The PulseHEVT Newsletter

Spring 2016

Why performance hybrids? Because a beautiful car deserves a beautiful planet.

“ has given me an inside look at what it takes to redesign a car...and made me want more of it in the future!” —Matt Nikkel

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HEVT

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Spring‘16

Tech Update

Member Profile

Sponsor Spotlight

Inspiring Future Engineers

Welcome New Sponsors!

We roll up our sleeves and get our hands dirty!

From under the hood to behind the wheel, Nikkels dreams of international racing

Mar-Bal is the king of composites and a champion of HEVT

First ever PowHERed by STEAM luncheon empowers young girls to pursue engineering

Eight new sponsors in three months? Thank-goodess we have room for so many stickers on the car!

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Technical Update3. 4.

When the Camaro came in Decem-ber, we knew we had our work cut out for us. From swapping the en-gine and transmission to designing the P3 motor to assembling the ESS, the early-May ship date for compe-tition hardly seemed far away.

With the help of our sponsors and a seemingly endless amount of coffee and hours in the lab, we’re proud to say we’ve hit a few major mile-stones.

The engine and transmissionWe ran into a bit of luck finding the V8 that will power our Camaro.

We found a wrecked 2014 Chev-rolet Silverado, but its powertrain was still fully-functional, which meant we were able to find it at an auction. Continental, the Student Engineering Council, and the Vir-ginia Tech College of Engineering helped supply the funds that made the purchase possible. We success-fully removed the V8 from the truck and got it running on a test stand wielded by a few mechanical and controls sub-team members.

We also ordered an 8-speed trans-mission from General Motors and recently integrated both the engine

and transmission into the vehicle.

ESS

A123 sent battery modules, allow-ing us to launch into work on the ESS.

Our electrical and controls students began assembling the battery mod-ules using a variety of small donat-ed parts from Panduit. According to Desmond Claytor, electrical sub-team member, the donations from Panduit enabled the team to have a direct supplier for wire termina-tions, which are necessary through-out our ESS.

“We have been specifically request-ing wire termination and protection items from Panduit,” said Claytor. “They are important to the ESS build because we need the right ter-minals for certain connections and using incorrect terminals could re-duce system performance.”

A major milestone: after trou-ble-shooting connections in the ESS low-voltage wiring harness, we got the contactors to close. This marked the completion of communication testing. Our next step? To assemble the ESS and perform high-voltage testing before installing it into the vehicle. Just this week, we were able to read 347 volts, and we’re do-ing the final preparations before in-tegrating the ESS into the Camaro.

P3 Motor and InverterWe have been working with In-Motion to design the P3 motor, the keystone component of our design which provides traction in EV mode, and provides both regenerative ca-pabilities and extra performance. We also started working with them on developing the code for the in-verter, which will control the motor. By the beginning of April, we will begin motor testing with our recent-ly acquired inverter.

Floor Plan Modification

In order to make room for the P3 motor, mechanical subteam leader Dan Chadwick designed a custom floor-pan. The newly welded floor plan will hold up the motor and align it with the drive shaft correct-ly. A poorly structured floor plan could harm the car, making it essen-tial to do a good job.

Altec provided the material, manu-factured the part, and offered feed-back that greatly enhanced the ac-curacy and manufacturability of the design plans.

“Their through-put was incredible,” said Quinn Roels, mechanical sub-team member.

Charge Port In order to convert the conventional Camaro into a plug-in hybrid vehi-cle, we needed to cut a hole in the rear body panel on the driver’s side and install a charge port. The charge port door is a mirror of the fuel door but once opened, there is a charge port instead of a fuel filler neck.

Collision Plus cut the body panel and welded the charge port door onto our Camaro, along with install-ing the actual charge port using nuts

and bolts, and matching the paint on our car.

“Collision Plus was extremely gracious and helpful to HEVT and without them, none of this would have been accomplished,” said Abdus Khan, mechanical subteam member. “We are very thankful to our sponsors for supporting us and allowing us to be able to succeed in the EcoCAR 3 competition. I want to reiterate that Collision Plus did a phenomenal job with all requested tasks including installing the charge port door and the actual charge port.”

