Powertrain for RIT EV Team TT-Zero Race Bike

Powertrain for RIT EV Team TT-Zero Race BikeR12900Sean Harriman5/20/2012

Updated Mission Statement To design, bench test and implement an

electric drive system on a rolling chassis provided by the Electric Vehicle Team that operates at race speeds and has a just enough range to finish the TT-Zero around the Isle of Man Road Course while maximizing the power of the electric motor to the road through the use of a traction controller.

Place of Innovation “the Isle of Man TT, the toughest

motorcycle race in the world. The technology at work is so advanced, so unprecedented, that we may be looking not just at the future of motorcycles, but of all electric vehicles." From the article "Inside Story Motoczysz E1PC Worlds Most Advanced Electric Motorcycle"

Electric Motorcycle Racing 3rd year already approaching lap times of low end 1000cc Grand Prix Bikes

TT-Zero Race Details "The technical concept is for motorcycles (two

wheeled) to be powered without the use of carbon based fuels and have zero toxic/noxious emissions." -REGULATIONS TT ZERO

£10,000 for the first entrant to exceed the prestigious 100 mph (22 minutes and 38.388 seconds) average speed there are also awards for the first ten teams to break the record

Top competing university which is offered a prize of £5,000

Snaefell Mountain Course

Click icon to add picture

Length: 37.733 miles200 Corners60 Named CornersTT-Zero: 1 LapIsle of Man TT: one of the most prestigious motorcycle races in the world

Constraints: Race Date: May 28, 2013 (Assumed same date as

2012) Race Electrical Safety Regulations Input Charging Power: 240 V single phase 13 amp

max Vehicle Total Weight: 100kg-300kg (220lbs-660lbs)

Powertrain Weight Allowance (exclude batteries/motor): 60lbs (Subject to change)

Course Length 37.75 miles Qualifying time: 50 mins average course speed 45.3

mph Must perform standing start on 18% incline

Changes in Design Problem/Objective Needs Essentially Same Design Problem: Push Performance of

Electric Vehicle Design From reach spec of Range of 140 miles to easy 37.75

miles From easy spec of operating speeds 45-55 mph to reach

spec of 150+ mph Still high emphasis on fuel efficiency No longer constrained to road registered vehicle Still focus on powertrain More defined scope, meet race safety regulations and

constraints More integrated design with Traction Controller

Functional Decomposition:Flow Diagram

BenchmarksMotorcycles:Honda CBR1000RR (Course Record)MotoCzysz E1pc (2010/11 Winner)MIT EV Team eSuperbikeBrammo Empulse R (1st time Competitor)Honda Mugen EV (1st time Competitor)Specifications Compared:Motor: Style/output/operating Volts/ampsController StyleBattery Pack: Chemistry/volts/ampsWeightRange/Top Speed/Course Average SpeedTransmission

Honda CBR1000RR Motor : ICE 999cc

inline 4 178 hp/82.6 lb-ft

Wet Weight: 441 lbs Top Speed: 184.6

mph(stock) 200+ mph (race)

Course Average: 131.6 mph 17’12.3 min’sec

Holds Course Record

MotoCzysz E1pc Motor: DC perm magnet

‘D1g1tal Dr1ve’ 100 hp / 250 lb-ft

Battery: LiPo 500 V/ 125 Kwh

Top Speed: 140 mph Direct Drive Course Average:

99.604 mph 22' 43.68 min'sec

Current EV course record, winner 2010/11

Focused on developing fastest bike with sufficient capacity buffer. Finished w/ 60% charge left

MIT eSuperbike Motor: 2x Lynch DC

Thin-Gab Axial Flux Motors

Battery: A123 Automotive LiFePO4 Prismatic Modules

Top Speed: 100 mph Direct Drive Course Average

Speed: 79.163 mph 28' 35.81 min'sec

Metrics/Specifications

Metrics/Specifications 2

House of QualitySpec a.1 a.2 a.3 a.4 b.1 b.2 b.3 b.4 b.5 b.6 b.7 b.8 b.9 b.10 c.1 d.1 e.1 e.2 e.3 e.4 e.5 e.6 f.1 f.2 f.3 f.4 g.1 g.2 g.3 g.4 g.5 g.6 h.1 h.2 h.3 h.4 h.5 h.6 h.7 i.1 i.2 i.3

