EV.3.2 Energy Meter
EV.3.2.1 All Electric Vehicles must run with the Energy Meter provided by the organizer
Refer to the FSAEOnline Website AD.2.2 for detail information on the Energy Meter
Navigation to relevant documentation from FSAEOnline is as follows:
fsaeonline.com -> Series Resources -> Technical Inspection Resources -> Electric Vehicle -> Energy Meter Resources
This document clarifies that an Energy Meter must be installed in each vehicle at competition. Ultimately, it will measure energy usage as well as monitor for power or voltage violations. It will be provided by the competition organizers at technical inspection (though, each meter must be returned at the end of the competition).
More information can be found in the embedded document to the left (Note: The rules references don't directly align with the 2024 FSAE Ruleset, but in general, all of the same sentiment stands).
EV.3.2.2 The Energy Meter must be installed in an easily accessible location
Because the Energy Meter is distributed and returned at competition, it is important that it can be removed and installed without having to take the whole car apart. This rule seems to mostly be in place for ease of inspection.
That said, there is a dedicated header cell in the Electrical Systems Form (ESF) which requires an Energy Meter Download Picture Show. To prove compliance with rules in this section (Note: Rules from previous years such as 'EV.4.2.2' do not directly align with rules from this year).
EV.3.2.3 All Tractive System power must flow through the Energy Meter
The goal of the Energy Meter is to measure the amount of energy flowing out of the negative side of the battery. As depicted in the schematic below (Ref. Tractive System Schematic for the ESF), both ends are connected to the negative terminal. The fused wire in the second port measures the voltage of the tractive system using the positive high voltage (HV) line.
Within this process, the Energy Meter acts like a current meter for the negative wires on either end, and uses the positive wire as a voltmeter. This leads to a system which can collect both amperage and voltage of the high voltage system while driving.
As shown by both schematics, the motor controller (MC) is powered with positive and negative battery terminals. Before the negative supply can enter the motor controller, it is forced to flow through the Energy Meter. This connection MUST be in series with the high voltage supply, because if it happened to be in parallel with any other tractive system lines, energy could run past the meter without being accounted for.
EV.3.2.4 Power and Voltage limits will be checked by the Energy Meter data.
Energy is calculated as the time-integrated value of the measured voltage multiplied by the measured current logged by the Energy Meter.
"The analog-to-digital conversion (ADC) is operated with a data rate clock of ~500kHz and an over-sample ratio of 4096 to produce a sample rate of ~120Hz. The energy meter internally processes every sample and uses fixed-point 32-bit math for calculations. Each sample is first scaled to physical units using calibration factors that are unique to each Energy Meter, and then processed to monitor for violations of the power or voltage limits as defined in the FSAE rules.
Whenever the tractive system (TS) is energized, the energy meter logs the measured current and voltage at 10Hz. If a violation of the power or voltage limits is detected, a high-speed buffer of 120Hz data is stored containing 1 second of data centered on the violation."
But what is analog-to-digital conversion (ADC)?
ADC's essentially utilize sensors, which measure a physical parameter and produce a voltage signal proportional to the changing input, to produce a series of discrete values which approximate changing signals. Measured in bits, the ADC's resolution represents the number of discrete amplitude levels available in its digital output. Of the three types of ADC's, the Sigma-Delta type is generally used for high precision measurements (like applications within our Energy Meter).
But how are these signals used to calculate energy?
It's important to note that power is calculated as the product of voltage and current, which can both be measured from an electrical system. If energy is the time-integrated value of voltage and current, this essentially means that energy is the product of power and time.