uvicfh / home Goto Github PK

Context

We need to clearly define the purpose and function of the isolation board.

Outcomes

Documentation of

• Purpose
• Functionality
• Relation to rules

Related Issues

This will serve the next generation of UVic Hybrid members who will ask these same question.

Background

A meeting was held June 24, 2017 with those interested in working on powertrain projects and development. The goal of this meeting was to identify interested members and work out what our individual goals were in order to develop the goals of the team.

Attendance

Chad McColm (discussion leader)
Benjamin Kosten
Kurt Elliott
Ciara Duesterwald

Outcomes

We decided that our primary short-term goal was developing knowledge about the current systems through inspection and experimentation. Our other goals were as follow:

• Catch up on all overdue or unknown maintenance
  • Clean Air Filter
  • Clean Fuel Filter
  • Clean Injectors
  • Change Spark Plug
  • Check Oil Pressure Reg. Valve
  • Change Clutch Hydraulic Fluid
• Remove the engine two weeks from now if the car isn't running by then
• Develop a voltage divider circuit that will be safe to use as the ETB signal
  • Between 0-5V
  • Releases if it is dropped or let go
• Plan a thermostat project

Further Actions

Further actions include:

• Designating who will design the thermostat
• Designating who will design the voltage divider
• Contacting previous powertrain group to see if any maintenance items above have been done but haven't been recorded

Context

At comp something shorted on the rear power distribution board. It now no longer requires the reset button to be hit to be active, and upon GLV turning on it momentarily turns on multiple circuits (including the engine starter). This should not happen. Schematics for the reset circuit and rear power distribution can be found on the google drive.
Also note: for the engine starter to be tripped both it's fuse and the relay (which is currently missing since it was removed at comp and not put back) must be in place.

Outcomes

• Truth table for inputs (AMS, IMD, reset button, GLV, etc.) and the state of the reset circuit/power distribution
  • For the board which is performing unexpectedly
  • For the repaired board producing the expected behaviour
• Documentation of exactly what was wrong and why we believe it happened
• Documentation of how to prevent what happened in the future (procedure, or some change to hardware)

Constraints

Pinouts must remain the same

Related Issues

A potential short may have occurred in the wiring harness end on the left side where there's no pin cap; additionally, there is a free red wire near the end of the harness (I believe TSMS) which may have been powered by the power supply when debugging at comp when it shouldn't have; both of these may have caused or contributed to the trouble with the rear power distribution board.

Steps to reproduce behavior

Power AMS & IMD lines to reset circuit and turn on GLV, many breakout circuits will momentarily turn on, including the engine starter. The reset button should have to be hit before anything on the rear power distribution board is powered on. Note: the MicroSquirt light should always be on once the reset switch has been hit and AMS & IMD are powered, this is because the MS should never turn off and serves as a useful debugging tool.

Project Tiltle - Approx Cost - Description

Chassis - 1500( Geoff's estimate ) - Redesign and fabrication of chassis whith emphasis put on performance. The 2018 season chassis will be smaller, lighter, and have improved handling compared to the 2017 season chassis. Because nearly all system components are know the space constraints of the 2018 car will be optimized.

Suspension - 1500 - Redesign and fabrication of a new suspension system. This project will also take advantage of the fact that nearly all system components are know. The result will be optimization of the Hybrid racecar's vehicle kinematics to thier full potential.

Bodywork - 1500 - New outer panelling will be needed to keep our car aerodynamic, asthetically pleasing, and able to accomadate sponsors' information.

Steering Wheel - 500 - Design and fabrication of a new electronically faceted steering wheel. A new steering wheel presents a unique design project that encompasses ergonomics, user interfacing, and integration of electrical systems. This project would also eliminate the need for a dashboard.

This list should be edited by everyone ;)

Context

We must debrief GM to recieve the last installment of funding, ($5000).

Outcomes

A short debrief video to send to GM.

Constraints

Should be finished ASAP

Related Issues

Objectives our team had in our funding proposal were not met.

