UniBo Motorsport: The 3 projects of 2023

The 2023 season has been a rollercoaster for UniBo Motorsport, the racing team of the University of Bologna.

The team designs and builds three projects: an electric motorcycle and two Formula SAE cars, one electric and the other combustion. During the summer, both Formula SAE cars participated in three competitions. The combustion car, Ultimae LM, stood out, securing the second overall position in both the home race. FSATA at Varano, and the FSEast competition in Hungary. In the Croatian race, FS Alpe Adria, it achieved a respectable fourth place but clinched an extraordinary first place in the Business Plan Presentation, one of the static events. A result that the team hadn’t accomplished in five years.

The details of the PCBs used for our combustion vehicle:

The Gear Position Sensor PCB plays a crucial role in providing gear stage information to the Engine Control Unit (ECU). To mitigate mechanical failures, the team opted for a hall effect sensor. Utilizing an integrated circuit to measure the absolute angular position of a dipole magnet connected to the gear selector. This technology ensures a reliable assessment of the current state of the gearbox.

For enhanced data collection on vehicle speed and aerodynamics behavior, we designed a new Differential Pressure Sensor PCB. Connected to a pitot tube, this board collects the differential pressure between the two tubes, transmitting the data to the ECU via CAN Bus. The collected information is then analyzed and compared with GPS, IMU, and signals from phonic wheels.

The Plenum Pressure Sensor PCB marks a significant advancement this year, as Eurocircuits facilitated the complete manufacturing process. In our pursuit of better performance, we replaced the OEM sensor measuring pressure inside the intake manifold. The custom PCB allowed us to choose a sensor with a larger voltage range (5V), addressing the limitations of the previous sensor (1V). The sensor’s positioning informed the design of a 3D printed enclosure, aligning it with the location of the old sensor.

The electric vehicle

On the other hand, the electric vehicle faced challenges. In Varano, the team could only participate to static events due to critical delays in the delivery of essential mechanical parts for the prototype. In the contexts of FS Austria, held at the Red Bull Ring, and FS Alpe Adria, the vehicle, eRBT-23, was ready but it couldn’t compete due to rigorous mechanical inspections imposed by the judges. However, electronic technical inspections were successfully passed.

Our success in this part of the competition was further enhanced by the strategic use of PCBs supplied by Eurocircuits. Notably, the Powerbox HV+ board, designed to accommodate 5 M8 press-fits, played a pivotal role in connecting the high-energy accumulator to our three-phase motor controllers. Similarly, the Powerbox HV- board, equipped with 4 M8 press-fits and 1 M6 press-fit, served as another crucial link in connecting the high-energy accumulator to our motor controllers.

The Gateway PCB emerged as the backbone of our CAN gateway, seamlessly interconnecting CANbus networks operating with different settings. Additionally, a significant breakthrough this year was the integration of a dashboard into the steering wheel. To achieve this, we designed and built an entirely new PCB dedicated to the steering wheel dash. This innovative PCB not only handles multiple buttons and rotary switches but also serves as the control unit for the dashboard, consolidating all interactions with our pilots. By minimizing external connections, it enhances safety and reliability in automotive applications.

The Cockpit Lights PCB, mandated by Formula SAE rules, effectively displays critical errors during dynamic events. With the capability to drive 4 LEDs and an integrated self-test for checking LED health, this board ensures swift identification of any issues.

Finally, the TSAL Led boards serve as indicator devices controlled by the TSAL logic board—a mandatory circuit board. Configurable for either red or green LEDs, these boards play a vital role in indicating the status of the tractive system. A symmetric design, coupled with a 4-layer layout, not only reduces costs but also enhances long-term efficiency by effectively dissipating heat.

However, despite the ambitious and well-studied nature of the project, acknowledged by the judges of the Design Event, the lack of a main sponsor and delays caused by other partner companies prevented the electric vehicle from fully realizing its potential.

The electric motorcycle

The electric motorcycle, Nemesi, competed in the MotoStudent competition at the Motorland Aragon international circuit in Spain, held biennially. The seventh edition, concluded on October 15^th, saw our team clinch all five awards. The three static event awards (Best Design, Best Innovation, Best Project), the first position in all dynamic events (combined scores of Gymkana, Acceleration, Brake Test), and the overall victory, thanks also to the pole position and first place in the race.

For 2024, our team’s objectives include the continuous development and improvement of the electric vehicle. The conversion of the combustion vehicle into a hybrid one, and the ground-up design of a new electric motorcycle set to hit the track in 2025, at the eighth edition of the MotoStudent competition.