Plug-in Hybrid Electric Vehicle

1. Plug-in Hybrid Electric Vehicle Daniel Taylor Timothy Lenberg James Kast Andrew Kuharske

2. Plug-in Hybrid Electric Vehicle Team Objective • To advance the development of an in house hybrid electric vehicle for use in testing Dr. Dean Edwards' experimental lead acid batteries. University of Idaho 2012 Capstone Design

3. Plug-in Hybrid Electric Vehicle EE Specifications • Operational Electric Car • Car Drives in a safe and reliable manner • Batteries can be charged from a 240V wall outlet • Auxiliary Power Unit (APU) • Charges batteries • Is operated by a stand alone microcontroller • Design Priorities • Safety • Functionality • Aesthetics • Cost University of Idaho 2012 Capstone Design

4. Plug-in Hybrid Electric Vehicle System Circuit Diagram University of Idaho 2012 Capstone Design

5. Plug-in Hybrid Electric Vehicle APU Flow Diagram University of Idaho 2012 Capstone Design

6. Plug-in Hybrid Electric Vehicle Electrical Final Achievements • Safety Features • Fuses, Relay, Quick Disconnect • APU • Microcontroller • Starts Engine • Gives Engine 2min warm up at 6,000rpm • Rev’s Engine up 12,000 rpm charging speed • Shuts off at user’s command • Due to problems operating at 12,000 rpmtests were not conducted and a future team will be designing for more around 6,000 rpm. • Car Drives! University of Idaho 2012 Capstone Design

7. Plug-in Hybrid Electric Vehicle ME Specifications • Structural Integrity • Completed Frame Model • Performed FEA • Made Additions to the Frame • Exhaust Routing • Designed Optimum Route • Integrated into the Vehicle • Safety • Battery Terminal Covers • Radiator Mounting • Motor Cover University of Idaho 2012 Capstone Design

8. Plug-in Hybrid Electric Vehicle FEA Original Frame - Stress • Test Bullet University of Idaho 2012 Capstone Design

9. Plug-in Hybrid Electric Vehicle FEA Original Frame - Deflection • Test Bullet University of Idaho 2012 Capstone Design

10. Plug-in Hybrid Electric Vehicle FEA Modified Frame - Stress • Test Bullet University of Idaho 2012 Capstone Design

11. Plug-in Hybrid Electric Vehicle FEA Modified Frame - Deflection • Test Bullet University of Idaho 2012 Capstone Design

12. Plug-in Hybrid Electric Vehicle Exhaust Requirements • Clearance Restriction • Route Away from Driver • Incorporate Muffler • Eliminate Safety Hazards (Heat Shielding) University of Idaho 2012 Capstone Design

13. Plug-in Hybrid Electric Vehicle Exhaust Final Product University of Idaho 2012 Capstone Design

14. Plug-in Hybrid Electric Vehicle ME Other Accomplishments • Mounted/Calibrated Throttle Body • Attached Rear Axles • Future Body Visualization • Misc. Mounting/Machining/Modification University of Idaho 2012 Capstone Design

15. Plug-in Hybrid Electric Vehicle Mechanical Final Achievements • Structural Integrity • FEA Showing Safe Conditions • Reduce Max Deflection • Add Recommended Beams to the Frame • Exhaust Routing • Design for Safe Operation • Implement into Vehicle • Safety • Machine and Implement New Terminal Covers • Mount the Radiator above the Alternator • Modify the Motor Cover to fit into Vehicle University of Idaho 2012 Capstone Design

16. Plug-in Hybrid Electric Vehicle Lessons Learned • Project Management • Set “mandatory” work times throughout the week • Split tasks as either ME/EE/Both • Dealing with Team Stress • Find humor in things gone wrong • Keep the End Goal in Sight • Don’t get caught up in the little things University of Idaho 2012 Capstone Design

17. Plug-in Hybrid Electric Vehicle CAR DRIVES! University of Idaho 2012 Capstone Design