Steps to reproduce behavior

• Gather information from other members on the GM funding and what this video should be
• Create Video outline
• Prepare shop and vehicle for filming
• Lend film/audio equipement from fine arts. HD camera with Boom mike.
• Film the debriefing, edit, send to GM.

Please collaborate in the GM Debrief folder

Context

For the 2018 racing season, the UVic Formula Hybrid team will be designing and fabricating a new chassis. As this is a major project that has a significant influence on the cars performance it must be researched thoroughly to ensure the final design is optimized for the team's objectives.

Outcomes

• Read chassis design texts specifically geared towards racing suspensions (2-3 minimum)

• Gain a solid understanding of the chassis design process and industry best practices

• Develop objectives and goals for the new chassis design

Relevant Texts

1 - How to make your car handle - Fred Puhn
https://drive.google.com/file/d/0B4eb3g6wMmHrS2hlOXRBTVp5UHM/view?usp=sharing
Straightforeward overall intro to vehicle dynamics.

2 - Racecar Vehicle dynamics - Milliken
https://drive.google.com/file/d/0B4eb3g6wMmHrUTlmQnVzcFlVckU/view?usp=sharing
So called "Holy bible" of vehicle dynamics. 4x as long as 'how to make your car handle'.

3 - Racing and Sports Car Chassis Design - Costin and Phipps
Paper copy, In the Hybrid shop or with Bennett Smith.

4 - Science of Vehicle Dynamics - Massimo Guiggiani

5 - Any thing Geoff wrote about vehicle dynamics - Geoff Scott
mech459
more reports

6 - FSAE internet forums
like this one that lists more relevant texts!

7 - Design Reports or Thesis from other teams
Worcester University 2009 FSAE Project Report
Lawrence Tech 2002 FSAE suspension design

Goals for new chassis design

• reduce weight by 20%
• retain 90% of current torsional rigidity
• lower COM by atleast 25.4 mm
• innovatively package critical vehicle components i.e. engine/motor mounting and configuration
• Introduce at least 1 innovation to the suspension
• Keep principles of suspension the same ( we have a winning design currently )
• Keep uprights, shocks, springs, pneumatic antiroll.

Context

There is a minor leak in the clutch cover or possible the oil sight glass, as well the transmission countershaft. The oil level is also high, which leads to concerns of an internal leak that could be causing an increase in the internal pressure; leading to the gasket and o-ring failures.

Outcomes

-Diagnosis Problem using troubleshooting skills.

Constraints

• If it's an internal leak, it could be hard to find.

Related Issues

Dyno-control panel - Engine will not be able to run well troubleshooting and probably shouldn't be run until the source of the leak is found to prevent any damage to internal components.

Steps to reproduce behavior

Steps for troubleshooting leak:
1 - Drain oil until level shows on the sight glass.
2 - When cold clean all oil off engine, frame, ground.
3 - Run engine for 30min.
4 - Find highest leak point on engine clutch cover.
5 - Order parts and perform the necessary repairs.

Ensure a priority, status, type, and time label are assigned to this issue

Context

The FH rules committee asked if we have a waiver for our charger. Somebody should investigate into whether or not the charger can be approved by UL. I do not know if this is possible.

Outcomes

UL recognized charger
or reasons why the charger cannot be approved, how could we modify in the future?

Constraints

Do not alter charger before 2018 competition to reduce risk of a non-functional charger.

Context

The wiring harness of our car routes low voltage wiring to the cars powered components:

• MABX controller
• Front power pcb
• Rear power pcb
• AMS

Power is routed from the AMS to the isolation board and IMD. Power is routed from the rear power distribution board to the ICE system.

This project will require a project proposal after initial research is completed and method of modelling harness is determined.

Outcomes

We need a BOM and wiring diagram for the wiring harness.

The BOM should contain the following for each wire:

• Pin labels
• Gauge
• Length

The diagram should clearly show what sections of the harness are routed where.

Constraints

This is a critical task in getting our vehicle ready for testing. Deadline for design is Jan 5th 2017. Deadline for fabrication and installation is Jan 19th 2017.

