2022 - 2024 Electrical VDR Documentation

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5.2.C Electrical Report

An electrical system technical report must be submitted to Headquarters as part of the Vehicle Design Report by the date indicated in Reg. 4.3.A.2. The tech report must document the electrical design approach. The tech report must include:

5.2.C.1 A functional system diagram and rough schematic showing all essential power circuits and electrical equipment, including the Solar Array of the solar car in schematic form. The drawing should include power generation devices (array, regen, etc.), power storage (batteries, etc.), Main Power Switching and isolation mechanisms, battery protection systems, motor, motor controller, Battery Fuse and any auxiliary circuits. MOVs must also include the details for their onboard charging systems, and must provide details on methods of securing the battery inside the car for impound purposes. Provide system power requirements, fuse specification sheet, high power wiring specification to support fuse & wiring selection. Anything not presented from Reg. 5.1.A.7 PVDR is also required in this report.

5.2.C.2 Battery Approval Forms for each battery type

5.2.D Battery Report

All storage batteries used in the solar car must be approved by Headquarters. The battery tech report must be submitted to Headquarters as part of the Vehicle Design Report by the date indicated in Reg. 4.3.A.2. Mass and cost will be based on manufacturer’s data. If a team wishes to use actual cell weights instead of data sheet weight, the procedure in Appendix M shall be used. If an intermediate supplier is used, submit only the cell manufacturer’s data as required on the Battery Approval Form. Battery Approval Forms shall be provided on the ASC Website, and in Appendix H. Please note the definitions included in Reg. 8.3.A. Each team must provide a copy of the manufacturer’s battery specification sheet, the Material Safety Data Sheet (MSDS) obtained from the battery manufacturer, and a battery approval form with the following battery information in the tech report:

5.2.D.1 Manufacturer’s name, contact information, and Cell Specification URL for the cell Manufacturer and MSDS.

5.2.D.2 Stock number, type, or description

5.2.D.3 Cell & Module voltage (e.g., 1.2, 4, 6, 12, or 24 V)

5.2.D.4 Bus voltage

5.2.D.5 Number of cells per module, modules per strings, strings in parallel, and total cell count 5.2.D.6 Manufacturer’s specifications, including capacity (kWh), weight (kg), and cost (US$)

5.2.D.7 Spill/damage protocols and procedures (if these are not provided in the MSDS then the team must obtain this information from the manufacturer and submit it to Headquarters with the MSDS)

5.2.D.8 A description of the battery box(es) and their mounting. Include the chemical compatibility of the box material and the electrolyte in case of leakage

5.2.D.9 Battery Approval Form for each battery type

5.2.D.10 Description of emergency procedures for a fire in the solar car that is noticed from the chase vehicle.

5.2.E Battery Protection Report

All batteries must be protected with technology appropriate to the chemistry used. The battery protection tech report must be submitted to Headquarters as part of the Vehicle Design Report by the date indicated in Reg. 4.3.A.2. The tech report must document the design approach used with respect to Reg. 8.3 including the following information:

5.2.E.1 Battery Approval Forms for each battery type

5.2.E.2 Battery pack configuration including cells per module, modules per strings, strings in parallel, and total cell count

5.2.E.3 Over temperature set points (charge and discharge if different) for each battery type

5.2.E.4 Under voltage set point for each battery type

5.2.E.5 Over voltage set point for each battery type

5.2.E.6 Over current set point for each (charge and discharge if different) battery type

5.2.E.7 Block diagram for BPS and component within battery enclosures for each battery type

5.2.E.8 Description of how the BPS will operate for start-up and fault conditions for each battery type

5.2.E.9 How firmware or settings will be rendered static and un-modifiable after inspection (i.e. sealed in battery enclosure)

5.2.E.10 Describe function of driver dash and BPS fault strobe for External Cutoff switch, ref. Reg. 8.6.C

5.2.F Solar Cell Report

Solar cell tech reports must be submitted to Headquarters as part of the Vehicle Design Report by Reg. 4.3.A.2. Each team must provide a copy of the manufacturer’s solar cell specification sheet with the following solar cell information in the tech report:

5.2.F.1 Manufacturer’s name and contact information

5.2.F.2 Stock number, type, or description

5.2.F.3 Manufacturer’s quote for cell area (cm2)

5.2.F.4 Manufacturer’s quote for performance

5.2.F.5 Cell area (cm2)

5.2.F.6 A detailed layout map of the vehicle, showing all cell types/sizes and locations, as well as calculations of total area