on a gasoline car. A. headlights B. crank C. muffler D. starter motor 78. When working on the 12-volt system of a vehicle, it is important to: A. remove the ground cable from the 12-volt power source. B. connect the positive and negative cable of the battery. C. remove the appropriate fuse from the fuse box. D. make sure the battery is discharged. 79. You are steadily driving an electric vehicle at 55 mph up a steep incline for two miles.

Suddenly a malfunction occurs and the vehicle coasts to a stop. What is the likely cause of this malfunction?

A. The potentiometer became disconnected from the accelerator cable. B. The main contactor opened up. C. The 12-volt system became discharged. D. A high voltage fuse blew. 80. In 1990, the California Air Resources Board adopted a ZEV mandate that required: A. major auto manufacturers to sell certain percentages of zero emission vehicles in California. B. major California cities to sell zero emission vehicles. C. that only zero emission vehicles could be sold in California. D. zero emission vehicles begin to phase out internal combustion vehicles in California. 81. A hybrid electric vehicle: A. usually has less range than a pure electric vehicle. B. gets all of its energy from a battery pack. C. has two or more power sources. D. always has a small internal combustion engine.

82. Vehicles A and B are identical except that their battery packs have different voltages. Although both battery packs contain 1000 pounds of deep-cycle lead-acid batteries, Vehicle A’s pack is 144 volts and Vehicle B’s pack is 96 volts. With fully charged packs under the same driving conditions, why does Vehicle A have a slightly greater range than Vehicle B?

A. Vehicle A has better batteries. B. Because the batteries in Vehicle A will not need to produce as much current as the batteries

in Vehicle B, the batteries in A will discharge at a slower rate. C. The batteries in Vehicle A are twelve-volt batteries and the batteries in Vehicle B are six volt

batteries. D. A higher voltage battery pack has more electricity. 83. Which of the following is an example of a good conductor? A. Copper B. Rubber C. Sulfur D. Water 84. What does the symbol below represent in a wiring diagram? A. A fuse B. A battery C. A light D. A coil 85. Electric energy is purchased from your utility in what unit? A. Kilowatts B. Amp-hours C. Volts D. Kilowatt-hours 86. A battery has a 20-hour rating of 100 amp-hours. This rating means that this battery can

_______________ before being discharged. A. produce 100 amps for 20 hours B. produce 100 amps for one hour C. produce 20 amps for five hours D. produce 5 amps for 20 hours 87. A parallel circuit: A. is better than a series circuit. B. has more than one path for current flow. C. has parallel wires in the circuit. D. is better for electric cars.

88. The torque of a series DC electric motor is normally the greatest: A. when the motor has high current flowing through it. B. when the motor has high RPMs. C. when the motor has low current flowing through it. D. both B and C 89. Torque is: A. a measure of rotational speed. B. often measured in foot-pounds. C. a measure of the horsepower of an electric motor. D. Both A and B. 90. An automobile’s suspension is designed to support the vehicle’s: A. gross vehicle weight. B. body weight. C. passenger load. D. cargo load. 91. A gear on the end of motor shaft has a diameter of 2 inches and has 20 teeth. This gear

drives another gear with a diameter of 4 inches and a 40 teeth. What is the gear ratio of this gear system?

A. 1:2 B. 2:4 C. 20:1 D. 2:1 92. What is the kinetic energy of a toy electric vehicle of mass 3 kg and velocity of

2 meters/second? A. 6 joules B. 1 joule C. 5 joules D. 12 joules 93. The controller in an electric vehicle performs a function that is similar to the ____________

in a gasoline vehicle. A. catalytic converter B. fuel injector C. engine D. gas tank 94. What force is needed to accelerate a 1000 kg electric vehicle at 5 m/s2? A. 1025 newtons B. 995 newtons C. 5000 newtons D. 200 newtons

95. An electric vehicle is driven at 30 miles per hour for 30 minutes. The driver then increases the vehicle’s speed to 60 miles per hour and drives for another 30 minutes. What is the vehicle’s average speed during the entire time?