Related Issues

Altium schematic will be provided as soon as FPD, RPD, AMS, Isolation, Telemetry systems are solidified with respect to their connections.

Wire destinations will also be provided at this time.

Steps to reproduce behavior

• Research various wiring harness softwares.
• Look into Siemens add on for Solidworks
• Learn to route wires, produce appropriate BOM and diagrams

Once data is available continue with final modelling of harness

• Route wires in the 2015 Frame CAD model
• Create BOM etc.

Context

Our engine is currently mounted at 4 points ( 2 points on 2 Bolts ). One side of the mounting system is unfinished. It must be redesigned and replaced or verified to be structurally sound through calculation or FEA.

The part is saved in grabcad -> 2016 grabcad -> subassemblies and components -> components-> Powertrain->Engine->Engine Mounts-> Rear clamp mount.

This is the minimum that must be done (Critical Path). Time and resources allowing we will look into implementing a tubular connection to the frame and include vibration dampening in our engine mount.

Outcomes

• Rear engine mount is designed
• Mount is verified through calculation or FEA
• Mount is fabricated and installed
  OR
• Verify that the current mount is structurally sound

Constraints

• Spacial contraints in the engine bay
• Manufacturability: Should be made in UVic Mech Machine Shop
• The mount must properly locate the engine and withstand its load

Related Issues

Testing should not happen without replacing these mounts

Steps to reproduce behavior

• Review previous design
• Calculate whether or not the current mount is structurally sound
• Learn how the current mount fits into the frame with the engine
• Design a system that will efficiently support and locate the engine.
• Design review: Mechanical and DFM
• Get Ben to fabricate
• Install and test

Resources

Questions can be directed towards @smithbe and @MrMikeGrant. Erric Harrop is the advisor for Mech design and DFM, contact him on slack. @chadjmccolm is the Powertrain project manager.

Context

We need the precise injector flow rate to calibrate our electronic fuel injection.

Outcomes

We want:

• max flowrate (cc/min)
• dead time (ms)

Context

The radiator stand was welded in haste by a beginner and one of the welds did not hold. The reason is
that too high amperage was used to weld it and the aluminum burned. The burned areas did not
conduct well enough to continue the weld.

The stand will need to be removed, the affected area sanded down to remove any burned material, and
re-welded. All other welds should be fine.

Additional info can be found in the engine review doc here.

Outcomes

The outcomes for the project are the following:

• produce a sturdy radiator stand

Constraints

There are no major constraints for this project

• radiator stand must mount onto engine stand or otherwise allow bench testing to happen without impeding operator safety
• radiator fill cap must be the highest point in the cooling system

Discuss on-boarding procedure with the team.
If you're coming think about 'your version' of what on-boarding should look like and be ready to discuss.

Context

Our tire covers need to be remade or altered to fit appropriately. These preserve the tires and look good.

Outcomes

• Alterations to the current wheel covers such that they completely cover the wheels and can be put on/removed with ease.
  or
• New wheel covers made from an aesthetically pleasing but durable material such that they completely cover the wheels and can be put on/removed with ease.

Constraints

• Budget is $50
• Car must be able to roll around with them on
• Must look Awesome

Steps to reproduce behavior

• Measure the dimensions required for the tire sleeve
• Decide on a good securing/tightening mechanism
• Decide what material will be used
• Decide how these will be manufactured
• Buy everything and make everything

Context

We must repair and service our brakes. PLEASE WEAR THE BLUE NITRILE GLOVES ON THE PPE SHELF, these will not be melted by the brake fluid ;).

