Sem Asia Technical Webcast Slides 15mar2011

SEM GENERAL DESIGN RULES
Official Rules 2011

Chapter 1
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(height 6.5cm, width 8cm)
Shell
®
Eco-marathon
ASIA 2011
Colin Chin
Technical Lead, Shell Eco-marathon Asia 2011
Copyright of Shell Global Solutions Sdn. Bhd. March 2011 1

Agenda
1.1. Rule changes

Rule changes in SEM
in SEM 20112011
2.2. General overview

General overview of rules
of rules Chapter
Chapter 1 1
Identification
1. 2.1 Identification
Driver
2. 2.2 Driver
General
3. 2.3 rules
General rulesfor
forvehicle
vehicle design
design
Prototype
4. 2.4 Prototype
UrbanConcept
5. 2.5 UrbanConcept
6. Energy
2.6. sources
Energy sources
7. Internal combustion engines
2.7 Internal combustion engines
8. Electric motors
2.8 Electric motors
9. The event in July
3. The event in July
3. Questions & Answers
4. Questions & Answers
Back Agenda
1.0
Rule Changes in SEM 2011
Rules 2011

Back Agenda
Rule Changes (1) – Electric Mobility
 Fuel options:
 LPG fuel option removed
 Battery only („Plug-In‟) fuel option introduced
 Electric Mobility category has been introduced, which encompasses:
 Hydrogen fuel cells
 Solar
 Battery only („Plug-In‟)
 Results
 The results for Electric Mobility will be expressed in km/kW
 All other fuels (gasoline, diesel, GTL, FAME, ethanol) remain in the Internal
Combustion category, with results expressed in km/litre

Back Agenda
Article 81: Plug-In Vehicle
 Maximum 48 Volts on-board
 Only super capacitors or lithium

battery
 Battery monitoring system for
lithium battery
 Auxiliary battery to power horn,
lights, data acquisition, etc is
permitted

Back Agenda
 Joulemeter inaccessible to driver
 Joulemeter can be read from outside vehicle
 Joulemeter must measure the output of battery :

 between battery and all electrical devices required for vehicle operation
(motor control, battery control, motor, inverters, etc...) excluding mandatory
safety devices
Control Unit
Battery All speed regulation
Motor

Back Agenda
Rule Changes (2) – Internal Combustion Engines
 Article 36 & 63: Clutch and transmission

 All Clutch systems used prior to 2011 must be reviewed with respect to
whether the clutch system remains not engaged at engine start up
 Article 75: Fuel system
 No filters or valves allowed after the fuel tank
 For gasoline/ethanol teams capable of 1500 km/litre, the whole fuel system
must be removable for weighing
 Article 78: Starter
 Starter light brightness has been specified.

Back Agenda
Article 36 & 63 : Clutch and Transmission
”Vehicles with internal combustion engines must be equipped with a

clutch system, so that during inspection and fuelling operations the
vehicle remains stationary with the engine running.”
 All Clutch systems used prior to 2011 must be reviewed with respect
to whether the clutch system remains not engaged at engine start up.
This means that:
 The vehicle wheels must NOT turn when the engine is started or at
idle (with brakes not applied)
 Engines
must have an idle speed speed (RPM) less than the clutch
engagement speed (RPM)
 The starter motor speed must always be below the engagement
speed of the clutch.
March 2011 8
Back Agenda
Rule Changes (3) – UrbanConcept Vehicles
 Article 48: Dimensions

205 kg max
 Vehicle weight limit increased to (car only)
205kg (previously 160kg)

70
 Article 57/58: Wheels & tyres
 Wheel rim dimensions are now
13-17 inches (previously 16 or
17 inches)
 In e-shop Michelin 95/80 R16
D
D = Rim
diameter 13 to Tire width >
17 inches 80 mm
Back Agenda
Rule Changes (4) – Hydrogen fuel cell vehicles
 Ventilation
2 ventilation holes required for hydrogen vehicles
 Extra ventilation point (5 cm²) (engine compartment & driver compartment)
now required in driver

Ventilation
compartment (previously only in
fuel cell compartment)
 PTFE (teflon) sealing tape not Ventilation Ventilation
allowed
 Pressure
Solenoid
Pressure
H2 Cylinder shutdown
 Flow meter after all pressure regulator
valve
regulators, must run at the Fuel
Cell pressure H2 flow
meter
Run at same pressure
Fuel cell

