FSAE Electrical Rules

What counts as a HV System?

>60V DC or 25V AC (RMS)

What is Galvanic Separation?

Isolation between circuits that prevents current from flowing between them, even if info is shared between them in other ways (such as through capacitance, inductance, etc).

Is the tractive system motor allowed to be connected directly to the accumulator?

No, must be connected through the motor controller

What is the maximum power draw from the accumulator?

80kW

What is the maximum voltage between any two points in the tractive system?

600V

How is the max power and voltage checked by the event organizers?

Through the Energy Meter provided by the event

What counts as a "violation"?

When the power or voltage values are exceeded either: a) continuously for over 100ms b) at all after a moving average over 500ms is applied

What is the penalty for a violation?

Best run of the team eliminated, or 60s penalty in endurance, plus add'l penalties at discretion of organizer up to DQ

What is the main restriction on drive-by-wire?

The algorithm may only LOWER the drive torque requested by the driver, it cannot increase the torque request

What is the brake pedal plausibility test?

Power to the motors must be shut down if the mechanical brakes are actuated and the accelerator pedal is at 25% pedal travel or more. Power must remain off until the accelerator pedal position drops below 5%, regardless of whether the brakes are still actuated

What is the maximum voltage and energy allowed in each segment of the accumulator?

120V, 6MJ

What voltage must every wire in the accumulator container (regardless of whether or not it is in the high current path) be rated to?

the max voltage of the accumulator

How many accumulator isolation relays are required?

Min. two

What is the maximum accum. cell temperature?

60deg C or max on the datasheet, whichever is lower

Where must the temperature on the cell be measured?

At the negative terminal on the terminal or the bus bar (if on bus bar, less than 10mm from the terminal)

What is the minimum number of cells that must have their temperature monitored by the AMS (BMS)?

20% for Lithium Ion, equally distributed through the pack

If the temp or cell voltages are exceeded, what must happen?

The AMS must open the AIRs (Accumulator Isolation Relays) and Red LED must turn on in the cockpit

All electrically conductive parts of the vehicle (parts made of steel, (anodized) aluminum, any other metal parts, etc.) which are within 100 mm of any Tractive System component must have a resistance below what?

300 mOhms

All parts of the vehicle which may become electrically conductive (completely coated metal parts, carbon fiber parts, etc.) which are within 100 mm of any tractive system, must have a resistance below what?

5 Ohms

Where must tractive system measuring points be placed?

Two on positive/negative inverter supply lines

Two on charger output lines

Physically, what should tractive system measuring points look like? How should they be enclosed?

Red 4mm shrouded banana jacks

Marked HV+ and HV-

Enclosed by nonconductive housing that can be opened WITHOUT tools

What value resistance should the tractive system measuring point have?

Vmax<=200V --> 5kOhm

200 -400V Vmax --> 10kOhm

400-600V Vmax --> 15kOhm

What should the system ground measuring point look like/how should it be enclosed?

Black 4mm shrouded banana jack, marked GND, next to tractive system measuring point

It must not be possible to touch any tractive system connections (wires etc) with a ___ mm long, ___ mm diameter test probe when the tractive system enclosures are in place.

100mm long, 6mm diameter

What IP rating should tractive system components and containers be rates to?

IP65 recommended, but actual rule is that it "must be protected from moisture in the form of rain or puddles"

What is the minimum insulation material temp rating?

90deg Celsius

Wires must be marked with ____

wire gauge, temperature rating, and insulation voltage rating. (serial number is sufficient if provided with a datasheet)

What is the minimum temp rating for tractive system cables?

90deg Celsius

All tractive system wiring that runs outside of electrical enclosures must be enclosed in _____

separate orange nonconductive conduit or use an orange shielded cable