This document describes a torque vectoring series plug-in hybrid electric vehicle (PHEV) with the following key specifications: - It can accelerate from 50-70 mph in 2.9 seconds, with a top speed of 85 mph and an electric range of 50 miles. - It has a power output of 536 hp and torque of 3098 lb-ft. - It uses torque vectoring and a fully electric drivetrain for propulsion.

1. James Goin and Hunter Goforth
Electrical and Computer
Engineering Presentation

2. Torque Vector Series PHEV
Performance
• IVM-60mph: 5.3 s
• 50-70mph: 2.9 s
• Top speed: 137 km/h (85 mph)
• EV range: 80 km (50 miles)
• Power: 400 kW (536 hp)
• Torque: 4200 Nm (3098 lb ft)
Unique Characteristics
• Torque vectoring
• Fully electric drivetrain
FRONT
REAR
Fuel
Tank
Generator
Bosch
SMG
180
80kW
Engine:
0.8L
E85
78
kW
Gearbox
4.2:1
Gearbox
4.2:1
Motor:
Enstroj
EMRAX
268
200kW
Charger:
Brusa
NLG513
ESS:
A123
7-­‐
mod
15s3p
Kit
18.9
kWh
Motor:
Enstroj
EMRAX
268
200kW

3. LV System Design and
Integration

4. LV Harness Design Methods
Identify components and signals
– Connector assemblies
– Controls team
• GPIO/analog
• CAN
– Mechanical team
• Possible routing
• Space claim

5. LV Harness Documentation
Mentor Graphics Vesys
– Schematic design
• 12V power
• CAN communications
• Analog/digital I/O
– Routing
• Component placement
• Bus design
– Validation
• Continuity
• Simulation
– Documentation
• Signal tables

6. LV Harness Routing
RELAYS
CHARGER
RELAYS
INVERTER
GENERATOR
CABIN
ELECTRONICS ESS
MOTOR
CONTROLLER
MOTOR
CONTROLLER
COOLANT
PUMP
HSC
RELAYS
HSC
FRONT
ACCM

7. LV Harness Routing
RELAYS
CHARGER
ACCM
INVERTER
GENERATOR
CABIN
ELECTRONICS ESS
MOTOR
CONTROLLER
MOTOR
CONTROLLER
COOLANT
PUMP
HSC
RELAYS
HSC
12V
FRONT

8. RELAYS
CHARGER
RELAYS
INVERTER
GENERATOR
CABIN
ELECTRONICS ESS
MOTOR
CONTROLLER
MOTOR
CONTROLLER
COOLANT
PUMP
HSC
RELAYS
HSC
FRONT
LV Harness Protection
ACCM
Example 1
Single-harness design
• Serviceable exterior routing
• Protected under body panel

9. ACCM
LV Harness Protection
RELAYS
CHARGER
RELAYS
INVERTER
GENERATOR
CABIN
ELECTRONICS ESS
MOTOR
CONTROLLER
MOTOR
CONTROLLER
COOLANT
PUMP
HSC
RELAYS
HSC
FRONT
ACCM
Example 1
Single-harness design
• Serviceable exterior routing
• Protected under body panel
Exterior routing
• Debris from road
• Liquids
• Mounting
Passing into engine bay and trunk
• Abrasion
• Tension strain

10. ACCM
LV Harness Protection
RELAYS
CHARGER
RELAYS
INVERTER
GENERATOR
CABIN
ELECTRONICS ESS
MOTOR
CONTROLLER
MOTOR
CONTROLLER
COOLANT
PUMP
HSC
RELAYS
HSC
FRONT
ACCM
Example 2
Route to cabin electronics
• Competition required LEDs/switches
• Shifting embedded controller
• Ease of access to engine bay harness

11. CCM
LV Harness Protection
RELAYS
CHARGER
RELAYS
INVERTER
GENERATOR
CABIN
ELECTRONICS ESS
MOTOR
CONTROLLER
MOTOR
CONTROLLER
COOLANT
PUMP
HSC
RELAYS
HSC
FRONT
ACCM
Example 2
Route to cabin electronics
• Competition required LEDs/switches
• Shifting embedded controller
• Ease of access to engine bay harness
Engine
• Vibration
• Heat
Passing Into Cabin from Engine Bay
• Abrasion
• Tension and strain relief