Overall vehicle design Remember when Car and Driver dubbed the 2016 Chevrolet Camaro “leaner, meaner and out for Mus-tang blood?” We’re having some trouble with the “leaner” part.

To help, the Ware Lab provided the team with scales that allow us to test the weight of different dimensions of the car, thus finding areas for im-provement.

“F=ma, more mass means more re-quired force to accelerate the car at the same rate. This includes lateral acceleration like cornering,” said Ryan Barrett, mechanical subteam member. “basically, if you were a wide receiver (a la sports car) would you want to be quick and nim-ble like a wide receiver or big and heavy like a lineman... you’re more maneuverable if you’re lighter.”

Want to know more? Feel free to post questions on our Facebook and Twitter page…we’re happy to answer!

“We had a rough design for them and they were able to get us the right part on time and made incredibly well.”

-Quinn Roels

Year Two:The Camaro Conversion

Technical Update 5. 6.

From behind the wheel to under the hood, Matt Nikkel combines the best of racing and computer engineering when mapping out his future

Growing up, Matt Nikkel, innovation sub-team member, always loved the thrill of racing go-carts. It wasn’t until last year, however, that he real-ized he could actually pursue car racing as a career.

“I realized I was an adult who could pur-sue my dream,” said Nikkel. “After much fi-nancial planning, I decided it was feasible and have been pursing cheap-ish race options since!”

In addition to cars, Nikkel also loves to code. These passions drew him to HEVT.

“EcoCAR 3 has given me an inside look at what it takes to redesign and rebuild a car for

a specific purpose,” said Nikkel. “Seeing this has made me want more of it in the future!”

On HEVT, Nikkel works on both advanced driver assistance systems and redesigning the team website.

Currently, Nikkel is the only computer engineer-ing student on the team. He takes pride in apply-ing his knowledge of both how code and comput-ers work as well as how cars and drivers work to helping the team make progress with the Camaro.

“Making these two systems [how computers work and how drivers work] work together is a challenge,” Nikkel said. “But solving the challenge in a well-struc-

Future racer in our midst

tured competition prepares me for future work.”

Looking forward, Nikkel dreams of one day winning the championship of a top-level, interna-tional racing series such as the FIA Rally Cross Series. In the meantime, he would like to com-pete in a national or international racing series.

Nikkel’s love of cars doesn’t stop at driving. He also wants to help advance technology in consumer cars.

“I don’t just want to be the fastest around the track, I also want to give good feedback to manufacturers and my team to improve and refine our approaches,” said Nikkel.

For aspiring computer engineering students, Nik-kel stresses the importance of ethics in engineer-ing. New developments, such as autonomous vehi-

cles and artificial intelligence, can bring significant damages if not handled properly. Creating safe and pro-social technology is one of the many motives that keep Nikkel working hard and looking forward.

“Getting into racing is normally about who wants to drive fast and has the money to do it,” said Nikkel. “I want to show that someone with a business plan, solid motive, and a passion for racing can enter into this field and suc-ceed, all while helping develop technology for the future.”

AutoMobilSport

Want to be featured?

Contact Sara Lepley, Communications Manager, at saradlep@vt.edu or direct message our Facebook page, Facebook.com/vtHEVT

Courtesy Matt Nikkel

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Mar-Bal invests in our studentsWe chat with one of our newest sponsors

HEVT would be nothing without our spon-sors. Mar-Bal, one of our new sponsors, has gone above and beyond in supporting our Camaro con-version, as well as our outreach and media ef-forts. We had the chance to chat with Ron Poff, global marketing and brands director of Mar-Bal.

HEVT: How would you describe the culture at Mar-Bal? How do employees interact with one another?

MAR-BAL: We are a 46-year-old manufacturing com-pany that is being led by the second-generation family; therefore, we have a very approachable leadership team that consistently promotes an entrepreneurial spirit within our daily interaction. This spirit allows our com-pany to be nimble while also being disciplined with im-portant processes. In addition, we have a great team at-mosphere where all of the cross-functional departments enjoy working together to move the company forward.

