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PROTON Green Mobility Challenge 2012

PGMC2012 is an initiative of PROTON, together with Agensi Inovasi Malaysia, to promote electric vehicles. Teams compete to build the best performing EV based on a standard 2nd generation Proton Saga.

Day 2: Fastest Time & V-Max

In the afternoon, two challenges were held together: Challenge 2: Fastest Time for 2 Laps and Challenge 3: V-Max

Day 2: Pit Walk

In between Challenge 1 and Challenge 2 & 3, the organisers provided some time for a pit walk session. Spectators are allowed to go into the pits to mix with team members and look closely at the electric cars.

Day 2: Quarter Mile Acceleration

The second day is the day of 'performance' challenges. It started with the scrutinising and safety inspection of the cars. Then, Challenge 1: Quarter Mile Acceleration starts.

Day 1: Pit Display

While most of the team work on the car, some members focused on sprucing up the pit. This is because there are also prizes on team identity and pit display.

Day 1: Registration & Practice

It's October 5th, and finally, we're in SIC. The first day started with the registration and scrutinising of all 10 cars by the PGMC 2012 TC. Only four team members were allowed to be present during the inspection.

Battery Management System

When using batteries as the power source, a battery management system (BMS) is very important. We use the Orion Li-Ion BMS.

Chargers

As an electric vehicle, the batteries used in the car has to be charged from time to time. The 12 V lead-acid car battery also has to be charged while the car is running.

Thermal Imaging

In order to get an idea of where the hottest and coolest parts of the components might be, we made use of a thermal imager.

Saga Model Incompatibility

When PROTON initially gave us the car, it was a Saga BLM 1.3 model. However for this competition, PROTON then decides to standardise the cars, based on the Saga BLM 1.6 model.

Controller Programming

The motor controller given to us was preprogrammed. To win a race however, one has to evaluate the objective of the race and tune the controller accordingly.

Track Familiarization Day

On 17 September, teams were again invited to the Sepang International Circuit, where the challenge will be held, for driver circuit familiarization.

Thermal Management

Thermal management consists of the management of heat dissipation of the motor, motor controller and lithium-ion batteries with different methods.

Test Drive

The I.C.E. Terminator EV is moving!

Completing The Circuit

With the new electric engine in place, we reconnect all the wires and install the vacuum pump. Put the tyres back on and it's system go.

Mounting

We have had some problem with adapting the transmission to fit the motor and the car. But finally, we got the parts together and mounted the new electric engine.

Battery Compartment

For the purpose of safety and thermal management, the batteries must be enclosed in some sort of compartment.

Component Assembly

The concept of ICEV to EV conversion is simple enough where the original engine is to be replaced with the electric motor provided by the organizer.

Third Progress Update

Following the previous visit, PROTON and the PGMC2012 Technical Committee visit the teams again for the third progress update. They visited us on 14 August.

In-Car Wiring

Now that the car and its electrical engine system are together in the EV Lab, the wiring of the two can be integrated together.

Sunday 14 October 2012

Day 3: The End

After 9 months of hard work and 3 days of action, the PROTON Green Mobility Challenge 2012 comes to an end. The closing event started with the VIP guests meeting the participating teams and viewing the participating electrical vehicles at the starting grid. Then it's flag-off for the PGMC 2012 EV parade, by the advisor of PROTON himself, Tun Dr. Mahathir. At the end of the parade, all 10 cars parked under the podium where the prize-giving will be held.

First, each team leader is called to the podium to receive the certificate of participation. Then, the prizes are given one-by-one, from the side prizes up to the ultimate winners. We didn't win any, but congratulations to seven other universities who did. The major winners are:
  1. Overall Champion: Smart Mobility of IIUM (also Fartherst Distance & Fastest Time for 2 Laps)
  2. 1st Runner-Up: UMP EV of UMP (also Quarter Mile Acceleration)
  3. 2nd Runner-Up: Evergreen of UTeM (also V-Max)
Lining up for parade
Under the podium
Dr. Wan Faizal
With DVC Prof. Ir. Dr. Othman A Karim
 
Time to clean up. Goodbye.
Partial preliminary results

Thursday 11 October 2012

Day 3: Farthest Distance

The final day saw the main event, Challenge 4: Farthest Distance. Contestants try to do as many laps as possible on a (hopefully) full charge in a two-hour window.