12. LV Harness Protection
Protection Methods
• Shielded Champlain® CAN cable
• Layers of protection
• Taped wire bundle
• Split loom
• Thermal tape
• Outer layer Tesa® acrylic adhesive
Abrasion resistant
Noise damping
Temperature resistant
Strength ideal for bundling

13. LV Harness Protection
Justification
Adherence to electrical design rules for
competition:
• “SAE J1128 or J 1127 standard for wire,
automotive rated insulation”
• “Exterior routing must use split loom”
• “Protection by cable grommets at pass-
through locations”
• “Wiring cannot be installed below components
containing liquids”
• “Strain relieved and securely fastened to
prevent movement”

14. LV Fusing and Relays
12V
BaTery
Front
Fuse/Relay
Box
Radiator
Fans
Generator
Control
ACCM
HVIL
CompeYYon
LEDs
Front
Cooling
Pump
Rear
Fuse/Relay
Box
HSC
BMS
Motor
Controllers
Rear
Cooling
Pump
Team-added components

15. LV Fusing
• Multiplexed Vehicle Electrical Center (MVEC)
– Power distribution slave module
– CAN controlled
– 8 relays and 16 fuses
– 30 A per output pin
– 200 A maximum rating
– 2 MVECs used

16. LV Fabrication Methods
• Champlain EXRAD 150UT Powertrain Wire
• Best practices for
– Crimping
– Soldering
– Strain relief
– Packaging
– Shielding
– Abrasion / thermal protection methods
– NASA guidelines
• Weekly training workshop

17. LV Validation Methods
Hardware-in-the-Loop (HIL) Testbench
– Fabricated harnesses testbenched with dSPACE HIL
Simulator
– Determines potential harness connection faults
– Confirms component functionality

18. LV Design
Planned but un-
integrated LV
harness locations
Motor
controllers
RouYng
from
engine
bay
to
rear
Full integration of LV
harnesses part of Vehicle
Development Process Year 3

19. LV Integration
Engine Bay
Engine
MVEC
Inverter/Converter

20. LV Integration
Split
loom
conduit
• Abrasion
resistance
• Protects
from
liquids,
debris
• SYffness
preserves
bend
radius

21. LV Integration
Adhesive
thermal
padding
and
grommet
for
pass-­‐through
• Provides
sealing
of
cabin
from
engine
bay
• Protects
harness
at
point
of
pass-­‐through
• Restricts
harness
movement

22. LV Integration
LV
routed
away
from
HV
• Avoid
harmful
EMI
issues
• Simplifies
rouYng

23. LV Integration
LV
routed
away
from
liquid
holding
components
• No
risk
of
spillage
on
electronics

24. HV System Design and
Integration

25. HV Component Location
Component
• Energy Storage System (ESS): A123
7 module 15s3p LiFePo4 battery
pack.
Front
Energy
Storage
System
(ESS)
Requirements
• Simpler space claim
• Simplified routing
• Improved consumer acceptability
• Protection
Tradeoffs
• Less accessible for maintenance

26. Requirements
• Allows torque-vectored design
• Controller/inverter near motors,
simplified routings
Tradeoffs
• Weight distribution
HV Component Location
Component
• Motors: EMRAX 268 200kW motors
• Inverters: Bamocar D3 motor
controller / inverter
Motor
Energy
Storage
System
(ESS)
Motor
Inverter
Inverter
Front

27. Requirements
• Space claim with ESS location
• Weight distribution
Tradeoffs
• Heat/vibration/noise near other
components
HV Component Location
Component
• Engine: 800 cc E85
• Motor: Bosch SMG 180
Motor
Energy
Storage
System
(ESS)
Motor
Inverter
Inverter
Motor
Engine
Front

28. Requirements
• Gensert proximity to engine
• Proximity to 12V batter
Tradeoffs
• Must route more connections
through junction box
• Less room for additional
components in engine bay
HV Component Location
Component
• Inverter: INVCON generator
controller / inverter with built in
12V DC / DC converter and ACCM
power.
Motor
Energy
Storage
System
(ESS)
Motor
Inverter
Inverter
Motor
Inverter
Engine
Front

29. Requirements
• Proximity to front junction box for
routing
• More trunk space
Tradeoffs
• Proximity to engine
• Long route to ESS
HV Component Location
Component
• Charger: Brusa NLG513 liquid
cooled
• Charge port: Chevrolet Volt charge
port
Motor
Energy
Storage
System
(ESS)
Motor
Inverter
Inverter
Charger
Motor
Charge
Port
Inverter
Engine
Front

