Malte Marko Daniel MacDonald Stephen Thomas Matthew Gleddie Supervisor: Dr. Lukas Swan Team 1 Electric Trials Motorcycle MECH 4010 Final Presentation December 3rd, 2012

Outline Problem Definition Design Process Final Design Budget Larger text, more corney photos? Cite Mat and steve here S. Thomas, 2012 M. Gleddie, 2012

What Is Trials Motorcycling? Technical High Torque Low Speed High Control Not a race! Dan/Matt! Photos from Trials Day and/or photos from last year’s presentation S. Manchester, 2012

Design Requirements Throttle Response Battery Leads New: Battery Management System! Drive through water – 4 m long, 3 cm deep S. Manchester, 2012 Water Resistance Noise

Sound Testing M. Gleddie, 2012

Prototype 2 Sound Requirement 91 dB 25 % reduction in sound wave pressure CITE EQUATION!!! 88 dB

7

Re-Orientation of Leads Side View Top View S. Thomas, 2012 Re-orientation Plan, drawings? Figures? S. Thomas, 2012 Power and BMS Leads to Top of Pack Consolidate Wiring Plugs to Single, Central Point. Messy, Prone to Damage

Battery Management System

Battery Management System Constantly check between cells for over-voltage (3.6V) Manually turn on/off power supply Shunt power resistors 1. Take note of any cell sets approaching overvoltage. 2. IF greater than 4 cell sets have approached overvoltage in the same 3 minute time period, pack is charged. 3. ELSE IF one cell set has approached overvoltage - shutdown charger, use quick-connect and power resistor to bring cell set back to pack voltage at a rate equivalent to that of charging. 4. ELSE Maintain charging. S. Thomas, 2012

Rejected ideas – BMS On-Board BMS Weight No need for discharge balancing (Throttle Response) Arduino Control W/ Relay Power Resistor Emulates physical charging sequence Complicated apparatus, high likelihood of user error/malfunction CCCV power supply shutoff problems Shortened Photo necessary? http://arduino.cc/en/Main/ArduinoBoardMega2560 Arduino, 2012

Battery Management System Final Design: FET Circuit Limits cell voltages to 3.6V Dissipates excess current to heat sink Selectable characteristics

Full FET Circuit 8 FET circuits in total Dissipate over- voltage power through back of FET to common heat sink (Al, finned, 10cm x 40cm) CITE STEVE

BMS Plan B PreFab Unit Over-Designed, Expensive - Capable of measuring up to 108 cells connected in series based on configuration. - Performs intelligent cell balancing (passive). - Calculates state of charge (SOC). - Uses professional automotive-grade locking connectors. - Calculates discharge current limit (DCL) and charge current limit (CCL). - Can measure cell voltages between 0.5v and 5.0v. Dr swan: is this dumb? Orion BMS http://www.orionbms.com/products/orion-bms-standard/ Capable of measuring up to 108 cells connected in series based on configuration. Configurations available in increments of 12 cells in series. Centralized design provides high EMI and noise immunity. Performs intelligent cell balancing (passive). Calculates state of charge (SOC). Uses professional automotive-grade locking connectors. Calculates discharge current limit (DCL) and charge current limit (CCL). Can measure cell voltages between 0.5v and 5.0v. Dual (x2) CANBUS 2.0B interfaces (fully programmable). OBD2 diagnostic protocol support. Orion BMS, 2012

Drive Train Design Process

Current Drive Train Problems Motor and shaft mounts are separate Bent shaft mount – misalignment Open motor 7:1 reduction Noise! CITE STEVE S. Thomas, 2012

Rejected Ideas Planetary Gear Flywheel and Clutch Reduction One Stage Gear Reduction Hub Motor Dr Swan: Is this dumb? CITE OURSELVES Goldenmotor.ca

Motor Selection

Selected Motor HPM-5000b from goldenmotor.com 5kW 48 V 100 amp continuous 300 amp peak (30 seconds) Water resistant Aluminum case, SS shaft 4000 RPM on 48 volts Sexier photo! CITE PHOTOT Goldenmotor.ca

Primary Reduction - Belt Gates Mectrol 2012 Gates Mectrol 2012

Drive Train Primary Reduction Secondary Reduction Change ratio to 3:1 (from 1.8:1) Secondary Reduction Change ratio to 5:1 (from 7.1:1) Use lighter 520 chain Use stock parts Poly Chain® GT® Carbon™ Belt Designed to replace roller chain 98 % efficient (according to manufacturer)

Drive Train Bracket Minimize loads TBD Protect components Mount to frame TBD Stress calculations Build prototype

Controller/Throttle Response Kelly KBL48201 (from department) 48 V 100 amp continuous 200 amp peak (1 minute) 260 amp boost (10 seconds) Sealed Torque control, speed control, or a mix S. Thomas, 2012

Final Design

Final Design Component Design Requirement Met Re-Designed Drive Train 3:1 Toothed Belt Noise Reduction 5:1 Chained Reduction HPM5000B Motor Water Resistance BMS FET Circuit Automated BMS Kelly KBL48201 Controller Throttle Response Re-Orientation of Battery Leads Protection of Cabling

S. Thomas, 2012

Budget Major Items Cost [$] Motor 600 Battery Charger 500 Drive Train Components 670 BMS Components 630 Miscellaneous 150 Controller Total 2550

Goals for the winter term December Finalize FET circuit Order Parts Bracket stress analysis January Program controller Assembly February-April Testing Fix Go play in the mud! M. Gleddie, 2012

Thank You! Michael Traves Jon MacDonald Angus MacPherson Albert Murphy Dr. Tim Little Sebastian Manchester 2011/2012 ETM Design Team Dr. Lukas Swan Dr. Julio Militzer

References Arduino Mega Photo – Slide 11 http://arduino.cc/en/Main/ArduinoBoardMega2560 Orion BMS – Slide 14 http://www.orionbms.com/products/orion-bms-standard/

Extra Slides

Battery Energy Storage System

Recommendations from 2011/2012 team Existing Prototype Recommendations from 2011/2012 team Belt on Primary Reduction Reduce Noise Waterproofing Protect Battery leads Smaller chain Cite Dan Photo of last year’s bike, side-on. Point to design recommendations.

Sound Testing Results From Fall 2012 Term Report

Battery Energy Storage System 48V System 64 Li-Ion Cells Nominal 3.3V each, 3.6V full charge Nominal 528 Wh of energy storage Brief!! Energy Storage? Dr. Swan? Two 24V in series

FET Characteristics FET Specs: V1 < V2 < 3.6V Capable of dissipating 20A at 3.6V (72W) To be finalized based on VDC

Battery Energy Storage System Across Increase wire gage from 16 to (14, 12?) to handle increased current potential.