Outcomes

• Fresh brake fluid
• Sealed brake reservoir
• Tied up brake lines so they do not rub on anything ( can use conduit instead of tying these up, ask ben if he has extra in machine shop )

And more non-critical path objectives

• More efficient brake line routing
• Reduced spongy feeling in brakes
• Design easy bleeding system

Constraints

See Formula Hybrid Rules!
The lines may not be anywhere they could be easily kicked or damaged

Related Issues

This must be finished for vehicle testing

Steps to reproduce behavior

• Search for brake documentation
• Determine best routing of braided lines to mitigate rubbing
• Determine what is wrong with the bleeding mechanism and sponginess of brakes
• Determine why reservoir leaks
• Put together some possible solutions in a project proposal and show the rest of the team ( ask ben for proposal template/help )
• Design review
• Repair reservoir
• Tie up lines
• Bleed/flush brakes ( ben's roomate is going to help with the service )

Context

Packaging design is needed for space constraints on frame.

Objectives

• Optimize space efficiency of engine bay
• Minimize COM height
• Minimize polar moment about z

Constraints

• Rules
• Design must fit in engine bay ;)
• Must allow mounting of engine and motor to come dirctly from the frame, triangulation of tubing should be possible.

Related Issues

Chassis design finilization will require the final COM.

Steps to reproduce behavior

• Use 2016 frame model or 2017-2018 frame model.
• Brainstorm and test fit configurations for the motor, engine and differential. Brainstorm ides for mounting the components.
• Include the exhaust in your model and make allowance for cooling system tubing, fuel line, and air filter.
• Search the web and other resources for alternatives and ideas.

Context

We must service or suspension system to ensure it is safe and operating properly.

Outcomes

Minimum:

• New sleeves in A-arm mounting points
• New spherical bushings in controll arm linkage

More:

• Inspect shocks, dampeners, pneumatic cylinders for wear. Repair or replace.

Constraints

We must complete the minimum objectives to test the car.

Related Issues

Suspension/VD: We should complete all tasks before calibrating the suspension.

Steps to reproduce behavior

• Look for the suspension sleeves/spacers cad in GC
• Verify the dimensions are correct by measuring the component in the car
• Source and order new spherical bushings
• Machine the spacers (lathe, machine shop, ben)
• Install components

Context

When the fuel pump turns on the TPS signal get's noisy and the range changes. This makes controlling the TPS nearly impossible. A voltage drop is observed from 12 to 10V at the Microsquirt.

Outcomes

Clean Up Signal to TPS and let TPS controller work effectively

Constraints

We would rather not replace the fuel pump but with that wine we may have to.

Steps to reproduce behavior

Plug in the Arduino controlling the TPS and open Arduino software on the computer to monitor the serial port. Serial plotter is helpful.

Power the ECU etc. off the main switch and observe the ETB's function. Now power on the fuel pump and observe the signal.

Suggestions

As discussed in the meeting there are a number of reasons why this could be happening. Off the top of my head:

• the draw may be loading the power supply such that the actual voltage is fluctuating and causing the sensor values to fluctuate
• there may be induced EMF due to the electric motor in the fuel pump

If it was the first one, the problem would be fixed by running the fuel pump off a different 12V source. Not it may draw up to 6A continuous.

If it was the second one, you could fix it with shielding the wire and grounding the shield OR you could change how much voltage is induced by altering the path the wires needs to take from the sensor to the Arduino.

Context

We want to send the car's data to a server and display it on a webpage to reduce the amount of information clogging up the driver's display and allow for easier data logging.

We have previously purchased parts for this:
https://www.ubnt.com/airmax/rocketm/
https://www.ubnt.com/airmax/nanostationm/
https://www.ubnt.com/airmax/airmax-omni-antenna/

The data will be sent via the MQTT protocol to a server created by @BrendonEarl.

The server is powered by NodeJS. The data will likely be sent by an Arduino running an MQTT client like this one.

The flow will be as shown here:

Outcomes

• Create a link between the car and the server
• Setup a MQTT server
• Configure the Arduino to read CAN and send via MQTT over Ethernet
• Create a web page to view the data recieved

Constraints

We should use the technology we've already purchased.

Need to teach everyone how to use GitHub

Context

The bench wiring harness was made as a prototype and needs some housework before it can be expected to work reliably.

Additional info can be found in the engine review doc here.

