College - Author 1
College of Engineering
Department - Author 1
Electrical Engineering Department
Degree Name - Author 1
BS in Electrical Engineering
Date
12-2025
Primary Advisor
Jason Poon, College of Engineering, Electrical Engineering Department
Abstract/Summary
The Power Distribution Controller (PDC) is designed for low-voltage (12V) automotive applications, specifically Formula SAE vehicles. It aims to replace the current and outdated MOSFET-based system, which suffers from inefficiencies such as lossy current sense resistors and limited configurability. Instead, this new system uses a PROFET-based architecture controlled over the Controller Area Network (CAN) and an updated microcontroller, enabling intelligent power management and data logging.
Designed with FSAE regulations in mind, the PDC not only enhances the reliability of low-voltage systems but also provides a quickly adaptable solution to fuse boxes. It achieves this by providing firmware-adjustable overcurrent protection, incorporating smart slow-blow and emergency fast-blow fusing mechanisms without reliance on physical fuses. Fusing is done by continuously monitoring voltage and current data, which the microcontroller uses to determine each channel’s status through a state machine and reports data to the logger over CAN. Engineers can then use the logged data to debug and diagnose electrical failures and develop load-shedding algorithms for low-power applications. Unlike traditional fuse boxes, which lack real-time monitoring and configurability, the PDC offers a solution tailored to Formula SAE teams that can adapt to their evolving needs.
Although off-the-shelf solutions to smart E-Fusing for automotive applications exist, the PDC is a more affordable and FSAE-oriented open-source design. This design increases accessibility for groups with limited budgets or who want to integrate their own custom devices into an existing system. By combining advanced power-protection features with real-time data logging, the PDC provides a robust, reliable solution for managing electrical loads in high-performance student-built race vehicles.
URL: https://digitalcommons.calpoly.edu/eesp/705