Hot Wheelz
What is Hot Wheelz?
"A student-run organization aiming to provide women with the tools to learn and explore possibilities for future employment in all industries. Hot Wheelz is dedicated to the enrichment of the RIT students’ education by offering one of the best ways to apply team work and special skills. From engineering to marketing, we are a Formula SAE Hybrid Racing Team that has something to offer everyone. We are dedicated to professionalism, mentorship, experimental learning and preparing women for leadership roles through real world design and building experience."
Website: https://www.rithotwheelz.com/
My Roles
Programming and Telemetry Associate Designer (2016-2017): Utilized a PCAN to connect to the CANbus of the vehicle. Used a router to bridge a connection from the PCAN system to the team laptop. Programmed in python utilizing flask to collect and display the data gathered while the vehicle was running.
Controls Co-Lead (2018-2020): In charge of the Battery Management System (BMS), motor controller, PCBs, safety system, telemetry system, and water cooling of the vehicle. I researched and chose the controller for 2017-2018 vehicle, designed the telemetry system, and designed and built the water cooling system with a contact at GM.
Major Contributions
Basic System Flow
Designed & Developed the Telemetry System
Created a configuration decision matrix to determine which telemetry system to design
Compared:
Microcontrollers
Multiprotocol boards
Transmission devices
Antenna types
CANBus connectors
Coding languages/capabilities
Libraries
Hardware resources
Developed program to read and send key CANBus parameters wirelessly to a laptop over 1 mile away
Designed Configuration
GUI (1 second refresh rate) with vehicle's data (speed, battery temperatures, etc.)
Hardware:
Arduino Uno
Multiprotocol Shield
CANBus Module
Xbee Pro S3B
RF ANT 2.4GHZ
Researched and Sourced Motor Controller (still used on current vehicle)
Created comprehensive decision matrix to determine which motor controller to source
Needed to be compatible with Emrax 228 MV motor
Compared criteria (in no specific order):
Operational voltage
Provided documentation (based on the amount of resources)
Pre-charge capabilities
CANBus type
Regenerative braking capabilities
Weight
Cost
Liquid cooling capability
Waterproof IP rating
# of outputs
Sourced Cascadia Rinehart PM100DX
Design Flowchart
Designed the Water Cooling System
Worked with Steve Showalter (General Motors)
Main components:
CWA-50 Pump
SPAL 10" Fan
Custom GM Radiator
Calculated radiator heat rejection based on the anticipated load heat (motor + motor controller)
Heat Rejection (radiator) = 3.4 kW (motor) + 3.02 kW (controller) = 6.42 kW
Graphed different LPM (liters per minute) flow rates (series and parallel) to determine an optimal configuration
Decided on 12 LPM in Series
Main Responsibilities/Experience
Team technical lead for the motor controller
Design
Calculations
Motor tuning
Debug
Team technical lead for telemetry system
Mentored a team of 1-2 people to carry on my design and learn from me
Low voltage lead
Safety shutdown circuit
Latching circuit
Safety check for BMS (Battery Management System) and IMD (Insulation Monitoring Device)
Powering peripheral components
Fusing
Sourced main DC-DC converter (system high voltage (batteries) --> 12 VDC)
Hand's on skills
Soldering
Crimping
Molex
Wiring
Debugging
Prototyping
Oscilloscope
Waveform Generator
Multimeter
Power supplies
Learned how to quickly research and source major system components