PWR Racing Team – The 2021/2022 Season

About PWR Racing Team

PWR Racing Team is a Formula Student team from Wroclaw University of Science and Technology. Currently our organization consist of around 60 members, divided into several departments. Since our establishment in 2009 we have built 11 combustion cars, scoring numerous podiums and wins. We love challenges, and that is why we decided to switch to electric class, while at the same time develop our autonomous system.

2021/2022 Season

Season 2021/2022 was different compared to previous ones because for the first time we participated in electric and autonomous categories with our newest car – RT12e. We participated in 3 competitions: FS EAST in driverless category, FS Germany in electric category with autonomous systems and in FS Alpe Adria in electric category.

About RT12e

Electronics in RT12e consists of around 100 sensors and over dozens of self-made modules including power distribution module, ACAN (or Analog to CAN) modules, autonomous system actuators drivers to name a few.

The biggest challenge in the development of the RT12e was integration of HV system and autonomous components with the standard LV system while at the same time ensure reliability of the whole car. Thanks to Eurocircuits, we had access to high quality PCBs, which were used for a wide range of applications.

What we were able to achieve with the help of Eurocircuits

We develop our projects using iterative approach. We start with overall concept based on functionalities needed for certain PCB. We then test it, checking all subsystems of the project: power supply section, logic sections, etc. while at the same time creating crucial documentation necessary for further development. Therefore, we chose Eurocircuits as our PCB supplier – to minimize time of production, ensure very high production quality and extend testing time.

Steering Actuator Driver

One of the PCBs responsible for the autonomous functions is steering actuator driver. It’s a 2-layer PCB with increased copper thickness, for better thermal conductivity and bigger current capabilities. Advanced manufacturing process allowed us to make this PCB smaller and fast shipping time allowed for testing just a few days later.

TSAL System

During the development of the TSAL system, the team decided to shrink the design, which meant increased complicity of the project and manufacturing. Thanks to Eurocircuits we were able to keep the quality at the highest level and not be afraid of the dielectric strength of the PCBs core, which is very important considered there is both HV and LV present on the same board.

ACAN Module

Analog to CAN module allows us to read signals from analogue sensors like temperature sensors, pressure sensors and position sensors which then can be sent on the CAN bus. This module was created as sort of a backup in case we need to read and extra parameter from the car.

Power Distribution Module

Power Distribution Module is a crucial part of the LV system, responsible for correct distribution of power from LV accumulator across all the modules, actuators, cooling etc. Last season’s design was challenging because of all the extra power channels that had to be implemented for autonomous system actuators and additional modules required for electric vehicles.

Autonomous System Brake Driver

This module is responsible for braking while the vehicle is in autonomous mode. It contains necessary logic section which then supplies power to servo motor which actuates the brake by wire. It is a very crucial component of the autonomous system next to the autonomous steering system.

Pre-Charge Module

A crucial part of the electric powertrain is the Pre-Charge. It is a component, required to limit inrush current during activation of the drivetrain. As with TSAL system, PCB’s core dielectric strength is very important here because of high voltages fed to the board.