2022
HT06 on the Endurance Track at Formula SAE 2022
HT06 Took Third Place Overall at the 2022 Competition
Engineering Summary
In 2022, HyTech Racing focused efforts on building an extremely lightweight and reliable vehicle with a low center of gravity and high lateral acceleration at all parts of the circuit. This was accomplished through an iterative design process focusing on high-level performance metrics and designing to the limit of each critical requirement.
HT06 features many design improvements over its predecessors. A novel battery pack cooling design strategy enabled HyTech's most energy-dense and tightly packaged accumulator ever. Advanced composite structural simulation techniques led to the development of a lighter, stiffer, and stronger aero package. A complete ergonomic study and experimentally driven design iteration gave our drivers a comfortable seating and steering position while seating the driver in the lowest possible position to even further improve acceleration performance.
Tuning HT06 took place during hundreds of hours of on-track testing to validate structural components, dial-in suspension setup, test launch control software, and validate onboard cooling systems. An adjustable anti-roll bar, configurable aero elements, and software control of powertrain parameters allowed for quick on-track adjustment of vehicle balance and handling.
Results
HT06 placed 3rd overall out of 55 teams in the 2022 FSAE Michigan Electric competition. The team also received 2nd in cost, 3rd in acceleration, 3rd in skidpad, and 4th in design.
HT06 Vehicle Details
General
- Weight: 386 lb (175 kg) measured at Formula SAE
Chassis
Suspension
- Double unequal length wishbone
- Ohlins TTX25 dampers
Powertrain
- Chain sprocket reduction
- Clutch type limited slip differential
Electric Drive
- Motor: Emrax 207 Medium Voltage
- Inverter: Rinehart CM200DZ
- Battery: 84S1P LiCoO2 pack with 5.6 kWh energy capacity
- Peak outputs: 80 kW
- Peak torque: 160 Nm
Aero Package
- 2 element front wing
- 3 element rear wing
- Coefficient of lift: -2.6
- Coefficient of drag: 1.4
Electrical Controls
- Low voltage controls: Teensy 4.0 Microcontrollers that run 6x faster than previous Microcontrollers
- High voltage controls: New team-built precharge and discharge controls circuitry. Clean-sheet object oriented BMS management system embedded software
- Data Acquisition: Created two new PCBs to interface with various sensors, revamped parser and live telemetry console.
2021
HT05 on the Endurance Track at Formula SAE 2021
HT05 Took Second Place at the 2021 Competition
Engineering Summary
For the 2021 competition year, our team continued our iterative design approach building on the work that was unfortunately interrupted in 2020. We continued to apply our three design principles during our design of HT05: lightness, serviceability, and robustness.
Our weight only increased 20 lb (9 kg) compared to our 2019 vehicle, while also adding our first ever aero package.
HT05 was HyTech's first vehicle to implement an aerodynamic package, which consisted of carbon fiber composite front and rear wings. This package greatly improved the cornering performance of the car and with it skidpad and autocross times dropped significantly. The team also took a new, quantitative approach to tire selection, collecting experimental data on tire heating curves and comparing critical parameters such as tire rates, cornering coefficients, and max lateral force. With this data, the team settled on the stiffer Hoosier R25Bs to meet the demands of tight-cornered FSAE tracks.
Our team found many ways of increasing the robustness and reliability of the new design. We worked with our sponsors to rigorously test and validate every cell in our battery pack, allowing for better cell life models. We also continued to improve our assembly process and testing process for all boards, decreasing the failure rate and time spent overall. We also spent a large part of the year testing the vehicle on track, enabling optimal tuning of the vehicle setup and vehicle software well before comp.
Results
We won second place at Formula SAE Nevada, and had the fastest endurance lap overall. We were especially proud of successfully passing technical inspection in the 115°F competition conditions.
HT05 Vehicle Details
General
- Weight: 383 lb (174 kg) measured at Formula SAE
Chassis
Suspension
- Double unequal length wishbone
- Ohlins TTX25 dampers
Powertrain
- Chain sprocket reduction
- Clutch type limited slip differential
Electric Drive
- Motor: Emrax 207 Medium Voltage
- Inverter: Rinehart PM100DX
- Battery: 72S1P LiCoO2 pack with 5.8 kWh energy capacity
- Peak outputs: 80 kW
- Peak torque: 160 Nm
Aero Package
- 3 element front wing
- 3 element rear wing
- Coefficient of lift: -2.084
- Coefficient of drag: 0.907
Electrical Controls
- Low voltage controls: Updated vehicle ECU and created custom dashboard PCB
- High voltage controls: Isolated BMS utilizing Analog Devices LTC6811 chips and custom management software
- Telemetry: Live vehicle data transmission and graphing using AWS
2019
HT04 on the Endurance Track at Formula Hybrid 2019
HyTech's Car at the Finish Line
Engineering Summary
For the 2019 competition year, our team continued our iterative design approach. We applied three design principles during our design of HT04: lightness, serviceability, and robustness.
Our weight decreased 45 lb (20 kg) compared to our 2018 vehicle, with a noticable weight reduction in each vehicle subsystem.
We greatly increased vehicle serviceability in a number of ways. We implemented an easy-to-install eccentric chain tensioning system as well as a drivetrain package that could be installed and removed from the vehicle without dissassembling. Quick disconnect brake lines allowed us to remove the pedal box or corners without having to rebleed brake lines. Our high voltage battery pack redesign featured easily removable panels and a busbar layout that reduced dissassembly and assembly time.
