Formula Electric Racing NUST

Formula Electric Racing of NUST University (FERN) is a student team that manufactures formula electric vehicles in Pakistan. The team was formed in 2014 by a group of passionate electrical and mechanical engineers with the aim of promoting sustainability in the automotive industry of the country. As a team we participate in Formula Student competitions worldwide. Since manufacturing it's first vehicle, The Red Machine in 2016, FERN has participated in competitions such as FS AE in 2016, FSR in 2021 and FSUK in 2018, 2021 and the most recent participation in 2023 where the team received the highest overall rank amongst all Asian teams present, bagging top ten positions in three categories of the competition namely cost & manufacturing, business plan and the lap-time simulation event. The team also achieved a historic podium finish in Formula Student Russia in 2021 by securing an overall second position amongst all teams. FERN is driven by the constant urge to produce quality engineers for the automotive industry of Pakistan and contribute to technological innovations in the automotive sector globally.

The team is currently in the process of manufacturing its sixth electric vehicle with the aim of competing in the electric vehicle category of Formula Student 2025 for the fifth time. FERN will also be participating in the category of the competition marking us the first team from Pakistan to participate in this category. Last year the team achieved significant milestones at FSUK, including the 5th position in cost and manufacturing event. The competition inspired the team to build an even better vehicle for the next time we compete. Here is a link to get a glimpse of our journey at FSUK'23: https://www.instagram.com/p/CvpeS_qMWrb/?igsh=dDJ0NzQ1bXhreWxh

https://www.instagram.com/p/CvILo1-yLfQ/?igsh=MWtqYmNwanhjNWdodg==

Our team at FSUK'23

Looking forward, the team wishes to further enhance the Formula Student culture and sustainable energy in Pakistan and worldwide. We are committed to promoting and fostering an environment where students from different backgrounds can come together to tackle the problems of climate change and sustainability. Here is a link to a fun reel capturing our experience at FSUK'23:

https://www.instagram.com/reel/C1fAQP7syj1/?igsh=YXZ1eXcxa2VpMzFq

Our Formula Student vehicle integrates custom-designed PCBs that are essential for

1. optimal power distribution
2. precise control
3. data processing.

These PCBs are key to ensuring the efficient operation of critical systems throughout the vehicle.

The system includes four custom PCBs, each designed to manage power distribution across various low-voltage systems, monitor vehicle signals in real-time, and control multiple functions based on instantaneous feedback. Each PCB is meticulously engineered to comply with FSUK regulations, ensuring both performance and safety.

LOW VOLTAGE MASTERBOARD (LVMB):

The LV Master board contains all the LV circuits such as BSPD, RTDS Circuit, Shutdown Circuit, Delay Circuit, TSAL and Additional LEDs. The connections for all of these LV circuits runs through the LV box and into the Master board.

TEMPERATURE PCBS:

Our temperature PCBs play a vital role in ensuring the safety and reliability of our battery pack by monitoring approximately 35% of the cells. They are designed to detect critical temperatures that could pose potential hazards, enabling early intervention through our integrated shutdown systems. These systems communicate with the PCBs to enforce predefined safety limits effectively. Each temperature PCB is equipped with NTC thermistors, analog switches, and comparators that generate analog voltage signals. These signals are precisely converted to Celsius using the Steinhart-Hart equations, implemented through a microcontroller, ensuring accurate temperature mapping and real-time monitoring

BRAKE SYSTEM PLAUSIBILITY DEVICE:

This board is a non-programmable circuit designed to detect hard braking under specific conditions using sensor readings. Upon detecting a fault, it disconnects the main circuit to shut off the motor, preventing potential damage or accidents. Once the issue is resolved, the system automatically restores normal operation after a preset delay, ensuring seamless functionality. Its robust design and fail-safe mechanism make it a crucial component for enhancing the safety and reliability of the braking system.

TRACTIVE SYSTEM ACTIVATION LIGHT:

The TSAL (Tractive System Active Light) is a safety indicator designed to visually display the status of the Tractive System. It features a red flashing light that activates when the TS voltage exceeds a specified threshold and a steady green light that indicates the voltage is below this limit. The board relies entirely on hard-wired electronics, operating without software control to ensure reliability and adherence to safety standards.

TMA Data Logger PCB:

The major components in this PCB are Stm32, ESP32 , Accelerometer, CAN Tranceiver, GPS Receiver , Accelerometer ,Main I/O connector.

This datalogger wirelessly transmit live data using wifi.

Stem 32 gets different data (analog, digital, Can data , wheel sensors from input/output connectors and converts that data into logs and send them to esp32 using I2C which then send those logs to server using wifi.

The System is also capable of sending live data which include GPs location, Wheel speed , Axis Acceleration ,Stm32 core temperature.

CHALLENGES FACED

As a student team based in Pakistan, we face distinct challenges in sourcing high-quality PCBs within our tight timelines. Local manufacturing capabilities are often limited to two-layer boards, with production times extending up to three weeks, which slows down our ability to iterate quickly for testing and validation. FERN’s designs frequently require four-layer PCBs to meet the complexity of our systems. PCBWay’s rapid prototyping services would help us overcome these obstacles, enabling our team to access high-quality PCBs and accelerate our development cycles for improved performance and faster iterations.

THE IMPACT OF PCBWAY’S SUPPORT

With PCBWay’s sponsorship, FERN would be able to develop more efficient and reliable technologies, enhancing our ability to compete on the international stage. Your support would provide us with high-quality PCBs, enabling us to test, validate, and refine our designs with greater precision. Additionally, faster turnaround times would allow more team members to engage in the hands-on PCB design process, expanding their skills and experience.

Our collaboration with PCBWay would greatly elevate our technical capabilities, enabling us to focus on innovation and performance. This partnership would also align with PCBWay’s commitment to nurturing the next generation of engineers and supporting sustainable, cutting-edge projects in the tech and engineering sectors.

We are thrilled about the possibility of collaborating with PCBWay and achieving our ambitious goals with your support. Thank you for considering this opportunity to empower us on our journey to Formula Student 2025 and beyond.