30. Requirements
• More trunk space
• Protection
• Easy routing to front junction box
Tradeoffs
• Heat/vibration from engine
• More HV routing in engine bay
HV Component Location
Component
• Automatic Climate Control Module
(ACCM): Denso ES34 electric
compressor
Motor
Energy
Storage
System
(ESS)
Motor
Inverter
Inverter
Charger
Motor
ACCM
Charge
Port
Inverter
Engine
Front

31. Requirements
• Appropriate fusing
• Simplified HV routing
• Protection of fuses
Tradeoffs
• Less space in engine bay, and in
rear assembly near motor
controllers and motor
Component
• Mersen UL Rate Junction Boxes
HV Component Location
Motor
Energy
Storage
System
(ESS)
Motor
Inverter
Rear
JuncYon
Box
Inverter
Front
JuncYon
Box
Charger
Motor
ACCM
Charge
Port
Inverter
Engine
Front

32. HV System Component Location

33. HV System Design
Component
Min
Voltag
e
(V)
Nominal
Voltage
(V)
Max
Voltage
(V)
Energy
Storage
System
(ESS)
263
340
378
Onboard
Charger
200
360
520
Generator
(Built
in
DC/DC
Converter)
150
370
410
AutomaYc
Climate
Control
Module
(ACCM)
200
300
420
Motors
50
320
700
Motor
Controllers
200
300
700
Voltage (V)

34. HV System Design
Component
Min
Voltag
e
(V)
Nominal
Voltage
(V)
Max
Voltage
(V)
ConCnuous
Power
(kW)
Peak
Power
(kW)
Energy
Storage
System
(ESS)
263
340
378
60
177
Onboard
Charger
200
360
520
3.7
3.7
Generator
(Built
in
DC/DC
Converter)
150
370
410
42
85
AutomaYc
Climate
Control
Module
(ACCM)
200
300
420
8
8
Motors
50
320
700
80
200
Motor
Controllers
200
300
700
60
140

35. HV System Design
ESS
ACCM
CHARGER
TPIM
GENSET

36. HV System Design
Front
Junction
Box
Rear
Junction
Box

37. HV System Integration
• HV Junction Box Design
– Mersen Design Reviews
• 80+ hours of design review
• UL certification for final design
• Confirmation of simulation data
• Components sent from Mersen, students assembled boxes

38. HV System Integration
• HV Junction Box Design
– Humidity and temperature
– Heat generated
– Vibration
– Creepage and clearance
– Isolation
– Serviceability
– Optimized wire routing
– Minimal size

39. • Champlain EXRAD XLE
shielded cable
• Best practices for
• Wire sizing
• Crimping
• Soldering
• Insulating
• Strain relief / bend radius
• Shielding
• Abrasion / thermal protection
Methods
• NASA guidelines
• Training workshops
HV Fabrication

40. HV Validation
– Creepage/clearance
– Resistivity of connections
– Isolation resistance testing
– Ground fault detection
– Bus ripple
– Bus bleed-down
Ripple
Analysi
s
Frequency (Hz) 5,570.42 10,345.07 19,098.59
Voltage Ripple (V) 5 6 4
Current Ripple (A) 6 8 2

41. HV System Integration
Engine Bay
Design vs. Integration:
Rotation of junction box
180 degrees to fit bend
radius

42. HV System Integration
Front Junction Box

43. HV System Integration
Front Rear
Engine Bay to Rear Subframe
Design vs. Integration: Routing between fuel tank and
transmission tunnel to ensure HV is not lowest point on vehicle
and avoid routing underneath liquid-holding components.

44. HV System Integration
Bamocar Motor Controller/Inverter

45. HV System Integration
Rear Junction Box, Motors, ESS

46. HV System Integration
3-Phase Traction Motor Terminals

47. HV Fuse Overview
Load Conditions
• Nominal and peak current
• Operating voltage
• Load Type (capacitive or resistive)
Source Conditions
• Power output
• Ambient temperature (derating)
• Short-circuit current (I2t analysis)
• Intended cycle life
Standards
• UL certified
• IEC 60269 standard
• Mersen design reviews

