{"id":13393,"date":"2022-05-06T12:18:28","date_gmt":"2022-05-06T16:18:28","guid":{"rendered":"https:\/\/blogs.solidworks.com\/teacher\/?p=13393"},"modified":"2022-05-06T12:18:28","modified_gmt":"2022-05-06T16:18:28","slug":"wpi-engineers-build-fsae-car-for-competition-in-a-closet-and-succeed-at-formula-hybrid-electric","status":"publish","type":"post","link":"https:\/\/blogs.solidworks.com\/teacher\/2022\/05\/wpi-engineers-build-fsae-car-for-competition-in-a-closet-and-succeed-at-formula-hybrid-electric.html","title":{"rendered":"WPI Engineers Build  FSAE Car for Competition in a Closet and Succeed at Formula Hybrid + Electric"},"content":{"rendered":"<p>In 2019, <a href=\"https:\/\/www.wpi.edu\/\">WPI Engineers<\/a> had passion to build a competitive FSAE vehicle for Formula SAE Michigan.\u00a0 What they didn&#8217;t have is space.\u00a0 Assigned the former machinist&#8217;s closet\u00a0 the team successfully converted the space to design, build, test, widen the closet door, and get closer to competition. WPI completed all FSAE dynamic and static events in Michigan, rising 20 places and improving in each category.<\/p>\n<div class=\"video-container\">\n<div class=\"entry-content-asset\"><iframe loading=\"lazy\" title=\"WPI FSAE Build 2019\" width=\"1140\" height=\"641\" src=\"https:\/\/www.youtube.com\/embed\/CxTKRaU5D7k?feature=oembed\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture\" allowfullscreen><\/iframe><\/div>\n<\/div>\n<p>In the 2020-2021 season, the <a href=\"https:\/\/www.instagram.com\/wpi_fsae\/\">WPI FSAE team<\/a> had a new goal, create a Formula Electric car for competition. With the help of engineering advisors, Williams Michalson, electrical and computer systems, David Planchard, mechanical systems, department approval, and determined students,\u00a0 a two-year design, build, and race goal began.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13414\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-mission-615x615.jpg\" alt=\"\" width=\"615\" height=\"615\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-mission-615x615.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-mission-300x300.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-mission-120x120.jpg 120w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-mission.jpg 640w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>How do you transfer a mechanical engineering FSAE team to an all electric FSAE team?\u00a0 The first step was to recruit a multi disciplinary team, with mechanical, electrical, robotics, and computer science engineering majors.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13427\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Accumulator-Assembly-615x402.jpg\" alt=\"\" width=\"615\" height=\"402\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Accumulator-Assembly-615x402.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Accumulator-Assembly-300x196.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Accumulator-Assembly-768x502.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Accumulator-Assembly-728x476.jpg 728w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Accumulator-Assembly.jpg 1067w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>John Williams led the team in 2021 through a COVID-restricted year, shifting design focus to all electric.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13431\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-SAE-full-assembly-615x323.jpg\" alt=\"\" width=\"615\" height=\"323\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-SAE-full-assembly-615x323.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-SAE-full-assembly-300x158.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-SAE-full-assembly-768x403.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-SAE-full-assembly-1536x807.jpg 1536w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-SAE-full-assembly-2048x1075.jpg 2048w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-SAE-full-assembly-728x382.jpg 728w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>Scheduling around the clock was key, only a few team members could work on the car due to space constraints.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13432\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Testing-Welds-615x461.jpg\" alt=\"\" width=\"615\" height=\"461\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Testing-Welds-615x461.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Testing-Welds-300x225.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Testing-Welds-768x576.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Testing-Welds-1536x1152.jpg 1536w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Testing-Welds-2048x1536.jpg 2048w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Testing-Welds-728x546.jpg 728w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>In the first year of the electric build,\u00a0 small manual tests for material selection played a critical role.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13428\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Lateral-Shear-Loading-615x408.png\" alt=\"\" width=\"615\" height=\"408\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Lateral-Shear-Loading-615x408.png 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Lateral-Shear-Loading-300x199.png 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/WPI-Lateral-Shear-Loading.png 662w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>With limited space for testing, SOLIDWORKS Simulation was paramount.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13403\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Accumulator-Mounts-WPI-FSAE-Electrical-615x405.jpg\" alt=\"\" width=\"615\" height=\"405\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Accumulator-Mounts-WPI-FSAE-Electrical-615x405.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Accumulator-Mounts-WPI-FSAE-Electrical-300x198.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Accumulator-Mounts-WPI-FSAE-Electrical-768x506.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Accumulator-Mounts-WPI-FSAE-Electrical-728x480.jpg 728w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Accumulator-Mounts-WPI-FSAE-Electrical.jpg 791w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>Design review meetings were held through Zoom.\u00a0 The mechanical suspension team designed a new frame to support the electrical requirements, Simulations showed new possibilities.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13407\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Pedal-and-Foot-Placement-WPI-Formula-Electric-615x534.jpg\" alt=\"\" width=\"615\" height=\"534\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Pedal-and-Foot-Placement-WPI-Formula-Electric-615x534.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Pedal-and-Foot-Placement-WPI-Formula-Electric-300x261.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Pedal-and-Foot-Placement-WPI-Formula-Electric-768x667.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Pedal-and-Foot-Placement-WPI-Formula-Electric-728x632.jpg 728w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Pedal-and-Foot-Placement-WPI-Formula-Electric.jpg 875w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>To keep costs down, students designed and machined many new components including the foot pedal with extra room for the drivers foot to rest and new uprights for support.