2013 Electric Vehicle2013 Electric VehicleGrand Prix ChampionshipGrand Prix Championship
Washington DC
The Electric Vehicle The Electric Vehicle Association, Greater Association, Greater Washington Washington DCDC
Charlie GarlowUS EPA, EVADC
Solar Decathlon and Solar Decathlon and California EV ChallengeCalifornia EV Challenge
Richard KingUS DOE
The Washington DC The Washington DC Electric Vehicle Grand Electric Vehicle Grand Prix Prix ChampionshipChampionship
Dr. Nabih BedewiGlobal EEE
Question?Question?
What do you get when you combine some of the latest technologies from
Formula 1 racing, satellites, and F-16 jets
with the most energetic and innovative minds in universities worldwide?
Answer? Solar Race CarsAnswer? Solar Race Cars
Aerodynamic body designs with thousands of hours of
wind tunnel testing and computer simulations
Aerodynamic body designs with thousands of hours of
wind tunnel testing and computer simulations
Most efficient terrestrial and space
grade solar cells
Most efficient terrestrial and space
grade solar cells
Advanced peak power trackers and
PV electronics
Advanced peak power trackers and
PV electronics
Latest encapsulation films for solar array
Latest encapsulation films for solar array
Most efficient LED technology for turn
signals & brake lights
Most efficient LED technology for turn
signals & brake lights
Advanced telemetry systems and
computer control
Advanced telemetry systems and
computer control
Most efficient custom wheel-
mounted electric motors on the planet
Most efficient custom wheel-
mounted electric motors on the planet
Lightweight and efficient custom wheels and low-
loss bearings
Lightweight and efficient custom wheels and low-
loss bearings
Advanced carbon-fiber composite chassis
fabrication
Advanced carbon-fiber composite chassis
fabrication
Advanced Kevlar and Nomex
fabrication for solar panel substructure
Advanced Kevlar and Nomex
fabrication for solar panel substructure
Lightest and most efficient Lithium based battery
technology
Lightest and most efficient Lithium based battery
technology
Sophisticated battery monitoring and management
system
Sophisticated battery monitoring and management
system
Sophisticated weather prediction and energy management/strategy systems and software
Sophisticated weather prediction and energy management/strategy systems and software
Lightweight and efficient low-scrub suspension and
steering
Lightweight and efficient low-scrub suspension and
steering
Advanced cockpit instrumentation and
control interface
Advanced cockpit instrumentation and
control interface
Lowest rolling resistance high
performance tyres
Lowest rolling resistance high
performance tyres
University ProjectsUniversity Projects
Engineering schools look for high Engineering schools look for high
school students with school students with
demonstrated involvement and demonstrated involvement and
hands-on experience with similar hands-on experience with similar
projectsprojects
2013 EV Grand Prix in DC2013 EV Grand Prix in DC
Opportunity for high schools in DC, MD and VA to get Opportunity for high schools in DC, MD and VA to get
startedstarted
First year competition limited to “novice teams”First year competition limited to “novice teams”
Cap on cost – level playing fieldCap on cost – level playing field
Partnered with NuGen Mobility to create kitPartnered with NuGen Mobility to create kit
– Minimize risk and unknowns for school/teacherMinimize risk and unknowns for school/teacher
– Allow time to build program, know-how and track recordAllow time to build program, know-how and track record
– Add more capabilities (design, welding, etc) following Add more capabilities (design, welding, etc) following
yearsyears
– Plenty of room for technical creativity and innovationPlenty of room for technical creativity and innovation
Partnered with EVA/DC to support schools and eventPartnered with EVA/DC to support schools and event
Top finishers have opportunity to compete in Irvine, CATop finishers have opportunity to compete in Irvine, CA
Teams can participate in other competitions in the USTeams can participate in other competitions in the US
2013 EV Grand Prix in DC2013 EV Grand Prix in DC