A. 35 miles per hour B. 45 miles per hour C. 50 miles per hour D. 55 miles per hour 96. Most general purpose wire crimpers can be used to: A. cut wire. B. crimp terminals on wires. C. strip insulation off wires. D. All of the above. 97. If a typical gasoline powered vehicle is driven 15000 miles, approximately how many

pounds of carbon dioxide does it release into the air? A. 1000 pounds B. 5000 pounds C. 10000 pounds D. 15000 pounds 98. The strength of an electromagnetic coil: A. can be increased by placing an iron bar within the coil. B. cannot be easily changed. C. can be increased by reducing the current in the wire. D. can be reduced by increasing the number of wires within the coil. 99. Battery box ventilation is important to prevent the accumulation of: A. battery acid. B. hydrogen gas. C. sulfur dioxide gas. D. carbon monoxide gas. 100. Many people wonder whether you could extend the range of an electric vehicle by

attaching an alternator to an axle and charge the batteries as you drive down the road at a steady speed. Why will this not increase your range?

A. The energy needed to drive the alternator would be more than the energy created. B. An alternator could not be connected to an axle. C. Alternators are too complex. D. There aren’t any alternators large enough to charge a large battery pack.

Equations Needed for Electric Vehicle Technology Course #7409 Exam Ohm’s Law: R = V / I where R = resistance, V = voltage and I = current Average speed = total distance / total time Total distance = average speed X total time Kinetic Energy = ½(mv2), where m = mass and v = velocity Newton’s Second Law: F = ma, where F = force, m = mass, and a = acceleration

EV Pre-Post Test Answer Sheet

1 A 35 B 69 C 2 D 36 D 70 D 3 B 37 C 71 B 4 B 38 A 72 D 5 D 39 A 73 A 6 C 40 B 74 A 7 D 41 D 75 B 8 C 42 B 76 C 9 B 43 C 77 D

10 A 44 D 78 A 11 B 45 B 79 D 12 D 46 B 80 A 13 A 47 D 81 C 14 C 48 B 82 B 15 C 49 A 83 A 16 C 50 C 84 B 17 A 51 D 85 D 18 A 52 B 86 D 19 C 53 B 87 B 20 C 54 D 88 A 21 D 55 D 89 B 22 D 56 B 90 A 23 C 57 D 91 D 24 D 58 C 92 A 25 C 59 B 93 B 26 B 60 A 94 C 27 B 61 B 95 B 28 C 62 D 96 D 29 A 63 B 97 D 30 A 64 A 98 A 31 A 65 A 99 B 32 D 66 D 100 A 33 B 67 A 34 C 68 B

High VoltageHigh Voltage - Low CurrentPotentiometer LeadsLow Voltage

G - MotorH - ControllerI - PotentiometerJ - 12V Auxiliary BatteryK - 12V Main FuseL - Key SwitchM - 12V Contactor FuseN - Chassis Ground

Test Point

A, B, C -- 12V Traction BatteriesD - High Voltage FuseE - Main DisconnectF - Main Contactor

#

4

5

6

8

3

2

1

7

9

10

D

33

N

F

B

A

C

E 19

20I

24

25

26

27

K

28

23

M

J

L

G14

15

B+

A2M-16

17B- H

13

18

22

2130

29

11 12

31

32

EV Challenge School Initiative Form

Page 1 of 8 Revised 01/2012

Directions for Students and Teachers: 2011-2012 School Year

1. On the following pages are the activities that a school may complete in the School Initiative activity. Review

these activities carefully and determine which ones your school will complete. Note that the timeframe for these activities extends from the day after last year’s Final Event through April 19, 2012.

2. Upon completing an activity, fill out the "Date Completed" and "Points Earned" box for that activity. All of the

information (including ALL dates) must be accurately completed to earn points. If you need more space than the form allows, attach your additional information to the forms.