Back Agenda
Rule Changes (5) - Emergency Shutdown Mechanism
 Article 43 & 66
 “Must be permanently installed

on all vehicles”
 i.e. not fixed on a detachable
part of body
 i.e. not on the top cover but on
the bottom part of body

Back Agenda
Emergency Shutdown Button (& Starter Light) Location
 CORRECT  WRONG
 Shut down button on permanent  Shut down button on removable
part of body part of body
 Remains fixed even if cover is  No longer part of vehicle if cover

removed is removed

Back Agenda
Rule Changes (5) - Recommendations
 Read the Rules thoroughly,
 Read the Rules thoroughly,
 ... and Read the Rules thoroughly !
 Website
 http://www.shell.com/home/content/ecomarathon/for_participants/rules
March 2011 13
Back Agenda
2.1
Identification

Back Agenda
Article 4: Identification
 For each side & front

 Shell Logo (20x20cm)
 Racing number/stickers (20x26cm) x
 For each side (lower part of 10 cm space

around Shell logo Other sponsor names/ logos
body) smaller than Shell logo
 Partner streamer (90x6cm)
 Logos
 A10 cm space on all four sides of
the Shell logo Race number Partner streamer
 Any other sponsor names/logos Shell logo
must be smaller than the Shell logo

Back Agenda
Article 4: Identification Examples

Back Agenda
Identification of driver coveralls
 These rules apply to drivers when they are on track
Shell pecten
placed at chest
level on the right
side Shell Eco-
marathon logo
placed at chest
level over the
heart

Back Agenda
2.2
Driver

Back Agenda
Article 21: Driver Weight
 Driver weight
Prototype
 In full driving gear – helmet, 50
gloves
 50 kg minimum for Prototype
 70 kg minimum for
Urban
UrbanConcept Concept 70
 Ballast provided by team

 Must be secured
 For UC cars: part of luggage
 Will be weighed before and
after each run

Back Agenda
Articles 22 & 23: Driver Attire
 Article 22: Helmet

 Proper motorcycle helmet
 Not bicycle helmet
 Must comply with standards
 Face shield or safety goggles
must be used
 Article 23:
 Fire retardant clothing
recommended
 Gloves and shoes mandatory
 Synthetic clothing forbidden

Back Agenda
Article 23A: Driver Comfort
 Heat
40 °C cockpit
 Cockpit temperatures of 40 °C temperature possible
are a possibility (depending on

Ventilation
vehicle design & weather).
 To avoid heat stress the
following are recommended Ventilation Ventilation
 Good ventilation
 Drinking bottle for driver
 Sunscreen / tinted windows
 Driver preparation
 Keep well hydrated
 Don‟t drive on an empty stomach Hands free drinking bottle
(firmly attached)

Back Agenda
2.3
General Rules for Vehicle Design
For both Prototype and UrbanConcept vehicles

Back Agenda
Article 27 & 50: Chassis/Monocoque Stability
 Chassis/ monocoque 70
Roll bar able to withstand
70 kgf in any direction
kgf
 Must be solid
 Wide and long enough to protect 5 cm min
5 cm min
driver
 (Foam no longer needed)
Chassis long enough
 Roll bar:
 >5 cm above helmet 70
kgf Chassis wide enough
 >5 cm above fuel tank Roll bar
 Extend beyond shoulders
 Withstand 70 kgf
70
kgf Roll bar extends
beyond shoulders

Back Agenda
Article 28 & 53: Visibility
 180° field of vision

 With the cover on
 2 mirrors each of 25
cm² min
2 mirrors 25cm2
180° field of vision

Back Agenda
Article 28 & 53: Visibility Testing
 180° visibility check

1
2
5m radius
30° 3
4
 Checking mirrors

Back Agenda
Article 41 & 64: Exhaust System
 Exhaust pipe requirements

 Exhaust pipe should exit the
vehicle body
 BUT, it should not extend beyond Exhaust pipe should exit
the vehicle
the rear of the vehicle
 Emissions
 Exhaust emissions must be
Rear of body
However, it should not extend
reasonable (e.g no gross amount beyond the rear of the vehicle body
of black smoke)

