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Friday, April 26, 2013

Make That Rear Traction Motor Spin


The controls subteam has been working tirelessly with the control code to spin our rear traction motor (RTM). In the early hours of spring morning, the team’s hard work paid off, and we saw the RTM spin for the first time!

The 125 kW rear traction motor is mounted on the rear subframe, which enables us to power the vehicle in all electric mode. First, the mechanical subteam made modifications to the rear subframe and designed mounts for the motor and single speed transmission that it’s coupled to. Then the electrical subteam stepped in to ensure that all of the high-voltage wiring was connected correctly and safely from the energy storage system to the inverter and then to the RTM.

The controls team then had to come in and make it all work together. Throughout the year the team has been creating and testing the code for this very moment. “We have been developing the control code since year 1 using logic blocks in MATLAB Simulink,” said controls subteam leader Kyle Caroncino.

The control code is loaded onto the MicroAutoBox, graciously donated by competition platinum-level sponsor dSPACE. The control code is then manipulated to satisfy the necessary “component-enable” conditions based on the readiness level of the vehicle. Only after each of the components involved have been properly enabled will the battery send high-voltage electricity to the rear-traction motor.

After many long nights working in the Ware Lab, the team was able to send commands to the RTM and spin the wheels!  Check out the video at the link below!


“It’s neat seeing all of the components we’ve been installing over the course of the year actually working together,” Kyle said. “It’s a visual recognition of our hard work.”

With less than two weeks from competition, we are working hard to make sure we have a running vehicle for competition. The RTM signifies a huge milestone for the team and we’re excited to see all of the other components come together.

Friday, April 19, 2013

Build Update 4.19.13


Last Friday, we received the finalized half shafts for the BorgWarner transmission we are using in the rear of the vehicle. Now that these shafts are the correct length, installation was as simple as sliding the splined shafts into one another.

With these parts installed we are able to mechanically link the transmission to the wheel hubs and drive the vehicle using the rear traction motor. With the addition of the half shafts we were also able to fill the BorgWarner transmission with fluid and assemble the entire rear cradle into the vehicle. This marks a major milestone, as it was the last mechanical driveline component to be installed in the car. Now it's off to the controls and electrical teams for testing and refinement!

Friday, April 12, 2013

Build Update 4.12.13

Last week we returned the P2 motor/generator to team sponsor Kollmorgen to fix fitment issues. Kollmorgen was very quick with the alterations and we received it back the next day.

With the P2 back in the lab, we were able to reassemble the front powertrain. Here’s to hoping the front engine, P2 and transmission assembly never have to come out of the car again! We started with the assembly of the P2 to the transmission by routing the three-phase and signaling wires from the P2 through the transmission and its bell housing. With these two connected, we sealed the P2 coolant fittings and the holes where the wires protruded.