3. Bring this completed form and any supporting materials and documentation to the registration officials on the

first morning of the Final Event. 4. EV Challenge officials will review your form and total your points. Scores will be announced at the Final

Event. 5. Please don’t hesitate to contact Kelly Peele, EV Challenge Program Coordinator, if you have any

questions or concerns: Kelly@ev-challenge.org.

EV Challenge School Initiative Form

Page 2 of 8 Revised 01/2012

I. Participate in Other Events Veteran Points

Rookie Points

Date(s) Completed

Points Earned

A. Other Alt Fuel Events. Participate in organized alternative fuel events other than the EV Challenge Final Event. 5 5

B. Display Vehicles at State Fair. Display EV Challenge vehicle(s) at your state fair. 20 20

C. Other Events. Drive vehicle in community parade or display vehicle at community festival or event. 5 each 5 each

D. Other Sports Car Events. Each Tarheel or other Sports Car Club event throughout year. Veterans – Compete. Rookies – Compete or at least 4 students and 1 teacher attend. 5 5

EV Challenge School Initiative Form

Page 3 of 8 Revised 01/2012

II. Educate Others Veteran Points

Rookie Points

Date(s) Completed

Points Earned

A. Posters. As an entire class assignment, have students create posters entitled “The Need For Alternative Fueled Vehicles.” Hang the posters throughout the school. Include at least one of the posters with your School Initiative forms and package that you bring to the Final Event.

6 6

B. Brochures. Prepare a brochure about The Need For Alternative Fuel Vehicles. Include the brochure with your School Initiative forms and package that you bring to the Final Event. 6 6

C. Essays. As an entire class assignment, students prepare a one-page essay entitled "How Alternative Fueled Vehicles Can Help Our Environment and Save Energy." Include at least one of the essays with your School Initiative forms and package that you bring to the Final Event.

6 6

D. Skits. Develop and present a skit about the environmental benefits of EVs. Present this skit to a local community group, elementary, or middle school. 6 6

E. Presentations. Prepare and present a live presentation to a local government or civic organization describing your school’s EV Challenge program and how it benefits your school.

9 9

F. Letters to Elected Officials. Write a letter to an elected official explaining the benefits of alternative fueled vehicles and how the EV Challenge is preparing you to make positive changes in the future. With the School Initiative package and forms that you bring to the Final Event, include a copy of at least one of these letters and a list of everyone else that received a letter.

5 total for all letters

5 total for all letters

G. News Articles. Get articles written about your school’s electric vehicle program in local newspapers. These may be written by the newspaper’s reporters or by students. Include a copy of each of these articles in your School Initiative forms and package that you bring to the Final Event.

10 each 10 each

EV Challenge School Initiative Form

Page 4 of 8 Revised 01/2012

II. Educate Others, continued Veteran Points

Rookie Points

Date(s) Completed

Points Earned

H. Press Releases. Send a press release to your local news media. Include at least one of the news releases with your School Initiative forms and package that you bring to the Final Event.

10 total for all releases

10 total for all releases

I. Radio or TV Press. Have a story about your EV program aired on local TV or radio. For each radio or TV piece, include a digital copy (CD, DVD, etc.) or web site link with your School Initiative forms and package that you bring to the Final Event.

10 each 10 each

J. License Plate. Order and install a new specialized/personalized license plate for your school’s EV. The license plate should somehow describe that the vehicle is electric. Be creative. Information can be found through your state’s DMV. Include at photo of your license plate with your School Initiative forms and package that you bring to the Final Event.