Competition to be held in DC Metro Area (location TBD)Competition to be held in DC Metro Area (location TBD) F1 style closed track – 0.5 to 1 mileF1 style closed track – 0.5 to 1 mile
One day raceOne day race Run on battery onlyRun on battery only One hour heatsOne hour heats Longest distance winsLongest distance wins
More than one team per institution may participateMore than one team per institution may participate
Registration fee: $250Registration fee: $250 Includes membership in EA – can compete elsewhereIncludes membership in EA – can compete elsewhere Receive official car number and design/rules handbookReceive official car number and design/rules handbook Covers track liability insuranceCovers track liability insurance
AwardsAwards
Overall Grand Prix winner – longest distance in one Overall Grand Prix winner – longest distance in one
hourhour
Fastest 0.25 mile dashFastest 0.25 mile dash
Best overall graphics designBest overall graphics design
SportsmanshipSportsmanship
Best team photoBest team photo
Best team videoBest team video
Trophies, awards, cash prizesTrophies, awards, cash prizes
ScheduleSchedule
Registration deadline: January 5Registration deadline: January 5
Kit orders: February 1Kit orders: February 1
Shipping considerations/lead time: 30 daysShipping considerations/lead time: 30 days
Kit delivery: March 5Kit delivery: March 5
Construction time: March 5 to May 15Construction time: March 5 to May 15
Test/optimization/driver training: May 15 – Test/optimization/driver training: May 15 – June 15June 15
Race: week of June 15Race: week of June 15
Teacher and Student SupportTeacher and Student Support
Technical support available throughoutTechnical support available throughout
Assembly overview session when kits arriveAssembly overview session when kits arrive
Guidance session for F&M studentsGuidance session for F&M students
Help students develop strategy and action Help students develop strategy and action planplan
Assist with fundraising proposalsAssist with fundraising proposals
Critique “elevator pitch”Critique “elevator pitch”
What is important?What is important?
EfficiencyEfficiency MotorMotor ControllerController Charger (in between events)Charger (in between events) ElectronicsElectronics TiresTires
Vehicle weightVehicle weight Driver weight not an issue – ballastedDriver weight not an issue – ballasted
Gear ratio selectionGear ratio selection
StrategyStrategy
DC Electric Vehicle DC Electric Vehicle Grand Prix Kit and Grand Prix Kit and ComponentsComponents
Eric TakamuraNuGen Mobility, Inc.
Key CategoriesKey Categories Chassis, Body & Wheels & TiresChassis, Body & Wheels & Tires
ReliableReliable
TestedTested
Easy to build / assembleEasy to build / assemble
Drive System: Motor, Controller, connection and mountingDrive System: Motor, Controller, connection and mounting
ReliableReliable
EfficientEfficient
Correct operational ZonesCorrect operational Zones
Safety & ElectricalSafety & Electrical
Five Point Seat beltFive Point Seat belt
All components to complete safe, functional and reliable circuitAll components to complete safe, functional and reliable circuit
Power & Energy: Batteries & Battery ChargerPower & Energy: Batteries & Battery Charger
Component SelectionComponent Selection Several suppliers existSeveral suppliers exist
Time and decisions to make Time and decisions to make choices and find suppliers choices and find suppliers could take weeks if not could take weeks if not monthsmonths
Quality/performance variesQuality/performance varies
Knowing what is requiredKnowing what is required
Cost: $4,500 - $5,500Cost: $4,500 - $5,500
Individual Shipping is highIndividual Shipping is high
Adds another $500+Adds another $500+
Result:Result: Logistic NightmareLogistic Nightmare
High risk High risk
Unknown CostsUnknown Costs
Key ObjectivesKey Objectives Hands On ExperienceHands On Experience
Students focus on assembly, learning & StrategyStudents focus on assembly, learning & Strategy
Don’t get bogged with logisticsDon’t get bogged with logistics
Affordable and level playing fieldAffordable and level playing field
Reduce effect that “$” winReduce effect that “$” win
Fun – Fun –
““Doable” : Doable” :
“ “Competitive”Competitive”
