launch workshop engineering(1)

8/11/2019 Launch Workshop Engineering(1)

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ENGINEERING TEAINFORMATION REQUIREMENTAND DELIVERABLES


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What is AVTC Program?Advanced Vehicle Technology Competition , Managed by Argonne National Laboratory for the U.S. DEnergy in partnership with the U.S. domestic automotive industryElite network of more than 93 educational institutions that have participated in AVTCs over the programs 2historyAn un-paralleled educational experience that will change future career path of students and provide immensgrowth opportunities.

Mission Stimulate the development of advancedpropulsion and alternative fueltechnologiesProvide the training ground for the nextgeneration of automotive engineers

How mission is achieved:Provide real-world, hands-on, systems-level eng

challenges for studentsChallenge students to design, build and refine adtechnology vehiclesMimic the auto industrys vehicle development pUtilize industry-leading engineering tools, compand hardwarePrepare students to be future engineering leaderswill transform the auto industry for generations t


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Introducing EcoCAR3Four year collegiate automotive engineeringcompetition series

Technical challenge: Reduce the environmental impactof vehicles while maintaining consumer acceptability,performance, utility and safety and also consideringcost and innovation.

A fourth-year over the road event, which will raise thestakes for vehicle readiness, dependability and safety.

Vehicle platform To be Announced on April 24 inWashington DC

Environmental Impact Goals Reduce energy consumptionReduce Well -to-Wheel greenhouReduce criteria tailpipe emissions


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EcoCAR3 Technical GoalsProvide a platform to facilitate multidisciplinary, systems-level

engineering curriculum and instruction

Incorporate the use of math-based tools to improve engineeringeducation

Introduce and challenge students to weigh all the engineeringtradeoffs of their design, such as energy efficiency and consumerfeatures vs. performance and cost

Enable participants to develop and refine complex vehicle controland safety systems by using industry testing/validation processesand methodologies

Incorporate technical innovations in student-built vehicles to serveas research test beds


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Team OrganizationEcoCAR 3 will have a strong multidisciplinary focus. Teams may design their own team structure and their GRA roles anywhere, based on their own needs and leadership style

Lead Faculty Advisor

ABDEL MAYYAS

Engineering Manager

Sushil Kumar

Electrical SubTeam Lead

Electrical Team

Controls Sub TeamLead

Controls Team

Mechanical SubTeam Lead

Mechanical Team

SM&S Sub TeamLead

SM&S Team

Innovation SubTeam Lead

Innovation Team

Communications FacultyAdvisor

Laurie Raltson

CommunicationsManager

Ashley Yost

CommunicationsTeam

P


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Team RolesLead faculty advisor:

Official university representativeEnsure that students test and operate the teams competition vehicle safely anteam, university, and EcoCAR3 safety procedures while working on-campus at univeras well as offsite at competition events

Chief Engineer/Engineering Manager:

Provides technical expertise and continuity throughout a large portion of the programOverseeing all technical sub-teams in the areas of Mechanical, Electrical and CompuEngineering, and Systems Modeling & Simulation and overseeing all technical asprogram


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Role of GRAs Engineering GRA

To support key technology development and explore complex engineering challenges, such apowertrain integration, controls/HIL, and/or energy storage system (ESS) integrationMust provide technical team leadership and maintain continuity within the engineering team

ECE GRA

To support the teams Computer Science/Software Engineering/ECE activities, particularly iinnovation.Provide technical electrical leadership and maintain continuity within the engineering team.


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Sub Team LeadersMechanical Sub-Team Leader

Will lead Mechanical Systems activities. Should possess good systems-level grasp of all Mechanactivities.

Should have some leadership/management ability (or potential) to be able to delegate tasks andlead a sub-team

Must have a mastery of CAD, Will likely spend significant time assisting in CAD training/mentoother EcoCAR3 students

Good grasp of the fundamentals of structural as well as Finite element (FEA) analysis.Good working knowledge of thermal system fundamentals

A big plus if they have prior experience working with or around vehicles (member of car club, centhusiast, mechanic in spare time, etc.)