Outcomes

The outcomes of this project should be:

• allow for the harness to be easily removed and reinstalled
• secure all ends and terminate all connections
• confirm that the wires are large enough for the current they need to carry
• label or otherwise find a way to ensure wire trace-ability
• shield the signal wires from interference from the coil

Constraints

There are a few key constraints in this project:

• wiring harness cannot change significantly
• wiring cannot be run near the exhaust
• should be adaptable to higher priority issues like finding an appropriate power supply

Related Issues

Related issues include:

• #24 AFR/O2 sensor
• #23 Switchboard design
• #20 ETB Driver socket and case
• #19 Engine Bench Power Supply
• #18 Wiring Schematic Fuses

Context

The wiring schematic used for the bench wiring harness was created by somebody with no Altium background (@chadjmccolm) and may impair use because of it's lack of convention

Additional info can be found in the engine review doc here.

Outcomes

The outcomes of this project should be as follows

• give a beginning team member a practical application of their Altium training
• make the wiring diagram legible
• make sure the objects in the wiring diagram match their physical units (i.e. change the MABX replicator to a ETB Controller and match the ports correctly)

Constraints

• wiring schematic must match reality

Related Issues

Related issues include:

• #24 AFR/O2 sensor
• #23 Switchboard design
• #20 ETB Driver socket and case
• #19 Engine Bench Power Supply
• #18 Wiring Schematic Fuses
• #16 Bench Wiring Harness Cleanup

Context

We need an accurate model of our engine and exhaust to maximize space efficiency in our engine bay. Dr. Deschev and Michael Peirone are willing to lend us their 3D scanner

Outcomes

Solidworks compatible 3D models.

Constraints

• Transport: We need to bring the scanner to Q-Hut. We do not know the size of the equipement yet.
• Computer hardware: Michael Peirone gave the following specifications: The requirements for the scanner are as follows: Display card：NVIDIA GTX660 or higher，Display memory：>2G，Processor：I5 or higher，Memory Storage：8G or more

Steps to reproduce behavior

• We must set a 3-4 day time period to work on this project as the 3D scanner can be lent for 3-4 days
• We require someone to lend a vehicle for the task
• We require a portable computer that meets the above requirements
• We require members to help with 3D scanning: This may include spraypainting the components to be scanned, cleaning components, making space in the shop, disassembly of hybrid car components and reassembly.

Components to scan

please feel free to add to this list

• Engine
• Exhaust
• Preheater
• Bennett in driver helmet: Ergonomic design and rendering of car CAD

• Confirm attendance
• Confirm shipping of our car
• Organize group to be present during the Launch Party

Context

Our Saietta motor is unprotected from water and contaminants. We must research/test if this is OK or if we must protect the motor more.

Constraints

The motor cannot be damaged. !!
Hybrid rules
Air flow into the motor it cannot be significantly restricted

Related Issues

The motor cap design is almost done. ( nov 20th )

Steps to reproduce behavior

[List of steps to reproduce]

delete here & below before submitting
Ensure a priority, status, type, and time label are assigned to this issue

Context

The 3D printer is nearly functioning properly. Overheating is still an issue. We must mount an additional or a larger fan to cool the printer's extruder head area.

Outcomes

A fan and an alternate fan mounting system that better directs airflow to the extruder and work piece. The new design could use the existing fan.

Constraints

Mounting system should be easy to manufacture, a 3D printed part would be good as long as temperatures are not going to melt it.

Related Issues

Joel from Robotics has been working on this printer. It was an abandonned and poorly engineered project from before anyones time. Joel took it from nothing to almost working perfect.

Steps to reproduce behavior

At your own discretion.

• Get data for space constraints around the extruder head and temperatures there.
• Review other designs and cooling solutions online
• Decide on a design concept and a fan model, run this by Joel/Ben.
• CAD for manufacture, Source fan.
• Design review.
• Implement.

The cost of this project should be negligible. This project does not require project proposal or project report, however it is recommended that a short project report be kept for notes/colab.

Context

The current power supply has some limitations that prevent it from being used full-time as well as some
unsolved problems. Ideally, both can be addressed.