HEVT: What motivated Mar-Bal to sponsor EcoCAR 3 teams?

MAR-BAL: The EcoCAR 3 project represents one of our university outreach programs and we are very excited to be working with Virginia Tech and West Virginia University on this revolutionary develop-ment. We started 2015 with a strategic marketing plan to engage with the university community - both students and faculty – to share the benefits and ad-vantages of composites while also developing re-lationships with the next generation of engineers.

HEVT: How would you describe composites to someone who had never heard of them before?

MAR-BAL: Composites are made of two or more dif-ferent materials combined together to become stron-ger and better. With regards to automotive applica-tions, light-weighting is very important. Composites materials are both strong and light. That’s a winning combination. Who wouldn’t want to work with a ma-terial that’s simple to ship and carry? Lightweight composites can save you money and manpower.

HEVT: Why do you love working with and supporting students?

MAR-BAL: At Mar-Bal, we find that it is very import-ant to work with students to provide them with an op-portunity to gain experience within our industry while also providing us with an opportunity to learn new skills and perspectives from them. We want to create the next generation of specifiers and marketers of composite materials; the best way is to engage with them now.

HEVT: Is there anything else you would like to add?

MAR-BAL: It has been a pleasure to get to know the students and faculty involved with the EcoCAR 3 program over the past few months. Their eager-ness to expand their knowledge base about compos-ites and also get to know more about manufactur-ing has been very energizing. We believe that this is only just the beginning of a long-term relationship that we want to continue to build for years to come.

HEVT hopes to work with Mar-Bal on a compos-ites project with the goal of light-weighting cer-tain aspects of the vehicle during years 3 through 4.

Want to learn more about Mar-Bal? Check out their website, mar-bal.com

Mar-Bal Composites are used in a variety of products, from wind turbines to vehicles. We hope to work on a project with Mar-Bal soon.

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POW HER ED BY STEAM

Studies show that girls want to help people and make a difference in the world. While STEM offers an avenue to do so, and 74 percent of high school girls across the country show interest in STEM, few girls pursue a STEM education in college.

HEVT wanted to change that.

On March 19, we hosted a Powhered by STEAM lun-cheon that sought to inspire girls to see themselves as

engineers. STEAM refers to the fields of science, tech-nology, engineering, art and math. The women on our team served as panelists and distinguished speakers.

“Watching the conversations that happened at the ta-bles and letting the girls see you all as role models was very meaningful to us,” said Phyllis Newbill, the lead-er of troop 1032. “You guys are rock stars to them.”

Over lunch, the Girl Scouts got the chance to ask the

women of HEVT questions about EcoCAR 3, engineering and anything else that came to mind. “Table Talkers” sta-tioned at each table helped foster meaningful conversations.

After lunch, team members Portia Isaac and Samantha Ev-erett gave speeches about their experiences in the field.

“Sometimes you will be the only girl in your class and you might wonder if the boys think you are smart enough to be there,” said Isaac, who holds a plethora of leadership positions at Virginia Tech.

Isaac went on to encourage the girls to form a strong support group and to always believe in themselves.

Every member of the HEVT team encouraged the girls to pursue their love of learning and to follow their aspirations.

The troop leaders who attended expressed great interest in work-ing with HEVT in the future. The team is currently planning a similar event with the Girl Scouts of Nation’s Capital in D.C.

Furthermore, the luncheon attracted the attention of Virgin-ia First. News coverage can be found on our Facebook page, Facebook.com/vtHEVT

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Welcome to our new sponsors!

Thank you Shelor Motor Mile and Rocky for all of your help and discounts!

Thank you Magnaflow for your mufflers!

Thank you Jet-Hot for coating our V8 exhaust manifolds!

Thank you Sabic for donating the lexan lid!

Thank you Collision Plus for installing our charge port and door!

Thank you Altec for manufac-turing our custom floor pan!

Thank you Boyd Welding man-ufacturing our custom fuel tank!

Thank you McLaren for donat-ing the flanges!