48. HV Wire Overview
Exrad XLE Cable Specifications
• High voltage and current
• Automotive grade
• High dielectric insulation
• High temperature tolerance
• High bend radius
• Shielded (reduce EMI)
• Orange
Conditions
• Fuse blows before cable fails
Standards
• UL 758 and ISO 6722 accordance
• SAE certified

49. Selection Overview
Note: load profiles approximated from supplier specification sheet
Component Fuse
Size
(A)
Wire
Gauge
(AWG)
Wire
Ampacity
(A)
Nominal
Current
(A)
Peak
Current
(A)
Charger 12 10
Shielded 80 12.25
12.75
Genset
Inverter 300 1/0
Shielded 339 210 400
TPIM
(Inverter) 200 1/0
Shielded 339 200 400
ACCM 20 10
Shielded 80 12.5 25.6
Junction
Fuse 350 1/0
Shielded 339 250 500
ESS 350 1/0
Shielded 339 230 690

50. ESS Example
ESS
• V = 375 VDC
• R = 0.05 Ω
• isc= 7.34 kA
Fuse
• 350 A rated
• Δtpeak >> 100 s
• Max V = 700 VDC
• Max isc = 100 kA
Dual Motors
• iavg = 230 A
• ipeak = 690A
• Δtpeak = 10 s
Requirements
• Capacitive load = time delay fuse to prevent nuisance blows
• 1.5 x 230 A (nominal) ≈ 350 A (rule of thumb)
• Allowed time at peak current:
• 10 s (Motor Δtpeak ) < 150 s (fuse) < 300 s (cable)
• Max voltage
• 375 VDC (ESS) < 700 VDC (fuse) < 1000 VDC (cable)
• Short circuit current
• 7.34 kA (ESS) < 100 kA (fuse)
1/0 Cable
LoadSource
1/0 Cable

51. ESS Fuse
350 A Fuse Specification
Model: Mersen A70QS350
• Type: Time Delay
• Max Voltage: 700 VDC
• Impulse: 100 kA I.R
• Temperature: 25°C
Paramete
r
Current
(A)
Melt Time
(s)
Nominal 230 >> 100
Peak 690 >> 100
Extreme 1500 3
Short
Circuit 7.3k < 0.01
Nominal
230A
Peak
690A
Extreme
1500A
3 s

52. ESS Design and
Implementation

53. ESS Design
Trunk Installation
• Rugged lid
• Easy to access MSD

54. ESS Design
Trunk Installation
• Rugged lid
• Easy to access MSD
Two-tier Design
• Simplified packaging
• Improved routing
• Serviceable hardware
shelf

55. ESS Design
Trunk Installation
• Rugged lid
• Easy to access MSD
Two-tier Design
• Simplified packaging
• Improved routing
• Serviceable hardware
shelf
Routing
• Serviceable
• Minimizes EMI noise
• Bus bars
• Connectors route
easily to rear junction
box

56. ESS Design
350V Output
• Finger-proof
• Pluggable
• HVIL
• Simplified routing

57. ESS Design
350V Output

58. ESS Design
Separation of HV and LV on shelf to minimize EMI risk

59. ESS Design
Separation of HV and LV on shelf to minimize EMI risk

60. ESS Design
Separation of HV and LV on shelf to minimize EMI risk

61. ESS Design
Separation of HV and LV on shelf to minimize EMI risk

62. ESS Integration

63. ESS Integration

64. ESS Integration
Design vs. Integration: Extra length in wire
runs to meet bend radius

65. ESS Integration
Design vs. Integration: Additional quick-
disconnects to remove shelf

66. ESS Integration
Bus bars and finger-proof covers

67. ESS Integration
Pluggable, rotating HV connectors

68. ESS Integration
Design vs. Integration
Bottom of trunk
Aluminum ESS
enclosure
Interior connection

69. ESS Integration
6mm clearance
NYSR: 12.7 mm
(>300V)

70. ESS Integration
Design vs. Integration
Bottom of trunk
ESS enclosure
(conductive)
Lug connection
Acrylic
Spacer

71. ESS Integration
Design vs. Integration
Acrylic
Spacer

72. ESS Integration

73. ESS Integration

74. ESS Integration
Design vs. Integration: Moving lugs to maintain clearance from lid

75. ESS Integration
Design vs. Integration: Moving lugs to maintain clearance from lid

76. ESS Integration
Design vs. Integration: Moving lugs to maintain clearance from lid

77. ESS Integration
Design vs. Integration: Moving lugs to maintain clearance from lid

79. Questions?