Having some practical knowledge of vehicles coming is very valuable


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Sub Team Leaders contd.Electrical systems Sub-Team Leader

Responsible for leading the Electrical Systems activities

Valuable skills to have:Competent with circuit design, simulation, and analysisProgramming experienceExperience designing and building low power electrical systemsExperience designing and building high power electrical systemsValues quality over quantity

Serves as a mentor for undergraduate student electrical team


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Sub Team Leaders contd. Controls Sub-Team Leader

Responsible for leading the Controls Systems activities

Valuable skills to have:Mastery of MATLAB/SimulinkProgramming experience or backgroundFundamental understanding of physics and powertrain componentsFundamental understanding of closed-loop control systems and rule based control logic

Ability to work extremely closely with the SMS sub-team leadLeads Design Failure Mode and Effects Analysis (DFMEA), which will determine how robu

your vehicle is to failure

Serves as a mentor for undergraduate student controls team


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Sub Team Leaders contd. System Modeling & Simulation Sub-Team Leader

Responsible for leading the System Modeling & Simulation (SMS) activities

Valuable skills to have:Mastery of MATLAB/SimulinkProgramming experience or backgroundFundamental understanding of physics and powertrain componentsFundamental understanding of closed-loop feedback systemsAbility to work extremely closely with the controls sub-team leadAbility to visualize how a physical system can be represented through simulation

Serves as a mentor for undergraduate student controls team


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MentorsGM Mentors

GM will identify an experienced engineer to both guide the team through the EC3 VDP, bethe point contact at GM for technical help and be the team champion in working internallywith EC3 organizers

GM mentor with be an expert in a specific area of automotive engineering

GM mentor will be one of our best resourcesHe will know a lot about project management and specifically how to get our team to meet deadlinesassociated with the VDPHe will know who in GM knows how to fix our technical problems and how to get us the help weneed to fix themHe will know how to work with competition organizers to keep our team out of trouble and the bestways to approach organizers when our team does have an issue

GM mentor is the competitions best all around resource and lifeline. The more we workwith our GM Mentor, the easier it will be for our team to succeed and, should our team beoff track, for the competition organizers to get us the help we need


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Mentors Contd. Other Sponsor Mentors

Sponsors who provide in-kind software, hardware or engineering support willassign mentors to the competition teams

Mentors are available to be a personal point of contact for each team toanswer questions and provide technical support

4 or 5 mentors for all teams 4 or 5 mentors for all teams

2 mentors for all teams


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Subject Matter Experts (SME)For each part GM provides to teams, GM will identify at least one engineer who is

knowledgeable about the part (SME)

SMEs may be determined for vehicle systems should teams have challenges working with tsystems

SMEs are competition resourcesThey are not assigned to any specific teamThey are only to be contacted after approval from GM Tech Leads after team requests through theMentorSMEs will provide direction remotely to teams to resolve issues, however, since they are experts inapplication of the specific part, there will likely be some back and forth with teams to resolve issues

SMEs participate in the generation of competition ICDs, teams are expected to have comprehendand used the ICDs prior to requesting help from a SME


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EcoCAR3 Vehicle Development ProcessSimilar to GM, EcoCAR3 will have a VDP that grows in complexity as time goes on

yearly competitions with specific vehicle development levels targetedY1: Designs finalized, component bench testing achievedY2: Vehicle build & integration, 50% level of functionalityY3: Vehicle integration refinement, 65% level of functionalityY4: Vehicle system optimization, 99% level of functionality

A good design for all the systems in the first year is extremely important

There will not be time to redesign the vehicle every year


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Y1 Timeline/Events

Y1 Event Distribution

Y1 Timeline


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Y1 Engineering DeliverablesIn a Nutshell: 3 technical Papers and 2 Reports

Baseline vehicle modeling report

Feasibility Study PaperBuilds an understanding of reality/scope/feasibility of: Packaging envelope Component/vehicle performance Fuel type

Energy consumption/efficiency

Faux waiver submission

Architecture selection paperFacility Safety BinderSoftware-in-the-Loop simulatiCompetition donated componetestingFinal technical report

Competition


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WorkshopsKick off workshop

MathWorks will sponsor the Y1 Kickoff Workshop on Sept. 18-21, 2014GRAs, sub-team leads, project managers and comm. Managers are intended audience.Training will be heavily focused on software (MathWorks, Intro to NX), Non-year-specific rules (NYSR)

Fall WorkshopLocation and date TBD, but tentatively Oct 22-26, 2014Audience is full team from here on outTraining will be heavily focused on software (Autonomie, donated component models, more NX), year 1 rSM&S

Winter WorkshopLikely will be hosted by Freescale in Austin, TX date is TBD, but sometime in early January 2015Training will be focused on achieving deliverables, with the first scored event


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InnovationAVTCs goal for the innovation activity is to:

Allow teams to showcase some of these new technologies on their EcoCAR vehicleReward teams for thinking outside the box and taking riskEmphasize the technologies to the public

10% of total competition points will be assigned to innovation

Teams will select their own innovation topics, AVTC will NOT assign topics to teamsMust be related to automotive consumer acceptability, efficiency/fuel consumption, emissions or safe

Topics can be as short as a year or as long as 4 years

Cash prizes will be available for top 3


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Innovation Timeline and YearlyDeliverables


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Swim lane Chart

Swim Lanes: A high level guide to stay on track each year


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Swim lanes Explained: MechanicalSummary : Design, integrate and validate efficient systems for the packaging, structural and thermal aspects of the powertrain and amaintain the overall vehicle dynamics.