The power supply is limited to 40A continuous however the starter requires somewhere around 110A
(at best estimate) to start the engine. A car battery could easily supply this so long as it was sufficiently
charged. A car battery however will not hold its charge unless it is wired into the stator on the engine
through a rectifier. A suitable (supposedly – should be double checked) rectifier is currently on the car
and the stator wires are the only wires coming off the engine which are unused.

The other issue has an unknown cause. When running off the current power supply, sometimes the
output drops to zero and the engine shuts off. This may be due to vibration, spikes in the current draw
from the coil, or something else entirely. The only solution found so far is to unplug the power supply
entirely and shake it.

The spark plug coil takes 14A in bursts, the fuel pump takes about 7, and the Microsquirt takes about 0.1A.

Outcomes

The outcomes of the project are as follows

• provide power to all the engine electronics for bench testing

Constraints

• the draw of the individual components cannot be changed
• the power supply must not be so large that it impedes safety around the engine when it is on the bench and engine dyno or causes a trip hazard

Related Issues

Related issues include:

• #24 AFR/O2 sensor
• #23 Switchboard design
• #18 Wiring Schematic Fuses
• #17 Wiring Schematic Cleanup
• #16 Bench Wiring Harness Cleanup

Context

The current steering radius and steering wheel travel required to reach it are both too large.

Outcomes

We will reduce the steering radius and achieve max steer at 90deg steering wheel angle

Constraints

Do not radically modify vehicle packaging. Ensure clearance of A-Arm in rim during full bump/droop. The positionof the steering wheel cannot change. Ideally, only the rack/ pinion assembly or the control arm hard points should be modified.

Related Issues

This cannot interfere with scheduled testing starting in febuary.

Steps to reproduce behavior

• Determine reduction in steering radius
• Determine reduction in steering wheel travel
• Research changing the rack and pinion gearing ratio, changing control arm hard points, and other alternatives.

Context

The socket for the ETB driver is missing the required ground pins. Without those pins, the ETB driver will
not run (as the ground on the logic side jumps to 3V and it needs 3.3V minimum between ground and
power (5V)) to manage the power to the motor.

The current solution is to remove the ETB driver from the case and jump the grounds directly to ground.
This is not a permanent solution. The shield that attaches to the connector should be revised to include
the grounds.

The case itself has been damaged. The screws that hold it together have stripped their housings and the
top is no longer secured. This case will have to be remade. This may be a good opportunity to change
the connector too if the designer so desires.

Additional info can be found in the engine review doc here.

Outcomes

The outcomes for the project are the following:

• create a case for the ETB driver
• create a new breakout board that pins the two main grounds

Constraints

• must be vibration resistant (must not fall apart on the car)

Related Issues

Related issues include:

• #17 Wiring Schematic Cleanup
• #16 Bench Wiring Harness Cleanup

We must optimize the layout of our GitHub wiki.

Outcomes

An optimized layout for all team members

• Experienced
• Green
• First time users

Suggestions

• Our home page should be more concise.
• It should include a section that links to administrative information such as onboarding, safety, team member and projectlead/manager obligations.
• The current onformation should go to the onboarding section.

The above should be concise ass possible. The next section will be Projects, then Archived projects.

Context

A switchboard would be nice to connect to a power supply and have three switches for:

• the starter (needs to be a button)
• the fuel pump, and
• everything else

This could be a laser cut box or something to that effect with built-in fuse holders so that all the power
distribution can be controlled through it. Care will need to be given to the wiring on the starter so that
the current doesn’t burn through the wire. 10GA is recommended but will be determined with the draw
on the starter.

It is also possible to combine this function with the potentiometer used for throttle control as both with
be exclusively used for bench testing and will serve as a model for the final product that is run at
competition.

This is a low priority task because it would be used only for testing however if somebody is interested in running with it that would be awesome.

Additional info can be found in the engine review doc here.