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1.1 Meets All Race Safety Regulations 3 3 1 1 9 9 9 9 9 9 9 9 9 9 9 3 91.2 Range to just finish the race 9 9 9 9 3 3 3 3 3 3 3 3 3 3 3 9 3 91.3 Qualifies for the race 9 9 1 3 3 9 9 9 9 1 9 9 3 9 9 3 3 9 91.4 Operates at race speeds 9 3 3 3 9 9 9 9 3 9 3 9 9 3 9 1 9 91.5 Regenerative Capabilities 1 1 1 1 9 9 3 3 1 3 9 1 3 31.6 High Fuel Efficiency 1 1 3 9 9 9 3 3 1 9 1 9 3 9 9 3 3 3 92.1 Maximize power and torque to the road 3 1 1 3 9 3 9 1 9 9 3 9 3 9 9 9 3 9 9 9 9 9 9 9 9 9 92.2 Inform driver for optimal shifting 3 3 9 9 9 3 9 9 3 1 1 9 9 1 3 9 9 9 9 3 9 9 9 92.3 Operates consistently for entire race 1 9 3 3 3 3 3 3 3 3 3 3 3 3 1 3 9 3 3 1 3 3 1 3 3 3 3 3 3 3 92.4 Minimal recharge time 3 3 9 1 3 3 12.5 Easy Battery Swap out 1 1 1 1 33.1 Club members on MSD team 1 3 3 3 3 3 93.2 Club Advisor support 3 1 1 3 1 3 33.3 Space for senior design build in KGCOE and 1 1 1 1 1 1 1 1 1 1 3 3 3 1 3 3 1 1 33.4 Optimzed Race and Course Model 1 9 1 1 9 9 9 9 9 9 9 9 9 1 3 3 3 3 3 3 3 9 9 94.1 Fall Quarter MSD I Winter Quarter MSD II 34.2 Design small enough for senior design team 1 1 1 3 3 3 3 3 3 9 3 3 3 3 1 9 9 94.3 Powertrain budget 1 1 1 3 1 1 1 1 1 1 1 9 9 9 3 3 1 1 3 3 3 3 9 9 3 9 9 9 9

Volts KWh C rating Chemical Make Up yes/no yes/no volts IP kohms kohms volts/hz volts/hz yes/no volts/sec yes/no volts Motor Style hp ft-lbs volts % yes/no yes/no # hp/ft-lbs yes/no units ±% yes/no yes/no yes/no yes/no yes/no yes/no yes/no yes/no yes/no mph mi lbs

0 0 0 LiPo yes yes 42 44 250 500 2000/50 4000/50 yes 65/2 no 12 0 140 250 0 0 177 yes yes 0 86.8 no no 30 25 no no no yes yes no no no yes 140 37.75 60

500 max 125 50 or more

LiFePO4 yes yes 42 55 250 500 2000/50 4000/50 yes 65/5 yes 12 DC Brushless 180 300 500 max 90 61.6 yes yes max 6 133.3 yes yes 15 10 yes yes yes yes yes yes yes yes yes 200 37.75 60

Race ready electric drivesystem for a motorcycle

Reliability/Ease of Use

Co-Development with Electric Vehicle Team

MSD Project Scoping

To design bench test and implement an electric drive system on a rolling chassis provided by the Electric Vehicle Team that operates at race speeds and has a just enough range to finish the TT-Zero around the Isle of Man Road Course while maximizing the power of the electric motor to the road through the use of a traction controller.

Marginal Value

Measure of Performance

Nominal Value

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Spec a.1 a.2 a.3 a.4 b.1 b.2 b.3 b.4 b.5 b.6 b.7 b.8 b.9 b.10 c.1 d.1 e.1 e.2 e.3 e.4 e.5 e.6 f.1 f.2 f.3 f.4 g.1 g.2 g.3 g.4 g.5 g.6 h.1 h.2 h.3 h.4 h.5 h.6 h.7 i.1 i.2 i.3Engineering Metrics

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500 max 125 LiFePO4 yes yes 42 55 250 500 2000/50 4000/50 yes 65/5 yes 12 DC Brushless 180 300 500 max 90 61.6 yes yes max 6 133.3 yes yes 15 10 yes yes yes yes yes yes yes yes yes 200 37.75 60


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MSD Project Scoping


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Volts KWh C rating Chemical Make Up yes/no yes/no volts IP kohms kohms volts/hz volts/hz yes/no volts/sec yes/no volts Motor Style hp ft-lbs volts % lbs-ft at wheelyes/no yes/no # hp/ft-lbs yes/no units%charge after race ±% yes/no yes/no yes/no yes/no yes/no yes/no yes/no yes/no yes/no mph mi lbs




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MSD Project Scoping


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Staffing Ideal ScopeDiscipline How

Many? Anticipated Skills Needed

EE 2 EE1: Main Circuit Design, onboard/accessory circuit design and assemblyEE2: Power system optimization, battery management, controls system design

ME 3ME1: CAD Drawing, Interfacing w/ Traction Controller, Physical mountingME2: Transmission Modification/Optimization, Final Drive DesignME3: Machining/Assembly Experience/Test Design

CE 1 CE1: Embedded real time system, fuzzy logic control algorithm. Device programming. Signals Processing

Feedback From Electric Vehicle Team Scoping

Ideal Situation: Top Speeds 200 mph Course average 131.6 mph 17'12.30 min'sec Goal: Beat Course record

Powertrain Budget: $15,000 Medium Scope: Top Speeds 140 mph Course

average 100 mph 22'38.33 min'sec Goal: Beat 100 mph EV course record win 10,000

pounds prize and top competing university win 5,000 pounds prize

Powertrain Budget: $7,500 Smallest Scope: Bench Test scaled components

and have Course Simulation of Ideal Scope Powertrain Budget:$500 MSD Funding

Feedback From Electric Vehicle Team Specifications:

The Electric Vehicle Team will Develop a Course/Race Model over summer Provide MSD I with more specific and optimized

specification values Battery/Motor selection

Staffing: Sean Harriman Electric Vehicle Team Powertrain

Project Manager: Lead Engineer-ME1 MSD Team Dan Brownlee Electric Vehicle Team Vice President:

ME2 MSD Team Andrew Robison Course/Race Model Developer:

ME3 MSD Team

Questions?

Powertrain for RIT EV Team TT-Zero Race Bike

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