Core activities for EcoCAR3:

Packaging and mounting of powertrain and peripheral componentsHeavy emphasis on Model Based Design (MBD) via CADHeavy emphasis on structural analysis, typically using as FEA a tool

Vehicle/subsystem integrationFollow MBD methodology and use CAM techniques to realize designs

Thermal systems (engines, batteries, motors, power electronics, etc.)Involves high-level design as well as low-level implantation (i.e., coolant line routing)

Vehicle dynamics(changes in vehicle mass and distribution necessitate changes to springs, dampers, etc.)

Y1 Deliverable Design : Package powertrain components for architecture selectionDrivetrain design (belts, chains, gears, connecting shafts, etc.)Initial designs for component mounting structureESS design (structural, packaging and thermal systems)Design, then build powertrain component bench test setup


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Swim lanes Explained: ElectricalSummary: Build and analyze vehicle electrical systems, design & implement a non-powertrain

embedded control systemNon-powertrain embedded control system

Main goal: net vehicle energy consumption improvementDesign and implement an embedded controller to be integrated in addition to the supervisory propulsioncontrollerPCB design using a reference design or evaluation board from FSL as a starting pointEnergy analysisIntegration of system onto vehicle by Y3

Power distribution (HV & LV)Harness design & routing Fusing, wire sizing, shielding, grounding, external protection, connectors, pin selections, crimping, etc.

System simulation & validation with measured test data HV bus ripple, parasitic loads, accessory loads, EMI, etc.


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Tools/Skills needed for Electrical

Circuit simulation & routing software (OrCAD, pSPICE, or comparable freeware)

Software development tools (FSL CodeWarrior)

LV and HV parts sourcing (Newark, knowledge of ratings, design envelope)

Thermal protection of wires (internal and external)

LV and HV testing equipment (cat III multimeter, o-scope, CM & DM probes rated for at lea400V)


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Y1 Deliverables- Electrical

Energy consumption improvementSelect and simulate an electronic based system that can enhance/improve net vehicle energyconsumptionSelect and build functional proof of concept with FSL development kit or reference design

Power distributionHV bus analysis (bus ripple simulation) LV system simulation Accessory loads

Parasitic loadsDesign & build LV & HV harnesses for bench testing components and HIL


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Swim lanes explained: ControlSummary : Develop reliable and robust vehicle powertrain control algorithms through the use of a

iterative development process and closed-loop testingComponent control

InterfacingModular control developmentSimulation and bench testing

Vehicle controlPower split, hybrid drive modesSystematic failure remediationSimulation and in-vehicle testing

Closed loop testingModel in the loop (MIL)Software in the Loop (SIL)Hardware in the Loop (HIL)

Y1 Deliverables:Requirements, DFMEAClosed loop vs open loop controcontroller selectioncomponent control & fault detecbasic vehicle control, energy ana


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Swim lanes explained: SM&SSummary : Develop component and vehicle level mathematical and physical models that enable ra

control development through simulator validationPlant models

Component plant modelsFull vehicle model

Closed loop testingSoftware in the loop Integrating controller code into vehicle model to validate algorithms

Hardware in the loop Integrate controller code onto vehicle controller to validate interfacing and algorithms in real time (controls swim lane) Integrate embedded controller system to validate system functionality (ECE swim lane)

Automated testingRegression testingOptimization

Test plan development & documentation


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Y1 Deliverables: SM&S

Workflow management

Building models

Testing requirements

Fault insertion

MIL/SIL/HIL

MIL/SIL Demo

Lead Project


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BusinessManager

Finances, Budgeting,Tracking spending

RiskManagement

and HR

Proper Insurance,Enforcing Rules,Minimizing Risk,Tracking Team

Members

Quality Control,Quality Assurance,

and Change Control

Making sure productquality is sufficient,

maintaining highquality, tracking

changes on the vehicle

InternalCommunications and

Cost ControlManagement

Communicatebetween teams,

Making Purchasingdecisions

Manager

Managing all projectmanagement teams,

communicatingbetween faculty and

other team leads

Mark Neville

launch workshop engineering(1)

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