Electronics

Division Overview 

The Electronics Division is divided into two branches:

 Printed Circuit Boards (PCB)

• The PCB branch is responsible for designing and testing the printed circuit boards PCBs that manage the vehicles safety systems.

• It also works on the integration of the high-voltage and low-voltage systems particularly on team-built and non-team-built PCBs.

Low Voltage (LV)

• The Low Voltage (LV) branch is responsible for all systems and components that operate below 60 V.

• It is also in charge of the architecture and organization of the vehicles wiring harness, including both the design and assembly processes.

• Additionally, this branch is responsible for programming the vehicles ECU, a MoTeC M150, according to the required vehicle functions and sensor readings.

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Components of PCB

1. Shutdown Circuit Board 

• Must be highly reliable and redundant to comply with FSAE rules.   

• Central safety logic that opens the shutdown line when a fault is detected. 

• Interfaces with multiple systems to immediately disable HV if needed. 

  
  

2. Ready to Move Light Board  

• When there is high voltage in the system it emits light.

• Controls the indicator that alerts when the car is energized and capable of movement. 

3. BSPD (Brake System Plausibility Device) 

• Critical safety board required by competition rules. 

• Monitors brake pedal input vs. accelerator signal to detect unsafe simultaneous operation. 

• If a fault occurs, it opens the shutdown circuit. 

4. Precharge/Discharge Board 

• Gradually charges capacitors to prevent damaging current spikes. 

• Manages safe charging of inverter capacitors to avoid damaging current spikes. 

• Controls discharge path when the system powers down. 

• Protects both hardware and operator safety. 

5. Charging Shutdown Board 

• Works closely with the BMS for safe current flow.

• Ensures accumulator charging complies with safety protocols. 

  
  

6. BMS (Battery Management System)

• Monitors and protects the HV accumulator and when it detects a fault communicates via LV signals to turn of the shutdown line.

• Provides information on cell voltages, temperatures, and balancing operations. 

• Ensures safe charging/discharging by sending warnings or triggering shutdowns if faults occur. 

  
  

Components of LV

1. MoTeC

• Acts as the car’s central controller, processing inputs from sensors and driver commands. 

• Interfaces with shutdown circuits, and data acquisition systems.  

2. Wiring Harness    

• Distributes low-voltage power and communication signals to all electronic devices.

• Designed with proper wire gauge selection to handle current safely and minimize voltage drop. 

• Requires correct grounding and insulation to reduce electrical noise and prevent failures. 

3. Sensors

• Provide real-time data such as wheel speed, acceleration, temperature, pressure, and cooling system performance. 

• Used for performance analysis and safety monitoring.

• Signals can be analog (continuous values) or digital (on/off states), requiring different processing.  

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Software for PCB

• EasyEDA – for PCB design and manufacturing workflows. 

• Tina-TI, Falstad, Multisim – for circuit simulation and validation. 

• SolidWorks – for integration with the vehicle packaging.

  
  

Software for LV

• Excel

• Rapid Harness

• Solid Works

• EasyEDA

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Requirements for PCB

• FISI 3172: Physics II 

• INEL 3105: Circuits I 

• INEL 4201: Electronics I 

• Experience in circuit design  

Requirements for LV

• INGE 3016: Algorithms and Programming 

• INEL 3105: Circuits I 

• INEL 4201: Electronics I 

• Programming skills (C++, Python) 

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Division Knowledge Guide for PCB

PCB Architecture members must understand the end-to-end design process:  

1. Schematic  

2. Simulation  

3. PCB layout  

4. Rule check  

5.  Manufacturing  

6. Testing 

   
   

Additionally, they must apply essential formulas (Ohm’s law, power dissipation, current density for trace width) to ensure safe operation. The difference between analog vs. power traces is critical: analog signals require careful routing to avoid noise, while power traces demand wider copper areas and heat dissipation considerations. 

Decoupling capacitors are key for stabilizing voltage and filtering noise in sensitive circuits. Knowledge of PCB layers is also important: single-layer for simple circuits, double-layer for moderate routing, and multi-layer for high-density or HV/LV isolation. Component choices matter — SMD allows compact, lightweight designs but is harder to solder manually, while THT is more robust but bulkier. 

When testing, engineers follow a structured process: check continuity, component placement, and proper function step by step. If a PCB involves both HV and LV, designers must ensure clearance, creepage, and isolation to prevent dangerous failures. Poorly designed PCBs can disable the shutdown system or cause disqualification, showing why compliance and reliability are non-negotiable.   

Division Knowledge Guide for LV

Every Low-voltage member must be skilled in diagnosing electronic issues. If a component works only partially, common causes include poor grounding, damaged connectors, or incorrect wiring. Frequent fuse failures usually point to overcurrent, undersized wire gauge, or short circuits. Correct wire gauge is determined based on expected current draw, wire length, and safety margin.

Understanding digital vs. analog signals is fundamental. Analog signals (temperature, pressure) vary continuously, while digital signals (switches, wheel speed pulses) switch between discrete states. This distinction affects how the ECU processes information. Sensors integrated into LV also validate system health: traction sensors reveal grip conditions, and cooling system sensors ensure fans and pumps are functioning correctly. 

Troubleshooting is a core LV skill. For example, if the fuel pump fuse blows immediately, the process includes checking for shorts, testing pump current draw, and verifying grounding. Although LV runs at safe voltages, it directly supports high-voltage systems through the BMS, shutdown circuits, and data logging. This makes LV essential for both safety and performance monitoring. 

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