Progress Presentation 2 Team Hi-Voltage Tommy Drane Ajeya Karajgikar Will Patton Vanessa Pogue Nick Reagan Min-hee Sayer

Problem Statement Develop an electric vehicle charging system with following requirements: –Auto connection and disconnection –100% child/pet safe –Debris and moisture proof connection –Minimal manufacturer retooling –Minimal car owner assembly

Suggestions and Comments Apparatus on the bottom of the car –Protection from debris and water. –Make it concealable for aesthetics. –Clearance issues. Market –For home or wide spread use? –Customers without a garage? –Standardization? Power –Inductive charging like the electric toothbrush –Wireless electricity Design –Looks expensive.

Industrial Design Company logo

Market Research Current standard –SAE J1772 –120V/240V AC voltage –70A current –16.8 kW maximum power delivery

Market Research Frost &Sullivan by Sarwart Singh

Market Research Home ownersCar sharing companies (Zipcar) Company fleets Company/Community parking garages

Selected Design: Schematics Horizontal funnel

Selected Design: Details Extension off of a golf cart –To simulate ground clearance of an electric car. Constraints –Wheel chock for general placement –Funnel to aid exact placement –Assume angular variation of 5º Ground unit on rails –Side to side movement. –Allows greater tolerances. Car’s momentum forward to connect –Eliminates need for expensive motors For home garage use. Possibly for underground garage. –Eliminates need for weather proofing the ground unit.

Design Layout: Funnel with cover

Design Layout: Receptacle (resting)

Design Layout: Receptacle (active)

Design Layout: Rail/receptacle assembly

Physical Mock Up Composed of four subsystems: –Ground/rail subsystem –Receptacle subsystem –Cart subsystem –Funnel subsystem

Manufacturing Plan Material Selections –High density polyethylene (cart, receptacle: body) –ABS plastic (wheel) –Shoulder screw (axle) –Cold rolled steel (runner/track, end plates) –Rubber/Urethane (ramps, receptacle: insulation) –Tin plated brass (receptacle: terminal –Non-corrosive brass (plug) –Stainless steel (arm, funnel)

Manufacturing Plan Prototype production plan –Machining –Welding –Water jet –Casting Mass production plan –Injection molding –Die casting –Machining

Bill of Materials PartMaterialVendorPart # Price Eac hQuantity Price Tot al CartHigh Density Polyethelene (HDPE)McMaster Carr8671K15$2.062$4.12 WheelsABS PlasticMcMaster Carr8587K45$3.881 AxleSholder ScrewMcMaster Carr91259A537$0.994$3.96 Track1/8" thick Cold Rold SteelMcMaster Carr7779T12$ Base1/8" thick Cold Rold SteelMcMaster Carr8910K122$ End Plates1/8" thick Cold Rold SteelMcMaster CarrCut from Base $0.00 RampsRubberMcMaster Carr8981K159$34.952$69.90 ReceptacleHigh Density Polyethelene (HDPE)McMaster CarrCut from Cart $0.00 ArmHigh Density Polyethelene (HDPE)McMaster CarrCut from Cart $0.00 Funnel TopPolycarbonateMcMaster Carr8574K21$ Funnel SidesPolycarbonateMcMaster Carr3161T11$ PlugHigh Density Polyethelene (HDPE)McMaster Carr8671K63$6.271 Lower Torsion Spring R302 Stainless Steel Torsion SpringMcMaster Carr 9287K62 $4.121 Lower Torsion Spring L302 Stainless Steel Torsion SpringMcMaster Carr 9287K17 $4.121 Upper Torsion Spring R302 Stainless Steel Torsion SpringMcMaster Carr9287K127$4.501 Upper Torsion Spring L302 Stainless Steel Torsion SpringMcMaster Carr9287K122$4.501 Total Price $190.77

Plans Structural Analysis –Free body diagram Friction between rails and wheels. Friction between receptacle and funnel. –Spring analysis Necessary spring constant –Stress analysis Material selection verification –Power supply implementation Prototype Development

Questions