Outcomes

The outcomes for the project are the following:

• Combined power distribution and ETB control
• A stable piece of testing equipment that we can easily reuse next year

Constraints

Being a bit of a passion project for anybody who cares about it enough, the constraints are up to the designer.

Related Issues

Related issues include:

• #19 Engine Bench Power Supply
• #18 Wiring Schematic Fuses
• #17 Wiring Schematic Cleanup
• #16 Bench Wiring Harness Cleanup

Context

An AFR/O2 sensor needs to be added to the engine’s exhaust before tuning starts to help prevent
against damage to the engine which has occurred in the past. Whether Hybrid owns an O2 sensor is
unknown but if we don’t then one will need to be purchased, wired into the Microsquirt, and attached
to the exhaust. A heated wideband is preferred but it is at the discretion of the designer or project
manager.

Additional info can be found in the engine review doc here.

Outcomes

The outcomes for the project are the following:

• have a precise measurement of the Air Fuel Ratio

Constraints

AFR sensor cannot be anything but a wideband for safety reasons (and to protect the investment)

Related Issues

Related issues include:

• #17 Wiring Schematic Cleanup
• #16 Bench Wiring Harness Cleanup

Context

The ETB controller Arduino suffers from integral windup (or, more accurately, wind-down) when the
signal is zero. This is due to the calibration of the signal changing.

What happens is this:
• The user sets zero throttle input.
• The controller sends zero signal to the driver.
• The driver sends zero signal to the ETB.
• The ETB closes fully.
• The controller reads 4% or so from the TPS.
• The controller adds the error term to the integral (negative) which makes the integral large and
negative.
• The user changes the throttle request to 15% (for example).
• The integral term is so large and negative that it takes up to a few minutes for it to be accurate
again.

Uncaught, this could cause an integer overload as the integral term becomes extremely large and
negative. Practically, the only issue is that it makes the ETB unresponsive for a short period of time.
To eliminate this error code can be added to the existing code (on Google Drive) which sets the 0 point
on the TPS based on zero initial output when the program is first run. The maximum can be calibrated
when the users inputs 100% throttle and the maximum current is given to the driver.

Other solutions may exist and are at the discretion of the designer.

Additional info can be found in the engine review doc here.

Outcomes

The outcomes for the project are the following:

• reduce integral windup in the ETB Controller's PID scheme

Related Issues

Related issues include:

• #23 Switchboard design

2017-2018 Season Objectives

Administration/Policy:

• Develop written documentation for General Q-Hut Safety
• Develop written documentation for high voltage safety
• Develop written documentation for Q-Hut machine shop safety
• Create/document UVic hybrid specific CAD standards and naming conventions
• Develop procedure for working with GrabCAD
• Develop SolidWorks tutorials for new members
• Develop Altium tutorials for new members
• Organize and maintain Google Drive/Github/Slack/GrabCAD
• Organize vehicle testing proceedure like what is found here, Testing and the Site Map for testing
• Organize spill response proceedure, Spill Response

Recruitment:

• Recruit and retain 15 new members (5 Mechanical, 5 Electrical, 5 Software)
• Prepare a presentation for the clubs presentation day (new format promoted this year by ESS)
• Have every current member bring at least one potential recruit to at least one team meeting

Sponsorship/Fundraising:

• Raise $15,000 through sponsorship's and grants (this amount is the bare minimum we need to raise just to cover essential projects and pay the competition entry fee)
• Maintain solid relationships and communication with important sponsors (i.e. PED)
• Follow through on sponsorship agreements (mentions on social media, decals on car, etc.)
• Prepare and present debrief to GM to obtain $5K (USD?)
• Ask friends and family to contribute towards $10K crowdfunding goal (currently at $1,700 with 1 month left)
  2016 sponsor information

Social Media:

• Post a minimum of 1 new entry per month to facebook/website/instagram

Mechanical:

• Design/Fab Frame
• Poretrain configuration
• Design/Fab Suspension
• Design/Fab Firewall
• Design/Fab Packaging
• Design/Fab Mounts
• Design/Fab Nosecone/bodywork
• Shim or Rebuild Engine
• Complete CAD Master Assembly
• Brakes
• Design/Fab New Gas Tank