5 5

K. School Presentations. Travel to a local school and make a presentation on the EV program. 2 each 2 each

L. Display Vehicle. Display vehicle at local sponsor/supporter’s business or organization. 5 each 5 each

L. Publish Web Site or Blog. Create or maintain a web site and/or blog about your school’s EV program. 20 20

EV Challenge School Initiative Form

Page 5 of 8 Revised 01/2012

III. EV Challenge Supporters Veteran Points

Rookie Points

Date(s) Completed

Points Earned

A. Emails. Send a student-written thank you email to each of the following EV Challenge sponsors (past, present, future). Include a description of the benefits obtained by students and your community. Include a copy of the emails with your School Initiative forms and package that you bring to the Final Event. 1. NCCAR (North Carolina Center for Automotive Research) – Simon Cobb has offered his facility free of charge for the 2012 event: simon.cobb@nccar.us 2. Burroughs Wellcome – We have a grant from them for 3 years to fund the program. Carr Thompson: cthompson@bwfund.org Melanie Scott: mscott@bwfund.org 3. TE Connectivity – We have received funding from them for the event. Eric Freid: eric.freid@te.com

10 points for each

supporter contacted

10 points for each

supporter contacted

B. New Overall Sponsor. Obtain a new EV Challenge sponsor for the overall EV Challenge program. Each $1,000 of support obtained shall earn 50 points. List the sponsor(s) here:

50 each 50 each

C. Rides in Vehicle by Elected Official, including School Board Member Veterans -- Ride in or drive vehicle. Rookies – Visit your school and view EV project if your vehicle isn’t complete. List the officials here:

5 for each official

5 for each official

EV Challenge School Initiative Form

Page 6 of 8 Revised 01/2012

IV. Get Everyone Involved at Your School Veteran Points

Rookie Points

Date(s) Completed

Points Earned

A. Whole-school Presentation. Conduct a whole-school presentation about your EV program. As part of your School Initiative forms and package that you bring to the Final Event, include a description of the presentation.

5 5

B. School Employees. Get five school employees who have never driven your vehicle to drive your vehicle. List the employees here:

3 each 3 each

C. Class Projects. Get the EV Challenge taken on as a class project in at least three separate subject classes. (For example, Automotive, Electronics, Physics, English, Biology, etc.) List the classes here:

20 20

D. Essays/Journals. As an entire class assignment, write a one-page essay or journal entry entitled "What I’ve Learned from Participating in the EV Challenge.” Include a copy of at least one of these essays in your School Initiative forms and package that you bring to the Final Event.

5 5

E. School Newspaper Articles. Get an article about the EV program in the school newspaper. Include a copy of each of these articles in your School Initiative forms and package that you bring to the Final Event.

5 each 5 each

F. School Events. Display EV at a school event (football game, parent conferences, etc.). 5 for each event

5 for each event

G. Yearbook. Get your school’s electric vehicle program included as its own separate page or program in the yearbook. 6 6

EV Challenge School Initiative Form

Page 7 of 8 Revised 01/2012

V. Meet These Deadlines – Rookies Only Veteran Points

Rookie Points

Date(s) Completed

Points Earned

A. Receive Vehicle. Receive vehicle to be converted by December 1, 2011. 5

B. Remove Components. Remove engine, muffler, gas tank, and radiator by December 29, 2011. 5

C. Motor and Controller. Receive electric motor and controller by January 30, 2012. 5

D. Batteries. Receive batteries by February 16, 2012. 2

E. Install Motor. Install electric motor by February 28, 2012. 5

F. Drive Vehicle. Drive vehicle under its own power at 25 mph by April 1, 2012 20

EV Challenge School Initiative Form

Page 8 of 8 Revised 01/2012

VI. Other Activities Veteran Points

Rookie Points

Date(s) Completed

Points Earned

If your school completed other EV-related activities that are not listed on this form, please list them below. Challenge officials will award up to ten points for other activities that meet School Initiative goals.

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1

2

3

The School Initiative Competition is scored on the honor system. Challenge officials depend upon the instructors and students at each school to honestly and accurately complete this form.

I certify that this form has been completed with honesty and total accuracy: Printed Name of Lead Instructor Signature of Lead Instructor Date Printed Name of Lead Student Signature of Lead Student Date