Back Agenda
Article 29 & 54: Safety Belts
 5 point safety belt

 Proprietary (not self
Capable of withstanding 1.5 x driver weight
made) racing type belt
 Chassis mounting
 Single buckle
 Able to withstand 1.5x
driver weight
5 point chassis mounting
Single buckle

Back Agenda
Testing of Seat Belt Strength
 Tested by lifting with steel rod
 Force scale must register 70 kgf
70 kgf

Back Agenda
Article 30: Vehicle Access
 Exit
 Driver must exit unaided in 10
10 seconds to exit unaided
seconds
 Doors
 Door/opening should be securely
attached No adhesive tape allowed
Arrow to indicate method of opening
 No adhesive tape allowed
 No tools required for opening
 Method of opening marked by
red arrow on outside

Back Agenda
Article 31 & 61: Driver Position
 Only leg first position

is allowed
 No “head first”
position (for safety
Leg first
reasons)

Back Agenda
Article 32: Cockpit Ventilation
 See article 23A

2 ventilation holes required for hydrogen vehicles
 Adequate ventilation (engine compartment & driver compartment)
should be provided
Ventilation
especially due to the
heat in Malaysia
 For hydrogen vehicles Ventilation Ventilation

2 holes are needed:
 In the engine
compartment
 A the top of the
compartment if there is
a likelihood of
hydrogen entry

Back Agenda
Article 33: Engine Isolation & Fuel System Access
 Bulkhead Engine Driver compartment

compartment
 A permanent bulkhead must
completely separate the driver
compartment from the engine
compartment
 Fire retardant material
 Prevents driver access to engine
Permanent fire No gaps
compartment resistant bulkhead allowed
 Objective is to prevent liquids/
flames from reaching driver
 Fuel system must be accessible

for filling

Back Agenda
Article 33 – Example of Fuel System Access
 Fuel system should be accessible  Fuel system should be accessible

with a burette for fuelling with a burette

Back Agenda
Article 33: Example of Bulkhead
 Example of bulkhead  Example of bulkhead gap

Bottom part of car Big gap Body cover of car
Engine
compartment

Back Agenda
Article 33 – Example of Bulkhead Gaps
 The shape of the bulkhead should match shape of body/cover
 Gaps may be filled with aluminium foil or aluminium tape

 This will be rigorously checked during scrutineering
Not allowed OK
No gap
Cover/body
Bulk head
Bulk head
Gap Bulkhead

Back Agenda
Article 34 & 60: Horn
 A horn is mandatory
 Only the approved horn is

allowed (to ensure adequate
effectiveness) Horn
 Must be show in electrical circuit

diagram

Back Agenda
Article 35 & 52: Fire Extinguisher
Plumbed in
 Mandatory extinguisher
triggered by Handheld extinguisher
 ABC or BC type driver
 Full
 Valid at time of event
 Properly secured (not loose)

Firmly secured
 Can be plumbed in or hand-
held type
 Usage
 Driver must be trained in usage
 Exit vehicle before using hand-held
extinguisher

Back Agenda
Article 36 & 63: Clutch and Transmission
 Clutch
 To ensure that the vehicle
can stop with the engine
running (can be
immobilized at starting
line)
 Not required for electric Engine
motors Chain
 Chain guard Chain guard Clutch
 Mandatory if chain is
used (to protect
driver/technician) in
case of chain or belt
breakage

Back Agenda
Article 36 & 63: Examples
 Chain guard  Clutch

 Mandatory if chain is used (to  To ensure that the vehicle can stop
protect driver/technician) in case of with the engine running (can be
chain or belt breakage immobilized at starting line)
 Not required for electric motors
Chain
guard

Back Agenda
Article 37 & 57: Wheels, Axles, Wheel Hubs
 Wheels
Wheel securely
 Suitable for the car mounted
 Securely mounted
 Prototype:
 Any type allowed
 Urban
 Rim 13-17 inch
 > 80 mm width
D
D = Rim
diameter 13 to Tire width >
17 inches 80 mm
Back Agenda
Article 37 & 57: Wheel Bulkhead
 Wheel bulkhead
 Isolate wheel from driver
 No manipulation of wheel by driver
 Example of wheel mounting &
bulkhead 
Bulkhead to isolate wheel from driver Bulkhead to isolate wheel

