Low-Voltage Control Circuits of Formula Student Electric Racing Cars

Darwish, Ahmed and Sfranciog, Stefan and Hiranoyama, Jorge Takeshi and Ibarrola, Jaime Lacasta and Engstrom, James and Mikhail, Kirollos and Hartley, Joshua and Hunt, William and Nasr Esfahani, Fatemeh and Dexter, Amos (2024) Low-Voltage Control Circuits of Formula Student Electric Racing Cars. Hardware, 2 (3): 3. pp. 190-222. ISSN 2813-6640

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Abstract

Formula Student (FS) competitions aim to prepare and encourage engineering students to participate in the progression of automotive and motorsport industries. The built racing cars adhere to strict regulations set by competition guidelines to ensure the safety of both teams and spectators. For electric racing cars, the high-voltage (HV) battery system usually operates within a voltage range between 100 V to 600 V to supply the motor and its controller with the required electrical power. It is essential to ensure that these components are operating effectively to minimize battery and motor current as well as to ensure efficient and reliable performance throughout the race. A low-voltage control system (LVCS), usually operating at 12 V, is used to coordinate a wide array of critical operational and safety functions to control the HV system. These functions include: (1) turning on/off procedures, (2) monitoring speed, voltage, and current, (3) interfacing with pedals, (4) controlling dashboard features, (5) managing lighting, (6) facilitating data communication, and (7) implementing safety protocols. The design and operation of the LVCS are crucial for compliance with safety regulations and enhancing the FS electric racing car (FSERC) performance. This details and discusses the design procedures of the LVCS, using the Lancaster E-Racing (LER) FSERC as a case study. The LER car employs a 400 V battery system to power a 68-kW permanent manet synchronous motor (PMSM) using a three-phase voltage source inverter. Using mathematical analysis, SIMULINK/MATLAB® computer simulations, and the experimental real-data results provided by the LER FSERC, this study seeks to offer valuable insights regarding the LVCS practical implementation and optimization.