HEVT Gets an Early Christmas Present

Sometime over this past summer, our vehicle, Mary the Malibu, developed a ground fault that crippled our ability to run in EV (electric vehicle) mode. We spent roughly four months troubleshooting, but we recently received an early Christmas present — a running vehicle!

I repeat: Mary is mobile!

We were able to find an issue with our rear traction motor inverter and have it sent off to UQM for repairs. After getting our inverter back we were able to re-integrate it into our vehicle to use our high voltage system to run the rear traction motor. Being up-and-running again in EV mode is a huge step in the right direction. We'll now be able to do some vehicle testing and collect a lot more data. We'll be using this data to refine our control code and increase EV efficiency.

Where do we go from here? I'm glad you asked!

Our next major milestone is to get our front powertrain working. As discussed in an earlier post, we have been troubleshooting a fluid leak with our P2 generator motor. We have since narrowed down a few options and are collaborating with headlining sponsor GM to see which stock components may be conflicting with our system.

Next step is to validate our engine controls outside the vehicle using an engine test stand. We will first re-wire the engine on the test stand and then verify certain controls. Once we have done that, we can add our P2 to the engine and test that. Finally, we will add our transmission to the mix and test the engine system fully.

Once we can validate our complete engine components, we should be able to re-install our engine into Mary and run our front powertrain. This will give us our as-intended final product — a running series-parallel plug-in hybrid electric vehicle!

Be sure to like us on Facebook and follow us on Twitter for day-today updates and progress.

Have any ideas or advice for vehicle testing? Let us know in the comments below!

Alumnus Puts Training To Work With Proterra

Over the years, many of our graduates have gone on to do great things in engineering. The real-world experience gained from HEVT is always helpful in their new careers—none more relevant than 2012-2013 electrical subteam leader Brian Kelly.

Brian gives a thumbs up working in the Ware Lab.

Since graduating May 2013, Brian has been working with Proterra as a mechanical engineer. For those who don’t know, Proterra is the world's-leading manufacturer of zero-emission electric buses. They are also a bronze-level sponsor of EcoCAR 2. Brian’s experience with HEVT has given him a range of skills to use in his work with Proterra.

“I am in charge of all of the mechanical subsystems of the high and low voltage modules of the bus,” Brian said. “EcoCAR 2 helped me get a lot of electrical experience. I now know what conditions need to be met on both the electrical and mechanical side.”

Since Brian works on an all-electric bus as a mechanical engineer, he is a sort of hybrid himself. His co-workers jokingly call him a “mech-elec,” meaning mechanical electrical engineer. He is using a lot of CAD to work on designs for the newest version Proterra’s electric bus. He is in charge of all of the mechanical subsystems of the high and low voltage modules of the bus. If an electrical component needs a place to be mounted, he designs a way to integrate it.

“As the electrical subteam leader, Brian was in charge of all of the vehicle’s electrical work including the high and low voltage systems, said HEVT team leader Eli White. “This was majorly focused around the high voltage A123 battery pack we installed into the rear of our vehicle, which powers the rear traction motor.”

His experience working with high voltage electrical systems has been integral in his success with Proterra. Being a mechanical engineering major, he had very little knowledge of electrical systems before his work with HEVT. Brian leveraged his experience and networking from EcoCAR 2 to land his current job with Proterra. 

Brian says it best, "There is no doubt in my mind that I wouldn't be where I am today without my involvement with EcoCAR 2."

Do you or someone you know have a similar success story? Tell us all about it in the comments below!