**** Safe !**** Safe !
Kit componentsKit components
As mentioned, first year parts are standardized into kitAs mentioned, first year parts are standardized into kit
Experience: most suitable chassis/outer body - Blue Sky Experience: most suitable chassis/outer body - Blue Sky
DesignDesign
– Costs $1950 plus shipping from west coast (Costs $1950 plus shipping from west coast ( $300) $300)
– Steel ChassisSteel Chassis
– ABS outer body and FRP seat panABS outer body and FRP seat pan
– Acrylic tinted canopyAcrylic tinted canopy
– Wheels, brakes, steeringWheels, brakes, steering
Kit ComponentsKit Components
24V High Efficiency electric motor24V High Efficiency electric motor
24-48V, 300A controller24-48V, 300A controller
Reliable Sealed lead acid batteriesReliable Sealed lead acid batteries
Compatible Battery chargerCompatible Battery charger
Five point seat belt systemFive point seat belt system
Aluminum sprocket adaptor with freewheel and chain Aluminum sprocket adaptor with freewheel and chain guardsguards
Sprocket set (three, to allow different drive ratio's)Sprocket set (three, to allow different drive ratio's)
20” rear and 16” front high pressure tires and tubes20” rear and 16” front high pressure tires and tubes
All electrical components including sensors and All electrical components including sensors and display, battery power cable, copper connectors, 3 display, battery power cable, copper connectors, 3 stage master power switch, main power fuse, shunt stage master power switch, main power fuse, shunt resistor, potentiometer for accelerator, foot pedal, etcresistor, potentiometer for accelerator, foot pedal, etc
Estimated EffortEstimated Effort
Rolling Chassis Assembly: 5 hrsRolling Chassis Assembly: 5 hrs
Electrical & Drive System Integration: 10 hrsElectrical & Drive System Integration: 10 hrs
Outer body and canopy integration: 10 hrsOuter body and canopy integration: 10 hrs
Vehicle paint, decals, other finishes: 10 hrsVehicle paint, decals, other finishes: 10 hrs
Testing and adjustments: 15 hrsTesting and adjustments: 15 hrs
Some of these tasks run in parallel (total under Some of these tasks run in parallel (total under 50 hrs)50 hrs)
Group of 6-8 students can complete vehicle in 8 Group of 6-8 students can complete vehicle in 8 weeksweeks
Ordering ProceduresOrdering Procedures
Collect all orders at onceCollect all orders at once
Everything ships to NuGen facility near Dulles Everything ships to NuGen facility near Dulles AirportAirport
Overall shipping costs reducedOverall shipping costs reduced
Bring pickup or U-Haul to transport kits back to Bring pickup or U-Haul to transport kits back to schoolschool
NuGen personnel available for technical supportNuGen personnel available for technical support
Teacher session when kits arriveTeacher session when kits arrive
Kit price $4,500 + shippingKit price $4,500 + shipping
Project Management, Project Management, Marketing and Marketing and FundraisingFundraising
Charles GabrialDeloitte and Touche
Project ManagementProject Management
Project teaches leadership, team work, and Project teaches leadership, team work, and
managementmanagement
Create project organization chartCreate project organization chart
– Faculty AdviserFaculty Adviser
– Student Project LeaderStudent Project Leader
– Group leadersGroup leaders
o Chassis, steering, wheels, brakes & tires groupChassis, steering, wheels, brakes & tires group
o Outer body and canopy groupOuter body and canopy group
o Drive system and electrical groupDrive system and electrical group
o Graphics design and paint/decals groupGraphics design and paint/decals group
o Marketing and fundraising groupMarketing and fundraising group
o Logistics and testing groupLogistics and testing group
Project ManagementProject Management
Create and agree on project schedule and tasks Create and agree on project schedule and tasks
upfrontupfront
Meeting days and timesMeeting days and times
– After school M, W, F 3:00 PM – 5:00 PMAfter school M, W, F 3:00 PM – 5:00 PM
– Saturdays 9:00 AM – 3:00 PMSaturdays 9:00 AM – 3:00 PM
– Class timeClass time
All-hands team meeting at least once a week, not longAll-hands team meeting at least once a week, not long
Student Project Leader review schedule and make Student Project Leader review schedule and make
updatesupdates
Marketing/fundraising group activities importantMarketing/fundraising group activities important
Schedule testing and optimization phaseSchedule testing and optimization phase
MarketingMarketing
Important component of the projectImportant component of the project
– Dovetails with fundraisingDovetails with fundraising
Recruit creative students not interested in the scienceRecruit creative students not interested in the science
Create flyers, pamphlets, emailsCreate flyers, pamphlets, emails
Develop and maintain project web siteDevelop and maintain project web site
Use social media to rally the school communityUse social media to rally the school community
– Keep people informedKeep people informed