(protection against manual handling/ Wheel securely from driver (protection
accidental contact) mounted against manual handling/
accidental contact)

Back Agenda
Article 38/39 Steering & Handling (Prototype)
 Steering should be precise (no Steering wheel in straight position
excessive play)
 No specific steering mechanism
 Indirect steering is permitted as

long as adequate fail safe and No excessive play. Wheels respond to slight turn
of steering wheel
backup measures are in place
 No specific turning radius, but
must be sufficient to navigate the
track
Excessive play. Wheels do not respond
immediately to slight turn of steering wheel

Back Agenda
Article 56: Steering & Handling (UrbanConcept)
 Vehicle steering typical of

production vehicles
 Must be precise, with no
excessive play, no delay
 Turning radius should be < 6 m
 Turning diameter < 12 m
 Real steering wheel
 Steering bars, tillers, joysticks,
Turning
indirect or electric systems are not diameter
<12 m
permitted
Turning radius
<6m

Back Agenda
Vehicle Handling Course
 A slalom course will be used to 5m
test the vehicle handling 5
 No speed specified
22 m
4
11 m

Back Agenda
Article 40: Brakes (Prototype)
 2 independent braking systems
 Each must be capable of being operated separately
 Hydraulic brakes recommended
 Disc or V-brake acceptable
 Ergonomical (easy driver access, without lifting hands from steering)
One system for front wheels One system for rear wheel

Back Agenda
Disc brake V-brake

Back Agenda
Not ergonomical

Back Agenda
Article 62: Brakes (UrbanConcept)
 4-disc hydraulic brake system
 X - pattern or front and rear
 Brake pedal: 5 cm x 5 cm
 Must be effective
Disc brakes Hydraulic system

Back Agenda
Article 40 & 62: Braking (Effectiveness Test)
 The 2 separate systems will be

tested separately
 Each system alone must hold the
vehicle in place (with driver on
board)
 Slope is 20% (20:100)
 Height: Length = 20:100
Height
Length

Back Agenda
Article 42 & 65: Sound Level
 Must not exceed 90 dB from 4 meters away
 Not an issue for electric motors
4m
90 dB

Back Agenda
Article 43 & 66: Emergency Shutdown Mechanism
The starter light should be shown

 Mandatory in the electrical circuit diagram
 Must stop engine and isolate Starter Starter Starter

switch motor light
battery (1) This is used only when
starting the engine so
 Show in electrical circuit diagram the starter light should Engine
light up when this is
 Additional requirements for activated Ignition coil +
spark plugs
hydrogen cars
Horn
Horn
switch
Light
Lights
switch
Other Other electrical
switches systems
Ignition
switch
1
Emergency
stop button Battery
When this is pressed the battery should be isolated from

all electrical devices and engine ignition stopped
Back Agenda
Article 43 & 66: Emergency Shutdown Mechanism
 External shut down button

mandatory
 Location of button must be
indicated by a red arrow 3cm x
10 cm
3 cm
10 cm

Back Agenda
2.4
Prototype Vehicles

Back Agenda
Prototype
 Characteristics
 3 wheels (usually)
 Driver in horizontal position (leg first)
 Limited cabin space
 Sleek & aerodynamic
 No car lights (except starter light)

Back Agenda
Article 25: Vehicle Design
 3 or 4 wheels
No sharp objects inside
 No aerodynamic appendages
 No sharp edges outside
 No sharp edges inside
3 wheels
No aerodynamic appendages No sharp edges
4 wheels

Back Agenda
Article 26: Dimensions – Prototype
50 kg max
Parameter Limits
(driver only)
Height < 100 cm 140 kg max

(car only)
< 1.25 x track width

Height < 100 cm &
Width < 130 cm
Length < 350 cm
Track width >50 cm
Height:Track width
< 1.25
ratio
Track width > 50 cm

Wheelbase > 100 cm
Width <130 cm
Maximum driver
< 50 cm
weight
Maximum vehicle
< 140 kg
weight
Wheel base 100 cm min
Length 350 cm max

