Project of Status Indicator and Shift Light for Use on a Formula SAE Prototype

In the Formula UFSM team, we developed a formula-type vehicle prototype for the Formula SAE Brasil competition, an annual event organized by the Society of Mobility Engineers, SAE. In this event, engineering students from different Brazilian universities present their vehicle prototypes, competing in static tests with project presentations and dynamic tests, where vehicle and driver performance is essential.

In order to improve the performance of the prototype, we have developed a device to alert the pilot during dynamic tests. This system allows the pilot to know about possible abnormal situations, such as low oil pressure or high engine temperature, low battery, etc. We also added to this project a shift light that informs the ideal moment of gear shifting in the vehicle.

Taking into account the relevance of this project for our team, because without it we can have serious engine failures or not perform well on the tracks, the reliability of this system is essential. With this in mind, our PCBs (Printed Circuit Boards) needs to be of extreme quality to guarantee the functionality of the project during the tests.

In order to fulfill this project requirement, the need arose for a partner like JLCPCB, who besides using high technology in their processes, specializes in PCB prototypes like our project. JLCPCB (Shenzhen JLC Electronics Co., Ltd.), is the largest PCB prototype enterprise in China and a high-tech manufacturer specializing in quick PCB prototype and small-batch PCB production. Visit their website: jlcpcb.com

This part was designed through 3D modeling in the SolidWorks software, taking into account the integration with the vehicle panel, positioning it in a location with good visibility to the pilot.

The base of the LED panel was manufactured using additive manufacturing, respecting the limits of dimension and mass for this device, aiming at the integration between the case and the PCB. After completing the design of the plastic enclosure, the dimensions of the PCB were defined, aiming at the perfect fit in its support.

The electronic project consists of LEDs and resistors, the leds are activated by signals, coming from the ECU (Engine Control Unit) or switches installed in the vehicle. The supply voltage of the circuit comes from the battery that varies from 13V to 15V, based on these parameters, we dimension the resistors according to the calculations performed: Res=(Vbat-Vled)/Iled

The commercial value of resistors closest to the calculated is 620Ω. With this the 10mm and 5mm leds present in the device are supplied correctly. The Shift Light at the center of the project is an automotive lamp, powered directly by the battery and controlled by an outlet on the ECU.

The case was made in ABS, but tha painel, for mass reduction, we made in Carbon fiber with Epoxi!