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Formula Student Czech Republic

Hybrid System Description for Hybrid Vehicles

Coversheet
The Coversheet must contain the following:
- Heading “Hybrid System Description FSN, FSCZ 2022”
- University and Team Name
- Car number
Feel free to add team logo, car picture, and the like.

1. Requirements (delete this section after you have read and understood it):
2. Complete all sections and tables of the HSD. If a section is not applicable to your design
state that in the document, do not delete any sections.
3. Remove instructions (orange) from document as you complete the sections.
4. Provide hyperlinks to all datasheets.
5. If you are unsure with respect to feedback of the reviewer, do not hesitate to ask the Lead E-
scruti via E-mail
6. Parts of the HSD which are changed because of reviewer’s feedback must be marked in red.
7. Following these guidelines will guarantee a swift review process.
University Name, Car Number
__________________________________________________________________________

Table of Contents
1 System Overview................................................................................................................5
2 Hybrid System Schematics.................................................................................................5
2.1 Tractive System Schematic (Power Electronics ONLY).............................................5
3 Shutdown Circuit................................................................................................................6
3.1 Shutdown Circuit Schematic........................................................................................6
4 Hybrid Storage Container...................................................................................................7
4.1 Hybrid Storage Container.............................................................................................7
4.2 Segments......................................................................................................................7
4.3 Cells..............................................................................................................................8
4.4 Hybrid Measurement System.......................................................................................8
4.5 Charging.......................................................................................................................9
5 Motor controller..................................................................................................................9
5.1 Motor controller 1........................................................................................................9
5.2 Motor controller 2......................................................................................................10
6 Motors...............................................................................................................................11
6.1 Motor 1.......................................................................................................................11
6.2 Motor 2.......................................................................................................................12
7 Other Items........................................................................................................................13
7.1 Firewall.......................................................................................................................13

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University Name, Car Number
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Table of Figures
Figure 3-1 - Shutdown Circuit Schematic..................................................................................6
Figure 5-1 - Accumulator Schematic..........................................................................................7
Figure 7-2 - Firewall Location..................................................................................................13

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University Name, Car Number
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Table of Tables
Table 1-1 - High Level Specifications........................................................................................6
Table 2-2 - Fuse Specifications...................................................................................................6
Table 2-3 - Conductor Specifications.........................................................................................7
Table 2-4- Connector Specifications..........................................................................................7
Table 3-1 - Shutdown Circuit Loads...........................................................................................8
Table 3-3 - BSPD Current Sensor Specifications.......................................................................8
Table 3-4 - BSPD Operation Details..........................................................................................8
Table 5-2 - Segment Specifications..........................................................................................10
Table 5-7 - HMS Setpoints.......................................................................................................12
Table 5-9 - Charger Specifications...........................................................................................12
Table 5.1 General motor controller data...................................................................................14
Table 6.1 General motor data....................................................................................................15
Table 7.1 Torque encoder data..................................................................................................17
Table 7-1 - Firewall Specifications...........................................................................................18

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University Name, Car Number
__________________________________________________________________________

1 System Overview
Include a brief description of the vehicle (1 paragraph).

Complete the information in the table below.

Maximum Hybrid System Voltage: 40VDC
Nominal Hybrid System Voltage: 30VDC
Grounded Low Voltage System Voltage: 24VDC
Number of Hybrid Storage Containers: 2
Total Hybrid Storage Capacity: 500Wh
Motor Type: AC Induction
Number of Motors: Total 1
Maximum Combined Motor Power: 5kW
Table 1-1 - High Level Specifications

Insert a system overview block diagram showing major electrical components and system
interactions

2 Hybrid System Schematics

2.1 Tractive System Schematic (Power Electronics ONLY)
Insert a large (full page) schematic of the Hybrid system. This schematic should focus on the
components that are not within the accumulator. Provide boxes and 1st level interfaces, when
details will be provided later in this document. Some detail of components within the
accumulator may be included for better understanding (ie AIRs).
Figure must include the following:
 Wire Size (AWG or mm2)
 Relative fuse location (end of wire vs middle)
 Fuse rating (Amperage and Voltage)
 Motor controller (1st level interfaces...inputs & outputs)
 Motor
 Connection to GLVS (if any)
 Inline connectors and interfaces for charging
 Show enclosures as dashed lines