Back Agenda
Article 26: Dimensions - Track Width and Width
 Track width is the distance between the centre line of the left and right
wheels
 Width is the distance between the widest parts of the whole vehicle
 2 different scenarios are shown below
Track width
Vehicle with
Width
wheels inside
Track width
Vehicle with
Width
wheels outside

Back Agenda
2.5
UrbanConcept Vehicles

Back Agenda
UrbanConcept Vehicles
 Characteristics
 4 wheels only
 Upright seating of driver
70
 Typical of road car
 Lights

Back Agenda
Article 47: General Vehicle Design
 4 running wheels only
 No sharp appendages inside or

outside the vehicle
70

Back Agenda
Article 48: Dimensions UrbanConcept
Dimension Limits
70 kg max
(driver)
Height 100-130 cm
205 kg max
Driver compartment
height >88 cm
Height 100 -130 cm
Width 120-130 cm
(car only)
Length 220-350 cm 70
Track width (front) > 100 cm
Track width (rear) > 80 cm

Ground clearance >10 cm
Wheelbase > 120 cm

Driver compartment width
Width 120 - 130 cm
at shoulders > 70 cm
Driver compartment
> 88 cm
height
Track width Track width
Driver compartment >80 cm > 100 cm
> 70 cm
width (at shoulders)
Ground clearance > 10 cm
Maximum vehicle Wheel base >120 cm

> 205 kg
weight 205 kg Vehicle length 220 - 350 cm
Back Agenda
Article 49: Vehicle Body
Roof mandatory
 Roof mandatory
Windscreen mandatory
 Windscreen mandatory
 Body
70
 The body must cover all
mechanical parts
 Commercial body not allowed No Body must cover all
aerodynamic mechanical parts
 Wings must be integral part of appendages
body (not only attached to the

wheel)
 No sharp edges 70
No sharp edges inside

No sharp edges outside

Back Agenda
Article 49: Accessories
 Accessories
 Towing hook capable of
withstanding 200 kgf
 Space for suitcase of 40 x 50 x
20cm
 Orientation does not matter
 The suitcase-like object must be Suitcase Towing hook
(2000 N)
provided by the team
20 cm
Suitcase to be
40 provided by team
cm
50 cm

Back Agenda
Article 49: Wings/Fenders
 Wings must be integral part of

body (not only attached to the
wheel)

Back Agenda
Article 49: Access
 Typical of production car
 Mandatory side door
 Easy access inside or outside
 Driver can exit in 10 seconds

without assistance
 Handles inside and outside
OK OK

Back Agenda
Article 57/58: Wheels/Tyres
 Suitable for the car D = Rim diameter 13 or 17 inches (33 -43.2 cm)
 Securely mounted
 Proper isolation from driver

D
 No manipulation by driver
allowed
 Tyre width > 80 mm
Tyre width > 80 mm
 Rim diameter 13-17 inches (33-
43.2 cm)

Back Agenda
Article 59: Lighting
 2 headlights Rear light

Brake light
Head light
Front indicator
 2 rear lights
 2 rear indicator lights
 2 front indicator lights
 2 brake lights
Starter light
 Starter light (for ICE vehicles) Rear indicator

Back Agenda
2.6
Energy sources

Back Agenda
Article 71: Battery (On-Board Battery)
 Requirements  Only one

 Enough electricity for safety  May consist of more than one
devices sub unit, but only 2 terminals
 Should be located behind the  Maximum 48 volts
bulkhead, in the engine
compartment
 Restrictions
 Not allowed to power engine
cooling fans/devices (cooling
fans can only be powered by
electricity generated by the
engine)
 May be used to power a cooling
fan for the driver
Back Agenda
Article 71: Battery Definition
 Source of electrical energy
 Only two connectors
 Comes as a single unit.

 This single unit may contain more than one sub-unit
 Maximum of 48 V
Electrical
system 1
Electrical system
48V max
Electrical
system 2
+ - + - + - + - + - + -
Sub- Sub- Sub-
Battery Battery Battery
battery battery battery
1 2 3
1 2 3
“Single” battery

Back Agenda
Article 71: Battery (Others)
There are 2 other types of batteries used in the SEM event.