Our team found many ways of increasing the robustness and reliability of the new design. We designed a rigorous testing platform for our batteries, ensuring that each cell was reliable before assembling it in our high voltage pack. We retrofitted our new electrical system onto an old vehicle, allowing us to perform extensive testing early on in the development cycle. We also developed a new assembly process for our Battery Management System circuit boards, decreasing the failure rate and time spent on assembly.
Results
We won first place for the second year in a row at Formula Hybrid, placing first in the Design, Autocross, and Endurance events, and setting a record as the fastest electric team to ever finish the 44 km Endurance course. We also set our own personal record as this was the first competition where we successfully competed in every event.
HT04 Vehicle Details
General
- Weight: 368 lb (166 kg) measured at Formula Hybrid
Chassis
Suspension
- Double unequal length wishbone
- Ohlins TTX25 dampers
Powertrain
- Chain sprocket reduction
- Clutch type limited slip differential
Electric Drive
- Motor: Emrax 207 Medium Voltage
- Inverter: Rinehart PM100DX
- Battery: 72S1P LiCoO2 pack with 5.8 kWh energy capacity
- Peak output: 80 kW
- Peak torque: 160 Nm
Electrical Controls
- Low voltage controls: Power distribution module, telemetry and data logging system, and vehicle ECU integrated onto single PCB
- High voltage controls: Isolated BMS utilizing Analog Devices LTC6804 chips and custom management software
- Telemetry: Live vehicle data transmission via cellular network as well as onboard logging
2018
HyTech Racing at FSAE Electric 2018
HT03B on the track at Formula Hybrid 2018
In 2018, HyTech competed in both the Formula Hybrid and Formula SAE Electric competitions. Our team won first place at Formula Hybrid, placing first in the Design, Project Management, and Endurance events. We won sixth place at FSAE Electric, placing second in the Cost and Efficiency categories.
HT03B Vehicle Details
General
- Weight: 413 lb (187 kg) measured at Formula Hybrid
Chassis
Suspension
- Double unequal length wishbone
- Ohlins TTX25 dampers
Powertrain
- Chain sprocket reduction
- Clutch type limited slip differential
Electric Drive
- Motor: Emrax 207 Medium Voltage
- Inverter: Rinehart PM100DX
- Battery: 72S1P LiCoO2 pack with 5.8 kWh energy capacity
- Peak output: 80 kW
- Peak torque: 160 Nm
Electrical Controls
- BMS: Custom 5-board system utilizing Analog Devices LTC6804 chips
- Low voltage control boards: Power distribution unit and dashboard/torque controller unit
- Telemetry: Live wireless data visualization utilizing XBee modems
2017
HyTech Racing at Formula Hybrid 2017
In 2017, HyTech completely redesigned the mechanical and electrical systems on a new chassis, bringing the vehicle weight to under 380 pounds. We are proud to have taken first place in the design event at Formula Hybrid 2017.
2016
HyTech Racing at FSAE Electric 2016
HyTech Racing at Formula Hybrid 2016
This year HyTech designed and built our vehicle to compete in both Formula Hybrid and Formula SAE Electric competitions.
Chassis Details
- Completely new team-designed frame
- Torsional stiffness FEA: 2550 ft.lb/deg
- MDF jig designed for efficient and accurate chassis welding
Driveline Details
- Motor output (front) sprocket and rear sprocket designed and machined in-house
- Front sprocket machined out of Aluminum 2024 to reduce weight (versus Steel) while maintaining a factor of safety >1
- Hard mounted differential carriers machined out of Aluminum 6061; sticking to a robust and tested design
- Motor mount manufactured from Steel 4041- reduces stress points, holds up to the maximum torque
- Powered by the Enstroj Emrax 207 which is lighter than the other options in the market, yet powerful enough to handle the load of the car
Mechanical Controls Details
- Steering
- Custom 6061-T6 rack housing allows for low friction rack translation
- 32x force magnification from steering wheel to steering rack
- ~5° steering free play
- 32° of steering
- Brakes
- Adjustable pedal position for better ergonomics
- Manufactured with aluminum for decreased weight
Suspension Details
- Short 65" wheelbase for lower polar moment of inertia
- 52" track width reduces lateral weight transfer and increases lateral force produced by the tires when cornering
- Steering rods aligned to have just 0.1° of steer for two inches of wheel displacement
- Uprights and hubs CNC machined in-house.
- Hubs designed to be interchangeable between left and right corners
- Camber adjustable from 0° to -5.0° by use of threaded washers at the upper A arm point
- Suspension designed to keep outside wheels at a 0° of camber under the maximum allowable body roll of 2° when cornering
Electrical Controls Details
- Modular system of boards allows for easier development and replacement of controls system components
- Electrical boards designed using EAGLE CAD, then manufactured on campus by team members using printed circuit board milling
- Arduino software developed by team members and shared publicly as open source
- Aluminum battery enclosure and front controls enclosure created using water-jet and in-house welding
- Arduinos communicate with motor controller and battery management system entirely over CAN Bus network
- Real-time data is read by the Arduinos and sent to a steering wheel display
High Voltage System Details
- Emrax 207 Medium Voltage motor powers the drivetrain
- Rinehart PM100DX Motor Controller controls the Emrax motor
- Orion Battery Management System tracks cells
- Single accumulator container holds all batteries and most high-voltage components
- 4 team-packaged accumulator segments hold 82 LiFePo4 cells in series
2015
HyTech Racing at Formula Hybrid 2015
Vehicle Overview
CAD Design
Electrical Overview
2013
HyTech Racing's 2013 team is archived at this link.