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13413\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-electric-machining-615x348.jpg\" alt=\"\" width=\"615\" height=\"348\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-electric-machining-615x348.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-electric-machining-300x170.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-electric-machining.jpg 636w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>In 2021-2022 season, Jessica Babcock, mechanical project manager and Ilyas Sahli, electrical project manager brought sub-teams together with the goal of participating in <a href=\"https:\/\/www.formula-hybrid.org\/\">Formula Hybrid + Electric<\/a>.\u00a0 Pre judging occurred on site in the closet and students listened carefully to FSAE Hybrid + Electrical judge&#8217;s recommendations.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13415\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-frame2-615x615.jpg\" alt=\"\" width=\"615\" height=\"615\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-frame2-615x615.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-frame2-300x300.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-frame2-120x120.jpg 120w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-fsae-frame2.jpg 640w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>Then came the completed reports, structural equivalency, electrical systems, impact attenuator, change management,\u00a0 design, and sustainability.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13408\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-electric-mqp-2022-615x461.jpg\" alt=\"\" width=\"615\" height=\"461\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-electric-mqp-2022-615x461.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-electric-mqp-2022-300x225.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-electric-mqp-2022-768x576.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-electric-mqp-2022-728x546.jpg 728w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-electric-mqp-2022.jpg 1440w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>In addition to preparing for Formula Hybrid + Electric, many team members used the new vehicle design as part of their Major Qualifying Project (MQP)\/senior design capstone project, winning second place in the Provost award category.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13410\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-mqp2021-2022-Electrical-Panel-615x349.jpg\" alt=\"\" width=\"615\" height=\"349\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-mqp2021-2022-Electrical-Panel-615x349.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-mqp2021-2022-Electrical-Panel-300x170.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/wpi-formula-mqp2021-2022-Electrical-Panel.jpg 634w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>The weekend before competition, the team was &#8220;all-in&#8221;.\u00a0 \u00a0For the first time, the wheels turned and all simulated systems were now a reality.\u00a0 With no drive time, the WPI engineers took a chance and drove to the New Hampshire Speedway to begin a 4-day grueling competition.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13406\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Jess-WPI-FSAE-Electric-Formula-Hybrid-Electric-615x461.jpg\" alt=\"\" width=\"615\" height=\"461\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Jess-WPI-FSAE-Electric-Formula-Hybrid-Electric-615x461.jpg 615w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Jess-WPI-FSAE-Electric-Formula-Hybrid-Electric-300x225.jpg 300w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Jess-WPI-FSAE-Electric-Formula-Hybrid-Electric-768x576.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Jess-WPI-FSAE-Electric-Formula-Hybrid-Electric-728x546.jpg 728w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Jess-WPI-FSAE-Electric-Formula-Hybrid-Electric.jpg 1080w\" sizes=\"auto, (max-width: 615px) 100vw, 615px\" \/><\/p>\n<p>The students first endured the design judging and static events achieving the coveted &#8220;technical inspection&#8221; sticker.\u00a0 Next came the dynamic events and the WPI vehicle, named &#8220;Purple Haze&#8221;,\u00a0 performed beautifully.\u00a0 Finally on the last day, WPI&#8217;s first electric vehicle finished all 40 laps of endurance.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-large wp-image-13404\" src=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Excellence-in-Electric-Vehicle-Engineering-461x615.jpg\" alt=\"\" width=\"461\" height=\"615\" srcset=\"https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Excellence-in-Electric-Vehicle-Engineering-461x615.jpg 461w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Excellence-in-Electric-Vehicle-Engineering-225x300.jpg 225w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Excellence-in-Electric-Vehicle-Engineering-768x1024.jpg 768w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Excellence-in-Electric-Vehicle-Engineering-728x971.jpg 728w, https:\/\/blog-assets.solidworks.com\/uploads\/sites\/3\/Excellence-in-Electric-Vehicle-Engineering.jpg 843w\" sizes=\"auto, (max-width: 461px) 100vw, 461px\" \/><\/p>\n<p>WPI&#8217;s first Formula Electric vehicle achieved 4th place overall and won the <a href=\"https:\/\/www.ieee.org\/\">IEEE<\/a> Advanced Technology for Humanity Excellence in Electrical Vehicle Engineering award.<\/p>\n<p>Thank you WPI FSAE engineers for inspiring all of us to persevere and design well.\u00a0 \u00a0Proud Alum, Marie (MSME &#8211; WPI)<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>In 2019, WPI Engineers had passion to build a competitive FSAE vehicle for Formula SAE Michigan.\u00a0 What they didn&#8217;t have is space.\u00a0 Assigned the former machinist&#8217;s closet\u00a0 the team successfully converted the space to design, build, test, widen the closet<\/p>\n... <a href=\"https:\/\/blogs.solidworks.com\/teacher\/2022\/05\/wpi-engineers-build-fsae-car-for-competition-in-a-closet-and-succeed-at-formula-hybrid-electric.html\">Continued<\/a>","protected":false},"author":84,"featured_media":13416,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[5381,5499,5201,4015,4344,5211],"tags":[7095,7094,4064,3925,3931,4290,4219,7096],"class_list":["post-13393","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-cad-2","category-competitions","category-electrical-2","category-mechanical-engineering","category-sustainability","category-technology-2","tag-formula-hybrid-electric","tag-formula-sae-electric","tag-fsae","tag-simulation","tag-solidworks","tag-solidworks-simulation","tag-wpi","tag-wpi-fsae"],"acf":[],"_links":{"self":[{"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/posts\/13393","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/users\/84"}],"replies":[{"embeddable":true,"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/comments?post=13393"}],"version-history":[{"count":20,"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/posts\/13393\/revisions"}],"predecessor-version":[{"id":13434,"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/posts\/13393\/revisions\/13434"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/media\/13416"}],"wp:attachment":[{"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/media?parent=13393"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/categories?post=13393"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/blogs.solidworks.com\/teacher\/wp-json\/wp\/v2\/tags?post=13393"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}