 Battery to power electric motors (plug-in and solar vehicles only)
 This is separate from the on-board battery
 It‟s main function is to provide power to the power train
 A BMS (battery management system) is needed for lithium batteries
 A super capacitor may be used in place of this battery for plug-in and solar
vehicles
 External battery (hydrogen vehicles only)
 This may be used to start fuel cells only at the start line)
The same rules apply

 Max 48 V, “single” unit, 2 connections

Back Agenda
2.7
4A: Internal combustion engines

Back Agenda
Article 72: Propulsion
 The type or design of the

combustion engine is not
restricted, BUT
 Must run only on the fuel
provided by the Organisers
 Must not consume any engine oil.

Back Agenda
Article 73: Other On-board Energy Sources
 Non renewed energy (from on  No electrical pumps for fuel, oil

board battery) or water circulation systems
 May only be used for injection,  Flow/circulation only via:
ignition, starter, instrumentation,  Gravity feed
horn, EMS, emergency shut down
 Pressurized system
 If engine is water cooled
 Mechanical pump
 Only pure and unpressurised
water allowed
 No auxiliary calorific energy
source + -
 i.e. no additional fuel Battery
- +
Electric
Injector Pump

Back Agenda
Article 73: Other On-board Energy Sources
 No additional batteries or
power sources allowed
 This will result in immediate
disqualification

Back Agenda
Article 74: Fuel Tank - Requirements
 Only 1 SHELL fuel tank

 Other types of fuel tanks are NOT For gravity fed
fuel systems,
allowed drill a hole here
 If pressurized fuel system

 APAVE certification required
 Safety valve set to 5 bar max
 Hole
 Please remember to drill a hole in
the cover for gravity fed systems
(otherwise the fuel won‟t flow)
APAVE

Back Agenda
Article 74: Fuel Tank - Position
 Fuel tank position Tank should not stick out of body cover
 Inside body cover (not sticking

out)
 Must be 5 cm below the roll bar
 Vertical (not slanted) Tank should be inside body cover
 It should be positioned in such a Roll bar 5 cm
way that a 1 m long burette can

access it for fuelling and
measurement
Vertical NOT slanted

Back Agenda
Article 75: Fuel System
 Description and technical

drawing must be submitted
 Filters & valves

 No additional filters & valves on
the fuel line before the carburetor Filter
 A solenoid cut-off valve is needed Extra

valve
for diesel engines
 Must be able to be drained Carburetor / Carburetor /
injector injector
completely before inspection
Drain Drain
 Float chambers/carburetors valve valve
must have a drain valve at the

bottom
Back Agenda
Article 75: Fuel System – Fuel Line
 Fuel return line

 If there is a fuel return line it must
return below the fuel tank
 Fuel circuit
Fuel return
 Semi rigid, translucent hoses line
 2 sizes provided by Shell with OD

and ID of tubing are 8X6 and
6X4 mm respectively Carburetor Carburetor
Engine Engine
/ injector / injector

Back Agenda
Typical Pressurized Fuel Injection System
 Components required: Pressurized Air line (translucent)

bottle
 Translucent compressed air bottle
Air pump Pressurization valve
 Pressurization & pressure
Safety valve (5 bar)
adjustment valve
 Safety valve set to 5 bars max Pressure gauge
 Pressure gauge with normal Pressure

regulator
operating pressure marked
Pressure gauge
 The driver must not modify the
pressure during the competition
Fuel line (translucent)

Injector

Back Agenda
Examples - Pressurized Fuel Injection Systems

Back Agenda
Article 75: Fuel System
 Air intake manifolds:

 No fuel or blow by gas
 No blow by gas recycling
 Fuel temperature
 The fuel cannot be heated or
cooled
 If capable of >1500 km/l

 Entire fuel system should be
removable for weighing

Back Agenda
Article 77: Hybrid Vehicles
 Hybrid technology is only for

use in combination with internal
combustion engines
 A super capacitor (not a
battery) must be used to store
the recovered/ generated
energy
 Maximum voltage 48 V
 2 external connectors must be
provided to measure the voltage
of the super capacitor
 The entire electrical circuitry
must be fused
Back Agenda
Article 78: Starter
 The starter motor should not

provide any forward propulsion
to the vehicle
 When used it should be indicated
by a red starter light placed
outside the vehicle
 Exceptions for mechanical/hand
pulled starters
Red starter light should
 The starter light should be located at be clearly visible from
both sides of the track
the rear end of the car and visible (ideally should be on rear
from both sides of the track of vehicle)
 If possible it should be located on a

permanent part of the vehicle body
(like the emergency shutdown button)

