The Vehicle

Chassis

Designed using Solidworks CAD software to reduce mass and increase torsional stiffness Optimized using FEA software Removable cross bracing across fuel cell modules and fuel tanks for service

4130 Chromolly steel Many other materials and composites were analyzed and designed.  The mechanical properties, flexibility in joining, resilience, fixture design, and reparability on the salt all lead to its’ selection Range of cross sections (square, rectangular, round) Range of thicknesses (0.049”- 0.095”)

Aerodynamics

• Requirements & Considerations
  • Low drag
  • Low pitch sensitivity
  • Lateral/crosswind stability
  • Appropriate down force
• CFD
  • Computatinoal Fluid Dynamics: the use of numerical methods and algorithms to solve the Navier-Stokes equations, which define single-phase fluid flow, on discritized geometry
  • CFD provides a virtual wind tunnel: body shapes can be aerodynamically simulated without manufacturing physical prototypes, design changes can be evaluated quickly, accurately, and economically
  • Models solved in parallel on 12 processors
• Wind tunnel
  • Critical for CFD validation
  • 1/3 scale model
  • Open test section wind tunnel
  • 64 static pressure measurements for CFD correlation
• For more information on high-performance, parallel computing, see http://www.osc.edu
• For more information on FLUENT, see http://www.fluent.com
• For more information on the Penske Technology Group wind tunnel, see http://www.pensketechnology.com

Body

• Designed using Solidworks CAD software and optimized using CFD and windtunnel testing
• Carbon fiber skin
• Nomex honeycomb to increase stiffness and strength and reduce weight
• CNC machined molds for ultimate accuracy
• Multiple quick release panels to allow for easy access maintenance
• Interchangeable fin section to allow for future changes to vertical surface area.

Driveline

• Custom machined solid aluminum wheels and high speed Bonneville racing tires
• Semi-custom 6 speed transaxle (Transmission and Differential unit)
• Electrical Traction System
  • Custom built AC Induction Motor
  • 3 Phase
  • Lightweight design
  • 700+ Horse Power
  • High efficiency
• Motor Controller
• Converts DC electricity to 3 phase AC to drive the motor
• Very high efficiency

Safety

Driver tub

• Increase stiffness around driver
• Provide impact/ intrusion resistant wall between vehicle and driver
• Eliminate sharp edges and seems around driver
• Prepreg carbon fiber/ aluminum honeycomb composite tube
  • Six (three on either side) layer 3K carbon fiber and,
  • half inch aluminum honeycomb sandwich
• Integrated driver restraint points
  • Additional plys of carbon at driver restraint points
  • distributes loads
• Integrated molded beaded seat
• Mechanically fastened to chassis

Fuel Cell System (Power Plant)

•  Combines onboard Hydrogen & Oxygen to create electricity
•  Not all chemical energy can be transformed in to electricity (About 60-80%)
•  By-products are heat & water
•  The cells heat up just like and engine and need to be cooled
•  A radiator would cause to much drag traveling at 300 mph, so a ice bath was chosen an the cooling strategy
•  See www.ballard.com for more information.

Data Acquisition

• State-of-the-art Bosch Motorsport data acquisition system
•  Fully integrated double-layer CAN communication system
•  High range wireless telemetry for real-time monitoring of vehicle systems
•  On-board diagnostics for real-time driver feedback
•  High accuracy GPS-based position and speed logging
•  Over 50 channels of data