The day started with a briefing in the control room. Then, to make the event as fair as possible, teams push their cars to the starting grid, and start from the same position. The drivers were released two-by-two, and their time started when they were released.

In race control
Approved
 

Still time for driver interview
 
Thumbs up. With our guests from Germany
Our supporters still here
Lining up
 

Problem? No problem.


Wednesday 10 October 2012

Day 2: Fastest Lap

In the afternoon, two challenges are held together:
  • Challenge 2: Fastest Time for 2 Laps
  • Challenge 3: V-Max
The format is that all cars would do two full laps of the SIC, starting from and finishing at the pits. The faster of the two laps would count as each team's fastest time. Meanwhile, the speed of the cars would be measured three times as they passed the grandstand straight, once on their outlap, and twice during the two full laps. The fastest speed would count for v-max.


There's the team spirit
Go I.C.E. Terminator go!


How fast are we?

Tuesday 9 October 2012

Day 2: Pit Walk

In between Challenge 1 and Challenge 2 & 3, the organisers provided some time for a pit walk session. Spectators are allowed to go into  the pits to mix with team members and look closely at the electric cars. So while charging, some of us also took the chance to see other cars.

 
In the boot: some hide the battery pack, some show it off

 
In the bonnet: various arrangements of the engine components

PROTON also has some cars to display
 
Our supporters in the pit


Monday 8 October 2012

Day 2: Quarter Mile

The second day is the day of 'performance' challenges. It started with the scrutinising and safety inspection of the cars. Then, Challenge 1: Quarter Mile Acceleration starts. Two cars at a time are lined-up on the track in front of the North Grandstand, similar to drag racing. Each car is allowed to make two passes, and the car that took the shortest time to cross the finish line wins (barring any penalties).

Passes the second inspection

The challenge

Some of our supporters

'Live data' through the big TV

Both man and machine need to recharge afterwards

Sunday 7 October 2012

Day 1: Pit Display

While most of the team work on the car, some members focused on sprucing up the pit. This is because there are also prizes on team identity and pit display.

Banner and 'evaporating ice'

 


Judges evaluating

Saturday 6 October 2012

Day 1: Practice

It's October 5th, and finally, we're in Sepang International Circuit. The first day started with the registration and scrutinising of all 10 cars by the PGMC 2012 Technical Committee (TC). Only four team members were allowed to be present during the inspection. I.C.E. Terminator were represented by Wan Faizal (leader), Zulkhairi (driver), Hanief (electric) and Azhari (mechanical).

After that, teams were allowed to go to the pit area and work on their cars. All concerns raised by the TC must be addressed before teams are allowed to practice on track. Due to multiple issues, we didn't manage to solve everything until it was too late to go onto the circuit.

Besides working on the car, we also have a group focusing on the pit displays.

When all the problems have been ironed out, it's time to charge the batteries for tomorrow's events. This is also the time to finalize the strategy and tidy up the car and pit area.


Waiting for inspection

Front and back, resolving issues

Approved for testing



At the end of a long day

Friday 5 October 2012

Battery Management System

When using batteries as the power source, a battery management system (BMS) is very important. It functions to monitor the battery pack's state, calculating and reporting secondary data, protecting the battery, controlling its environment, and balancing it. We use the Orion Li-Ion BMS.

The BMS is another problem for us. It took more than a month to arrive, and when it did, we couldn't make it work. It was only later that we realised that the BMS was broken. We ordered a replacement, and just for back-up, we designed and built a basic BMS. As luck would have it, the second BMS arrived in KLIA on Day 1 while we were in Sepang. Pos Malaysia KLIA is only 5 minutes away, though it takes an hour and half to clear the Customs. Fortunately for us, the countless hours spent previously poring over manuals were not in vain, we were able to integrate the BMS almost immediately.

BMS integration

 
The software

Thursday 4 October 2012

Chargers

As an electric vehicle, the batteries used in the car has to be charged from time to time. The 12 V lead-acid car battery also has to be charged while the car is running. We used several types of chargers to facilitate this.

Lithium-ion battery pack charger
Lead-acid battery pack charger
12 V car battery charger
DC-to-DC converter

icelogofinale


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