Back Agenda
Article 78: Starter - Starter Light Clarification
The starter light should be shown

 Role of the starter light in the electrical circuit diagram
1
 Used to indicate when the Starter Starter Starter
switch motor light
electrical starter motor (if present) This is used only when
is switched on starting the engine so
the starter light should Engine
light up when this is
 Therefore it should be connected to activated Ignition coil +
2
the starter motor (1) spark plugs
 If no electrical starter motor is used, Horn

Horn
switch
then there should be no starter light.
Light
Lights
switch
 NOT used to indicate that the
Other Other electrical
engine is running (2) switches systems
 For internal combustion engines Ignition

switch
vehicles only
Emergency
stop button Battery
When this is pressed the battery should be isolated from

all electrical devices and engine ignition stopped
Back Agenda
2.8
4B: Electric Motors

Back Agenda
Article 79: Hydrogen
 Component sequence:  Shutdown mechanism

 Hydrogen tank  Hydrogen sensor (@ 1% H2)
 Pressure regulator linked to shutdown mechanism
 Solenoid shutdown valve  Shuts both solenoid valve & motor
 Hydrogen flowmeter  Shut down by either H2 leakage,

driver button or external button
 Fuel cell

Back Agenda
Article 79: Hydrogen - Example of Hydrogen System
Fuel cell vehicle should have the following features

 Note the sequence of the fuel system
Fuel system
Solenoid Purge (if

H2 Pressure H2 flow
shutdown Fuel cell present) outside
Cylinder regulator meter
valve vehicle
Shutdown mechanism activated Electrical storage

LEGEND
Hydrogen by either: (if present) should
Hydrogen
Electricity be Super
Electricity
Shutdown control capacitor only
Shutdown control Hydrogen sensor
Manual shutdown button Motorization

Shutdown Relay
(driver)
External shut down

button (with label) Motor

Back Agenda
 Electrical system
 On-board battery
 Cannot be used compressors, pumps or cooling components
 Is only for emergency shutdown, horn, lights
 Electrical/electronic casings must be transparent
 If fuel cell electricity is to be stored
 A super capacitor is mandatory
 2 external connections for measuring the super capacitor are necessary
Please bring a drawing of the

fuel and electrical systems to the
event
Back Agenda
Article 79: Hydrogen – Super Capacitor & Fuel Cell
 Super capacitor  Fuel cell

 Max 48 V  Max 48 V
 Fuse on +ve terminal  Fuse on +ve terminal
 Amps = 1000 W/voltage [UrbanC]  Amps = active area of 1 cell (cm²)
 Amps = 300 W/voltage [Prototype]
+
Prototype A = 300/V
-
A = S Amps
+
70
UrbanConcept A = 1000/V S = active surface area of one
-
cell in stack (in cm2)

Back Agenda
Article 79: Hydrogen – Flow Meter
 Hydrogen flowmeter  Teflon tape & Loctite must not be

 Will be calibrated before the used
event  These will actually damage the flow
meter as they could block the flow
 Must be visible from outside (with
over the sensor
the car cover on)
 Compression seal plus taper
coupling are sufficient to ensure
good sealing.
Coupling with Coupling
taper fitting with ferrule

Back Agenda
Article 79: Hydrogen – Flow Meter Location
 Flow meters must be readable from outside car (with cover on)
Flow meter visible Inacessible flow meter

from outside (deep inside vehicle)

Back Agenda
 Ventilation  Materials
 Ventilation hole of 5 cm² at  Piping and fittings appropriate
highest point of fuel cell for hydrogen (stainless steel if
compartment >1.5bar abs). Evidence must be
 Also applies to driver available.
compartment if hydrogen can go  Hydrogen storage (Shell supplied
there cylinder - Catalina MD)
 No oxygen or compressed air
reserves

Back Agenda
Article 80: Solar
 Electrical systems  Energy consumption measured

 Batteries/super capacitor using joulemeters
 Battery monitoring system for  Only cars that produce more
lithium polymer battery energy than consumed will be
classified
 Electric current
 <50 A permanent
 <150 A peak)
 Voltage < 48V
 Includes solar panel, super
capacitor and battery