2.1.1 Fuse Specifications

Complete the information in the table below.
Fuse Location Current Rating Voltage Rating Interrupt Datasheet
Rating

Table 2-2 - Fuse Specifications

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University Name, Car Number
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2.1.2 Conductor Specifications
Complete the information in the table below.
Rating of fuse
Conductor Voltage Ampacit
Size providing Datasheet
Location Rating y
protection

Table 2-3 - Conductor Specifications

2.1.3 Connector Specifications

Complete the information in the table below.
Wire
Includes Accepted
Ampacit Voltage gauge
Connector Location Interloc wire
y Rating connecte
k gauge
d

Table 2-4- Connector Specifications

3 Shutdown Circuit
3.1 Shutdown Circuit Schematic
Insert a large (full page) schematic of the shutdown circuit.
The schematic must include the following:
 All shutdown circuit switches/devices (indicate Normally Open or Closed)
 Hybrid Measurement System connection to shutdown circuit
 BSPD connection to shutdown circuit
 BOTS
 Inertia switch
 AIR coils
 Pre-charge relay coil (if used)
 GLV battery
 Fuse(s)
 Wire Size (AWG or mm2)

4 Hybrid Storage Container

4.1 Hybrid Storage Container
Insert a large image (top or nearly top view) of the complete Hybrid Storage Container
assembly without cover.
Figure must include the following:
 attachment points to car chassis
 HV electronics (at least one PCB mock-up)
 AIRs
 Main fuse
 Main power connector
(additional images may be needed to provide clear views of all elements)
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University Name, Car Number
__________________________________________________________________________

Figure 5-1 - Accumulator Schematic

4.2 Segments
4.2.1 Segment Overview
Insert a large image of the complete segment assembly. Describe segment materials and how
design provides a safe environment from dropped tools.

4.2.2 Segment Specifications

Complete the information in the table below.
# of Segments: 5
Cells per segment: 15
Cell configuration in segment: 5S3P
Energy in segment: 2.8MJ / 0.78 kWhr
Table 5-5 - Segment Specifications

4.2.3 Cell Connections

Describe how the electrical connections are made to the cells (welded/bolted/clamped)? 
Define what kind of weld (resistance/laser), what kind bolt (copper w/deforming nut),
material of clamp.  If bus bars are used what is the cross-sectional area and ampacity?  

4.2.4 Temperature sensors

Provide images showing where the temperature sensors are placed and how they are in
direct contact with the busbar. How many sensors are used and which percentage of cells is
monitored?
4.3 Cells
4.3.1 Cell Specifications
Complete the information in the table below.
Cell Make / Model / Style: Kokam XYZ- pouch, cylindrical, or metal can
Cell nominal capacity: 5.4 Ah
Maximum Voltage: 4.2 V
Nominal Voltage: 3.7V
Minimum Voltage: 2.8V
Maximum output current: 12A for 10s
Maximum continuous output current: 5A
Maximum charging current: 1A
Maximum Cell Temperature 65°C
(discharging)
Maximum Cell Temperature (charging) 55°C
Cell chemistry: LiFePO4

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University Name, Car Number
__________________________________________________________________________

Datasheet Datasheet
Table 5-1 - Cell Specifications

Explain how the power sinking elements of the precharge circuit are cooled.
4.4 Hybrid Measurement System
4.4.1 HMS Specifications
Describe the HMS that has been selected. Provide a datasheet, show the position of the
Measurement System in your accumulator. What is the sampling rate of your measurements?

4.4.2 Voltage Monitoring

Provide details of the voltage measurement system (accuracy, acquisition frequency, …).
Describe how and where the voltage sense leads are overcurrent protected (fused). What size
are the sense leads? What is their ampacity? If your sense leads are not fused please reason
why and how your system detects a malfunction of one of the measurements? Also include an
error calculation how precise your system is.

4.4.3 Temperature Monitoring

Provide details of the temperature measurement system (accuracy, acquisition frequency, …).
Give details of the temperature sensors used. Also include an error calculation how precise
your system is.

