500 V
Max Voltage
85 km/hr
Top Speed
100,000
Cost (USD)
500volt
Battery
85km/hr
Top Speed
100K USD
COST
107 hp
Peak Power
300kg
Weight
50km
Range
Background
After I built the electric scooter, I was intereted in deepen my knowledge in electric vehicle, and decided to challenge one of the largest automotive competition for student, Formula SAE Japan .
Goal
Building the first electrical student race car in our university, and the second in Taiwan!
Another goal was to bring back the experience of participating in international competition.
Role: Electrical System Lead & Founder
Leading 10 members team to build the entire electrical system of the race car.
Systems, Circuits, Mechanicals design, manufacture and assembly.
Fund-raising, Presenting to sponsors and suppliers.
Recuriting and Establish the team.
Skills
Leadership, Cross-functional Communication
System Integration
Founding the idea and fund-raising
Tool
Solidworks
AutoDesk - Eagle
Power Point, Word, Excel
Battery System Design
Insulation Monitor Device(IMD) detects leakage.
Main Fuse protect over current.
Main Relay to disconnect current path.
Pre-charge circuit, protect over current while turning on the system.
Discharge circuit, discharge energy after turning off the system
Battery Managment System(BMS) to control the system at a safe temperature range.
Battery Managment System(BMS) monitor every cells voltage.
Battery System Design
Designing the battery system architecture.
Battery System Assembly
Designing the layout and placement of the battery system.
Race Car CAD Assembly
Make sure the battery container fit in the frame of the race car.
Circuit Design
Shutdown Circuit, able to shutdown the entire system under any circumstance.
Brake System Plausibility Device, shutdown the system when acceleration is out of driver's control.
Tractive System Active Light, activate a warning light whenever the high voltage battery system is active.
Shutdown Circuit
Circuit Design
Manufacturing/ Testing
Assembling battery cells in series.
I was testing the circuit board function in the safe temperature range.
Shut Down Circuit, a safety mechanism to shut down the high voltage system in any emergency.
Assembling/ Integrating
Make sure the mounting point of the battery container and body frame align.
Assembling the motor on to the vehicle.
High Voltage Battery, we used caulk gun to seal the gaps for waterproof.
I was explaining our battery system design to the judges.
Rain test, validating the electrical system was waterproof.
Tilt test, validating the center of gravity of the car.
Result/ Test
Electrical System Form (pdf)
For more engineering design details, please read the following offical document, approved by JSAE judges.
NCKU-ESF4.0.pdf