Back Agenda
Article 80: Solar - Joulemeters
 Joulemeters
 Must have 2 labelled joulemeters (for solar panel & motor)
 Must be inaccessible to driver
 Able to be read from outside vehicle (with the cover on)
 Joulemeter configurations
1 joulemeter between solar panel and battery 1 joulemeter between battery and motor
Battery Motor
Battery Panel

Back Agenda
Article 80: Solar - Joulemeter Location
 Joulemeters must be readable from outside car (with cover on)
Joulemeter visible Inacessible joulemeter

from outside (deep inside vehicle)

Back Agenda
 Maximum 48 Volts on-board
 Only super capacitors or lithium

battery
 Battery monitoring system for
lithium battery
 Auxiliary battery to power horn,
lights, data acquisition, etc is
permitted

Back Agenda
Article 81: Plug-In Vehicle - Joulemeter
 Joulemeter must
 Be inaccessible to driver
 Be readable from outside vehicle
 Measure output of battery – between
battery & all electrical devices required
for vehicle operation (motor control,
battery control, motor, inverters, etc...)
excluding mandatory safety devices
Control Unit
All speed
Battery
Motor regulation

Back Agenda
Final Comments
 This slide pack does not replace Chapter 1 of the Rules & Regulations.
 It is meant only as a guide to assist in visualizing specific items
 You are advised to go through the articles in Chapter 1, one by one and
ensure that your vehicle complies with each rule.
 Key areas to be aware of are:
 Roll bar (strength and clearance to helmet)
 Bulkhead (no gaps)
 Bulkhead between tyres and driver
 Brakes (must work properly)
 Chain guard
 Make sure your chains are strong enough (lots of chains broke in 2010)
 Cars that are unsafe will not be allowed on track

Back Agenda
3.0
The Event in July

Back Agenda
Race Format
 4 laps  The organizers reserve the right
 Number of attempts: 5 to make changes to the race

format during the event in the
 Time limits - 28 and 23 minutes
interest of driver safety
for the UrbanConcept and
Prototype cars respectively
 UrbanConcept car to stop 3 x
10 seconds
 No driver change
Race Format
Distance Average Pit stop 1 Pit stop 2 Pit stop 3 Time Number
Number covered Speed (end of Lap 1) (end of Lap 2) (end of Lap 3) limit Driver
Vehicle Category of
of laps change
attempts
km km/h seconds seconds seconds minutes
UrbanConcept 4 11.2 25 10 10 10 28 5 None
Prototype 4 11.2 30 - - - 23 5 None
Back Agenda
What‟s Next
 A separate webcast will be held to explain

 The processes at the event (scrutineering, practice, competition)
 Details about the track and venue
 Good luck in your preparations & see you in Sepang

Back Agenda
Q&A

Back Agenda
Back Agenda

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SEM GENERAL DESIGN RULES

Official Rules 2011

Use this area for cover image

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 1

1.1. Rule changes

2.2. General overview

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 3

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 Maximum 48 Volts on-board

 Only super capacitors or lithium

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 5

 Joulemeter inaccessible to driver

 Joulemeter can be read from outside vehicle

 Joulemeter must measure the output of battery :

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 6

 Article 36 & 63: Clutch and transmission

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”Vehicles with internal combustion engines must be equipped with a

 Article 48: Dimensions

205kg (previously 160kg)

now required in driver

Run at same pressure

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 10

 “Must be permanently installed

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 Remains fixed even if cover is  No longer part of vehicle if cover

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 Read the Rules thoroughly,

 Read the Rules thoroughly,

 ... and Read the Rules thoroughly !

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 14

 For each side & front

 For each side (lower part of 10 cm space

 Partner streamer (90x6cm)

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 15

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 These rules apply to drivers when they are on track

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 Ballast provided by team

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 Article 22: Helmet

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are a possibility (depending on

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For both Prototype and UrbanConcept vehicles

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Chassis long enough

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 180° field of vision

180° field of vision

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 180° visibility check

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 Exhaust pipe requirements

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 5 point safety belt

5 point chassis mounting

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 Tested by lifting with steel rod

 Force scale must register 70 kgf

Copyright of Shell Global Solutions Sdn. Bhd. March 2011 28