– Announce fundraising and sponsor eventsAnnounce fundraising and sponsor events
– Solicit ideas and feedback for fundraisingSolicit ideas and feedback for fundraising
Integrate with school PR to reach out to parents and Integrate with school PR to reach out to parents and
alumsalums
MarketingMarketing
Work with graphics design and paint/decals groupWork with graphics design and paint/decals group
Hold student competitionHold student competition
– Team/car nameTeam/car name
– Car and helmet colors and graphic designCar and helmet colors and graphic design
– Team uniform (T-shirt design)Team uniform (T-shirt design)
Develop plan for sponsor logo space and size on carDevelop plan for sponsor logo space and size on car
– Size proportional to sponsorshipSize proportional to sponsorship
– Integrate throughout web site, T-shirts, pamphletsIntegrate throughout web site, T-shirts, pamphlets
FundraisingFundraising
Set realistic expectations for amounts and scheduleSet realistic expectations for amounts and schedule
Understand school rules and guidelines for fundraisingUnderstand school rules and guidelines for fundraising
May need commitment from school for front fundingMay need commitment from school for front funding
Invite teachers, students, and staff to brainstorming Invite teachers, students, and staff to brainstorming
sessionsession
o Target corporate sponsors (car dealerships, stores in Target corporate sponsors (car dealerships, stores in
vicinity, etc)vicinity, etc)
o T-shirt sales on campusT-shirt sales on campus
o Car/team appearances at athletic events, sponsor Car/team appearances at athletic events, sponsor
locationslocations
o $1 drive around the parking$1 drive around the parking
Grants: corporate/family foundations – Grants: corporate/family foundations – www.foundationcenter.orgwww.foundationcenter.org
Create action plan, student elevator pitch – rehearseCreate action plan, student elevator pitch – rehearse
OverviewOverview
Safety is critical to the success of any student Safety is critical to the success of any student
competitioncompetition
Address it with the students early on in the projectAddress it with the students early on in the project
Make it a culture of the projectMake it a culture of the project
– When making any decision - is it safe?When making any decision - is it safe?
– No shame in asking for help or getting instructionsNo shame in asking for help or getting instructions
– Always work in pairs, watch out for your buddyAlways work in pairs, watch out for your buddy
Two aspects to safetyTwo aspects to safety
– Phase leading up to competition (tools, lab, testing, etc)Phase leading up to competition (tools, lab, testing, etc)
– Vehicle safety and the competitionVehicle safety and the competition
Construction PhaseConstruction Phase
Use tools properly especially drills, saws, knives, etc.Use tools properly especially drills, saws, knives, etc.
Exercise care around electrical systems and magnetsExercise care around electrical systems and magnets
Wear goggles and mask when cutting fiberglassWear goggles and mask when cutting fiberglass
Insure proper ventilationInsure proper ventilation
Use common senseUse common sense
Testing PhaseTesting Phase
Supervised testing of the vehicle on campus or parking Supervised testing of the vehicle on campus or parking
lotlot
DO NOT drive the car on public roadsDO NOT drive the car on public roads
Initial testing at low speedInitial testing at low speed
Adequate communication with driver (radios or vocal)Adequate communication with driver (radios or vocal)
Team members surround test area with flagsTeam members surround test area with flags
Area well litArea well lit
Use common senseUse common sense
Car Design SafetyCar Design Safety
Race rules specific about safety requirementsRace rules specific about safety requirements– Chassis, roll bar, bumperChassis, roll bar, bumper
– Outer body protectionOuter body protection
– Five-point seat beltFive-point seat belt
– DOT certified helmetDOT certified helmet
– Stopping distanceStopping distance
– Head behind knees seatingHead behind knees seating
– Rearview mirrorRearview mirror
– Electrical disconnect and labelingElectrical disconnect and labeling
– Driver egressDriver egress
Cars will be inspected prior to, and during raceCars will be inspected prior to, and during race
Any changes made to kits need to be reported and Any changes made to kits need to be reported and
inspectedinspected
Race SafetyRace Safety
Race safety rules will be published in advanceRace safety rules will be published in advance
Learn meaning of flag colors (slow down, do not pass, Learn meaning of flag colors (slow down, do not pass,
etc)etc)
Driver/teacher meeting prior to the raceDriver/teacher meeting prior to the race
Stewards will issue warnings and disqualify driversStewards will issue warnings and disqualify drivers
It’s a race against the clock, not other carsIt’s a race against the clock, not other cars
Use common sense -- Have fun!Use common sense -- Have fun!