Design, Synthesis, Manufacturing, and Testing of a Competitive FHSAE Vehicle

The goal of this multi-year project was to create a fully functional University of Idaho entry in the hybrid Formula Society of Automotive Engineers (FSAE) competition scheduled for 2012. Vehicle integration has been completed as part of a variety of 2010-2011 senior design projects and 2011-2012 senior design projects. This leverages a variety of analytical and empirical studies undertaken in Fiscal Year 2010 that demonstrate feasibility of the electromechanical powertrain, the energy management system, and the chassis layout. This project has engaged a broad population of graduate and undergraduate students in implementing sustainable transportation technology as well as creation of knowledge management systems that will benefit current and future competition teams. Approximately 30% of the allowed 19.5 Mega-Joules (MJ) for the 22 mile endurance event will be supplied in the initial charge state of the battery pack. The remaining 70% is stored in the vehicle’s gas tank. Accomplishments to date include a road load energy model, inertia modeling of the YZ250F, acceleration modeling, performance testing of the electric motor/controller, solid modeling of a reconfigured YZ250F motorcycle engine, suspension modeling, frame design, and an electronic archive designed to serve as a resource for just-in-time learning of hybrid terminology, subsystem descriptions, analysis methods, and performance tests. Specifications are given for all major subsystems and components that comprise a hybrid electronic competition vehicle that is destined for the 2012 Hybrid FSAE Challenge.