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Thirty days. That’s how long until HEVT’s newly named Camaro Hybrid Super Sport (HSS) ships to Yuma, AZ, where 285 points are up for grabs. In Yuma, Eco-CAR 3 organizers will judge the progress and quality of vehicle integration. One week later, the team leaves for San Diego, CA, where 308 points can be earned

with top-notch presentations and demonstrations.

Week 1: Yuma, Arizona

During the first week at GM’s Desert Proving Ground, a 2,400 acre hot-weather test facility with 40 miles of roads, teams will strive to pass two stages of safety-technical inspection in order to compete in the on-road evaluation. The goal of Year 2 is to construct a 50% mule vehicle, which should feature integrated components and functional safety. As a bonus, it should be safe in a dynamic driving environment, and the

scoring structure at Year 2 competition incentivizes these priorities.

During stage 1 of safety technical inspection, 135 points can be earned for the presence and professional integration of all components. If requirements are met, teams may advance to the second stage, which focuses on functional safety and is worth 60 points. The judges will evaluate the basic controls and electrical functions of the vehicle. Does the engine start? Are the e-stops functional?

Teams that pass this stage advance to the shakedown and on-road evaluation, worth only 35 points. This por-tion of competition focuses on dynamic safety and be-gins with a shakedown, where clearance and behavioral tests will be conducted at rest and the antilock brakes will be evaluated on gravel. Next, low and high-speed on-road safety tests will evaluate vehicle braking and handling capabilities.

At the end of the week, teams will jet off to Califor-nia for the final stretch of Year Two of EcoCAR 3.

Week 2: San Diego, California

During the second week in San Diego, the team will be presenting to panels of judges on various technical topics, project management, and outreach. One event, the Consumer Appeal Presentation, requires cross-func-tional teamwork to demonstrate how consumer fea-tures will be integrated into the vehicle to meet market demands. The target market for the Camaro HSS are termed Forward-Thinking Patriots. “Forward-Think-ing Patriots are proud Americans, aged 30-50, with a family history of owning American-made muscle cars,” says Quinn Roels, a senior mechanical subteam mem-ber leading the consumer appeal effort. “As automotive enthusiasts, they understand the finer details of how cars work and appreciate the high-end packages.”

The team hopes to configure and purchase a specific HSS package tailored to these consumers. Historical-ly, upscale Camaro trim packages have included high-er-end tire assemblies. For this reason, the HSS will feature lightweight performance tires and 20” alloy wheels to enhance vehicle aesthetics and curb appeal. For more performance, Brembo brakes will replace the stock Camaro brakes. Finally, to brand the HSS and make the vehicle pop, HSS logos will be embroidered into the headrests, performance floor mats will replace stock floor mats, and colored knee pads and pedal cov-ers will be added. In all, these market-driven modifica-tions will cost approximately $4,000, and the team can use all of the help it can get.

San Diego, California

GM Proving GroundsYuma, Arizona

Money burning a hole in your pocket?

Support HEVT!Take a moment and think back on

your time on HEVT. The late nights in the Lab, the

thrill of finally, finally getting the engine to run, begrudging admitting that Nelson was right....again.

For many students, HEVT is where they realize they actually like this thing called engineering, and they take pride in what they do. Maybe it’s their first real engineer-ing job, or the first serious project they worked on that doesn’t come with an instruction book. What mat-ters is that even though it’s hard, it’s worth it.

Surely, you remember the thrill of working on a brand-new car. You remember the opportunities that opened up as a result of your work on the team. You probably also re-member the importance of spon-sors...and how much of a difference getting the right part can make to the progress of the vehicle.

HEVT is currently in Year Two of EcoCAR 3. The Camaro is here. Competition is coming.

As you reminisce on your days in the Lab, we ask that you consider donating to the Hybrid Electric Ve-hicle Team. Can you help us reach

our goal of $5,000? Even the small-est donation can make an enormous difference to the car, the team, and the individuals tirelessly working to make it all come together.

To donate, check out our Go Fund Me at gofundme.com/vtHEVT

Thank you so much for your continued support. If you have

any questions, comments or con-cerns, please do not hesitate to con-tact us at hevt@vt.edu

Thanks!

We love our alumni!

Thank you to our sponsors!