2. What we deal with:-
The electronics section of the formula student car is
often overlooked or totally neglected at all by
outsiders as it is a mainly mechanical engineering
project but vehicle electronics is as important as
the engine itself.
In real formula one cars around 800 bhp of engine
power is specially controlled by the ECU(Electronic
Control Unit)
The ECU of the real formula car is provided by the
McLaren Electronics system, Microsoft and
semiconductor supplier which controls the complex
Engine, transmission, steering, suspension and
other key components of the modern formula one
car.
3. In real formula one
Fast Facts
Sensors on a Formula One race car: 150 - 300
Data generation rate while racing: 100 kilobytes
to 0.5 megabytes per second
Data generated during 1 Grand Prix race per car:
1 to 2 gigabytes
Data generated during 1 Grand Prix weekend: 100
gigabytes.
ECU data collected per car per year (including
practice laps and equipment testing): 2 to 3
terabytes.
Application Platform Capabilities: Development,
Data Management
6. Cont…
It was the pic of the electrical systems in a modern formula one car. You
can see it is a quite complex systems.
Real formula cars’ ECU-s are based around Freescale’s 32 bit MCU, which is
built on four, 200 megahertz Power Architecture cores. Official name of the
unit is TAG-310B ECU.
In our Formula Student Car we also have an ECU which controls the
parameters of the Engine Like its AFR(Air fuel Ratio), Engine timings, its
power transfer to the wheels and much more in fact there is no direct link
between the driver and the engine when he open the throttle the Signal is
sent to the ECU and then it process the data and send the required
amount of fuel to maintain an optimum AFR.
7.
8. Electronic Circuit of our Car:-
It was the electronic circuit of our car.
As one can see all the components are given the power by the battery and
controlled by the ECM. There are many different sensors in the car like
TPS(Throttle position sensor), CKP(Crankshaft position Sensor),IAT(Intake
Air Temperature Sensor),ECT(Engine Coolant Temperature Sensor) and
many more as we can see almost each and every parameter which affects
the performance of the car is closely monitored and regulated by the ECM
of the car.
9. Electronic Components of the Car
Custom Harness.
Battery :- Amaron® Beta Pro AP BTZ
12V 7Ahr Sealed Valve Regulated
lead acid battery.
ECU :- Keihin 9016-103117.
Engine management :-Bazzaz Engine
management system.
10. What we add the car:-
Traction control System
Fuel map select switch
Launch Control
Shift indicator
RPM indicator
Shift count
Data Acquisition
Battery Level Indicator
Neutral indicator
Fuel Indicator
Speed indicator
Odometer
Paddle shifter
11. BATTERY:-
Amaron® Beta Pro AP BTZ 12V 7Ahr
Sealed Valve Regulated lead acid
battery.
Lead acid batteries are very reliable
and have a high charging tolerance.
We plan to use li-ion battery in ZFR4.0
As the li-ion batteries have higher
charge density and require low
maintenance and have a very low self
discharge rate by doing its simulation
on MATLAB Simulink™.
12. Custom harness:-
In custom harness we aim to build a more
reliable, well engineered and light weight
harness.
We aim to ensure the safety, protection and
proper functioning of the electrical system of
the cars.
We use sleeves, heat shrink tubes and rubber
tubing (3 layer insulation) to ensure the safety
of the system.
We ensure all the electrical rules of the car are
satisfied.
We also decide the thickness of the wire by the
current which is flowing through it.
15. Who needs it?
Every vehicle can benefit from fuel tuning.
Stock vehicles may come with an air/fuel mixture that can be too lean or
too rich in various areas, affecting performance.
Vehicles with any modifications (such as exhaust or high-flow filters) must
have their fueling tuned to accommodate the change in air volume to the
AFR.
Variables in fuel tuning include: fuel blend or type, engine wear, exhaust,
filter, engine modifications, air temperature, air pressure, and humidity
16. How it Works
Power is dependent on how well the air / fuel mixture is ignited in the
cylinder.
Air / fuel ratio (AFR) is controlled by the Engine Control Unit (ECU).
Bazzaz fuel controllers piggy back onto the ECU, intercepting the signals
sent to the fuel injectors and modifying them.
The precise data for these changes is stored in the fuel controller in the
form of a fuel map.
17. What we plan to do in the next car:-
Clutch less shifting:- We plan to install paddle shifters
along with clutch less shifting in ZFR4.0 so that the
shifting time in the race decreases and average speed
of the car increases thus reducing the lap time
Data acquisition : we plan to have a fully fledged data
acquisition system in the car next time. Data
acquisition (DAQ) is the process of measuring an
electrical or physical phenomenon such as voltage,
current, temperature, pressure, or sound with a
computer. A DAQ system consists of sensors, DAQ
measurement hardware, and a computer with
programmable software.
18. Cont…
Launch Control:- Launch control operates by using
an electronic accelerator and a computer program.
The software controls acceleration based on
engine specifications to make the car accelerate
smoothly and as fast as possible, avoiding
spinning of the drive wheels, engine failure due to
over-revving, and clutch and gearbox problems. In
racing cars, this feature is only available at the
start of the race, when the car is stationary in the
starting grid. After the car is running at a certain
speed, the software is disabled.
19. Summary
The Electronics department is underrated yet important department in any
vehicle. The reliability, performance and safety of any modern vehicle is
fully dependent on the Electronics of the vehicle. For example In case of
AFR(Air Fuel Ratio) which is controlled by ECU of the vehicle, if it is very
lean i.e. it the air is more and fuel injected is less then the engine would
overheat and piston heads would be damaged and if it is very rich the
engine would again overhear because it is burning more and more fuel to
provide power to vehicle. Thus it is very important to maintain an
optimum AFR so as to ensure the safety and performance of engine and
driver as well.
For the next car we are planning to simulate it fully on the MATLAB
Simulink™ and Siemens NX™ so as to maximize the efficiency and
minimize the weight.