4.4.4 HMS Limits

Complete the table below.
Max Cell Voltage: 6.8V
Min Cell Voltage: 4.2V
Max Temperature: 60°C
Min Temperature: -5°C
Table 5-6 - HMS Setpoints

4.5 Charging
4.5.1 Charger Specifications
Complete the information in the table below.
Make / Model: ElectronPusher Inc 100V200
Power: 0.082kW
Output Voltage: 30V
Output Current: 0.273A
Input Voltage: 120V
Input Current: 1A
Datasheet: Datasheet
Table 5-7 - Charger Specifications

Provide images of the charger assembly and charging setup as it’ll be used during the events

4.5.2 Charger Control

Describe how the BMS can control the charger, in particular how it can stop the charger.

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University Name, Car Number
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4.5.3 Charger Demonstration
Describe numbered steps you would use to demonstrate the safe operation of charging,
include how to connect, and how to disconnect. Include any safe use practices, as well as what
to look for proper operation vs. a faulted condition.

5 Motor controller
5.1 Motor controller 1

5.1.1 Description, type, operation parameters

Describe important functions, provide table with main parameters like resulting voltages-
>minimum, maximum, nominal, currents etc.
Fill out the following table:
Motor controller type: ABC Controller

Maximum continous power: 60kW

Maximum peak power: 75kW for 10s

Maximum Input voltage: 600VDC

Output voltage: 250VAC

Maximum continuous output current: 100A

Maximum peak current: 200A for 5s

Control method: PWM, analog signal...

Cooling method: Air, water, oil...

Auxiliary supply voltage: 24VDC

Table 5.8 General motor controller data

5.1.2 Wiring, cables, current calculations, connectors

Describe the wiring, show schematics, provide calculations for currents and voltages and
show data regarding the cables and connectors used.
Additionally fill out table:
Wire type: Company A, 0.205 mm²

Current rating: 150A

Maximum operating voltage: 800V

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University Name, Car Number
__________________________________________________________________________

Temperature rating: 150 °C

5.1.3 Position in car

Provide CAD-renderings showing the relevant parts. Mark the parts in the rendering, if
necessary.

5.2 Motor controller 2

…
If identical parts are used, just refer to the corresponding sections, don’t copy and paste.

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University Name, Car Number Error: Reference source not found Error:
Reference source not found
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6 Electrical Motors
6.1 Electrical Motor 1

6.1.1 Description, type, operating parameters

Describe the motor used, provide table with main parameters like resulting voltages-
>minimum, maximum, nominal, currents, resulting motor power, use figures to show
important characteristics. Describe the casing and if the casing rotates the finger guards used.
Please also include a picture of the Electrical Motor.
Additionally fill out table:
Motor Manufacturer and Type: ABC Motor

Motor principle Asynchronous, permanently excitated

Maximum continuous power: 25kW

Peak power: 70kW for 5s

Input voltage: 250VAC

Nominal current: 50A

Peak current: 70A

Maximum torque: 60Nm

Nominal torque: 20Nm

Cooling method: Water, oil, air,...

Table 6.9 General motor data

Give a plot of power vs. Rpm including a line for nominal and maximum power
give a plot of torque vs rpm including a line for nominal and maximum torque

6.1.2 Wiring, cables, current calculations, connectors

Describe the wiring, show schematics, provide calculations for currents and voltages, and
show data regarding the cables and connectors used.
6.1.3 Position in car
Provide CAD-renderings showing all relevant parts. Mark the parts in the rendering, if
necessary and clearly identify the structure used to protect all relevant parts. How do you
integrate the electrical Motor into your System?

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University Name, Car Number Error: Reference source not found Error:
Reference source not found
__________________________________________________________________________
6.2 Electrical Motor 2
…
If identical parts are used, just refer to the corresponding sections, don’t copy and pas

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University Name, Car Number

7 Other Items
7.1 Firewall
7.1.1 Firewall Layer Specifications
Complete the information in the table below.
Aluminum layer thickness: 0.2mm
Insulating layer thickness: 2mm
Insulating Material Make / Model: Conductive Co.
FLDPRDCT
Insulating Material Datasheet: Datasheet
Insulating layer side: Driver
Table 7-10 - Firewall Specifications

7.1.2 Firewall Location

Provide CAD rendering(s) or photographs showing the firewall components. Mark the parts in
the renderings, if necessary.

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