UWAFT Takes Delivery of GM-Donated Vehicle to Transform into Next-Generation EcoCAR

 

After an extensive year of planning, designing, and simulation testing, UWAFT has taken delivery of their GM-donated vehicle and begun the second year of the EcoCAR Challenge.

With their Fuel Cell Plug-in Hybrid Electric Vehicle (HEV) designs set, the team hopes to transform this vehicle into the next generation EcoCAR and prove they are the next generation of automotive engineers who will design and build the environmental vehicles of the future.

Excited by the opportunity to integrate their designs into the vehicle, UWAFT embarks on the physical stage of the competition, and will begin work under the hood of the vehicle and ultimately, take it to the road.

The team has already removed the engine and begun stripping down the vehicle into its bare chassis.

Most of the vehicle interior has been stripped clean including the seats and the battery. On the outside of the vehicle, the sub-frame and suspension have been disassembled.

A 93kW hydrogen fuel cell power module will be put into the vehicle. The fuel cell produces electricity that can charge an onboard battery or drive two electric motors that are coupled to the wheels. The best part about this engine is that it only produces H₂0 as a by-product.

A new front sub frame, steering column, and steering rack arrived at the garage. UWAFT also gained a new winter co-op student, Trevor, who has hit the ground running and is already ordering components and working on the vehicle.

Battery pack components are being sourced and ordered. The main elements involved are high-voltage (i.e. power) connections, controller communications, and thermal management.

ME 482 (mechanical engineering 4th year design project) students are working hard to finalize and fabricate mounting hardware for our major components.

The dash from the GM-donated vehicle has been removed.

Battery bench testing is underway. The Battery enclosure (what holds our A123-donated batteries and associated hardware) is built by our engineering machine shop.

UWAFT’s ChallengeX (last competition) hydrogen fuel cell vehicle is in the garage “donating” some parts to the new EcoCAR.

Our EcoCAR vehicle is having sheet metal modification work done at a local fabrication facility, Schwartz Custom Vehicle Fabrication. The work, which includes cutting out the entire rear floor pan (see photo), enables us to install the hydrogen storage tanks.

Small components continue to arrive, including our 12V manual disconnect switch, fluid fittings, and raw materials.

Our GM-donated vehicle has returned to the garage! After a busy Saturday fitting the hydrogen storage tanks into the newly cut hole in the vehicle floor (special thanks to Grant at Schwartz Welding for working on the weekend), we are ready to start mounting components.

Our battery enclosure has been installed. Next step is to drill holes for all our through-wall connectors and install the modules.

Fuel cell mounts are being fabricated. We expect to install our fuel cell / front motor assembly next week.

Stay updated on what’s happening in the UWAFT garage LIVE - visit the garage today! For more information on the vehicle’s propulsion technology, please visit the Vehicle Overview page.