Electrical:

• Debug and test rear power distribution board
• Debug and test wiring harness
• Debug and test AMS

Competition Documents and Logistics:

• Register for competition
• Organize transportation to competition
• Structural Equivalency Spreadsheet (SES)
• Project Management Plan
• Electrical System Form 1 (ESF-1)
• Fuel Request
• Program Information Sheet
• Interim Project Report
• Impact Attenuator Data
• Site Pre-Registration
• Electrical System Form 2 (ESF-2)
• Failure Modes and Effects Analysis (FMEA)
• Design Report
• Sustainability Report
• Design Specifications Sheet

Context

Public place to talk about how we work with GitHub

Outcomes

A document outlining how to work with our GitHub issue handling

Post Jobs

People looking for stuff to do refer to the issues page.

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Context

We don't have a solid documentation for how the motor controller works with the rest of the car and I would like to know:

• what inputs it needs
• what current those inputs will have
• what outputs it gives via CAN or other signals

Our controller is a Kelly Controls KDH14601E. All information can be found online as it is still an active product.

Outcomes

The following are desired outcomes of this investigation:

• pinout of the controller as it applies to our car
• wiring diagram in Altium
• data on CAN signals added to main spreadsheet

Related Issues

This will come together with #17 Wiring Schematic Cleanup to increase the validity and accuracy of the wiring harness so that we have 0 issues down the road.

Context

We need a thermostat and housing to prevent under-cooling in the engine. The operating temperature in the manual is 248 degrees Fahrenheit.

We also want to add the new radiator and get all the hoses setup for that.

Outcomes

Here are the goals of this project:

• cool the engine to the desired temperature
• choose an appropriate thermostat
• implement the new radiator
• chose appropriate hoses and connections for the links

Constraints

Notable constraints are as follows:

• minimum hose distance cannot be decreased
• new radiator must be used

Related Issues

This is under the powertrain umbrella #10 .

Context

We require enclosures for our PCBs

Outcomes

The enclosures should be able to do the following

• Provide mounting
• Provide vibration dampening
• Seal to IP code X4
• Allow the pcb to be removed by unscrewing 1 or 2 fasteners

Constraints

• All fabrication will be done in the mech machine shop. (ben)
• Budget should be no more than $100 for all the boxes and fasteners

Related Issues

We cannot fully design the enclosures until all the car PCB are designed. However we must validate our designs and develop a standard enclosure to use on each pcb.

Steps to reproduce behavior

• design test boxes to determine sealing method

• determine oring material, 20A durometer

• Determine the fundamental lid design

• Determine oring gland tooling

• Determine what heat set inserts we will use ( McMaster heatset inserts for plastics )

• Use test boxes to find out: How long can the wall be, how thick can the wall be, how does the heat set insert work?

Finalize a standard design for the electrical enclosures that can be used across the car.

To design an enclosure for the PCBs you must

• Create solid model of the PCB
• Get good solid models of the connectors etc. that will come through the wall of the enclosure ( connectors are in the 2017 elec enclosures grab cad )
• Learn to take profiles out of assembly into one part and unlink
• Design for front power, rear power, isolation board
• Double check all connectors are correct with pcb designers and wiring harness team.
• Design reviews throughout
• Fabricate.

Context

Fuses were not used in the prototype of the wiring harness because many of the operating currents were unknown and time was a large constraint. The wiring harness should have some form of built it fuses - whether inline or in the design of the switchboard (assume that is made). At the least, fuse sizes should be determined and added to the existing wiring.

Outcomes

The outcomes of this project are as follows:

• determine which components need to be fused and how large those fuses must be
• protect the controllers in the wiring from excessive current expose caused by shorts elsewhere in the harness

Constraints

• fuses must not impair function of the wiring harness

Related Issues

Related issues include:

• #23 Switchboard design
• #17 Wiring Schematic Cleanup
• #16 Bench Wiring Harness Cleanup