Design Proposal

 Project Goals ◦ Competition ◦ Overall System Design  Accumulator  Motor & Motor Controller  Battery Monitoring System (BMS)  System Control and Data Acquisition (SCADA)  Testing  Schedule  Conclusion

 Design, build, and test a functional electrical system for the SAE Formula Hybrid Competition ◦ From the ground up:  System Communication And Data Acquisition (SCADA)  Battery System (Senior Design 2011) ◦ Buy & Integrate with:  Battery Cells  Motor Controller  Motor

 Electrical/Mechanical Inspection  Design and Presentation  Events ◦ Acceleration: 75 m dash (4-7 seconds) ◦ Autocross: 1/2 mile weaving ( seconds) ◦ Endurance: 13.7 miles (~ 30 minutes)  Design system for efficiency

Accumulator o Battery Monitoring System (BMS) Motor o Motor controller System Control and Data Acquisition (SCADA)

Max 300 V Maximum Accumulator Capacity: 4,449 Wh Accumulator Cost Limit: $6, Chemistry Segment Energy Limit PbAcid 12MJ NiMh 12MJ LiIon (except LiFePO4) 5MJ LiFePO4 12MJ Capacitor 5MJ

Battery Chemistries  Li-Cobalt  Li-Manganese  Li-Phosphate  NMC

 Sufficient discharge current  Size considerations  Weight considerations  Cost efficient Tenergy H-38120HP HeadwayLiFePO4 Voltage (V) Capacity (Ah)208 Weight (g) Dimensions (mm)11.5x199x143h = 122, d = 38120x100x60 Max Discharge2C10C3C Cost ($)

Nanophosphate Lithium Ion Prismatic Cell 3.3 volts, 19.6 A-H, 496 grams, $ x 160 x 227 mm Max Discharge Rate: 15C (300A) Total Weight: roughly 109 pounds Total Volume: roughly.93 cubic feet Total Cost: $4,752 with discount Competitive price, unbeatable discharge

 Purpose ◦ Even cell charging distribution  Heat dissipation ◦ Maximizes Capacity ◦ Maximizes Lifetime ◦ Must actively monitor cell voltage, current, and temperature  Constraints ◦ Cell Size ◦ Handle 300 A

 Adapt the ECE 492 Spring 2011 BMS ◦ Needs to be redesigned for a car system  Should be able to handle at least 300 A  Easy shut-off ◦ Entire redesign of PCB ◦ Perform thermal analysis to select heat sink ◦ Design the master safety loop following the LPRDS design  $141.33/board (12-V packs)

 Controls the balancing algorithm of the cells  Capable of I2C Communication into and out of the board  Firmware designed in C using MPLab  Provides access to voltage, temp, and current of the pack to SCADA

Motor – Competition Requirements  "EV 2.1 […] Any type of electrical motor is allowed. The number of motors is not limited“ ◦ A lot of freedom ◦ No guidance on design

AC Motors: High efficiency when compared to DC motors Easily controlled with industry standard controllers. Less required maintenance than DC motors Capability of regenerative braking DC Motors Inexpensive Simpler implementation Higher torque at lower speeds

MotorsProsCons One Simplest to implementLess power/torque Lighter systemInefficient Regenerative Braking Two More controlMore Complex Differentials Handled ElectricallyHeavier System Better Regenerative BrakingMore Expensive FourMost ControlMost Complex System Differentials Handled ElectricallyHeaviest System Best Regenerative BrakingMost Expensive System

Base Price: $4300 Includes: Motor, Curtis Controller, Wire Harness, Display Properties: Diameter: 8 in Length: 16 in Weight: 122 lb. Voltage: V Amp Rating: 650 amp Motor efficiency: 89% Peak Power: 67HP Peak Torque: 110 ft/lbs RPM Max: 6500

TransWarP 9 (DC series wound) Base Price: $2000 Includes: Motor Does not include Controller Properties: Diameter: 9.25 Length: in Weight: 160 pounds Voltage: 72 Volts Amp Rating: 335A Motor efficiency: ~85% Peak Power: 32.3HP Torque: 70 ft/lbs RPM: 3,500 2 AC-20s Base Price: $2700 x 2 Includes: Motor, Curtis Controller, Wire Harness, Display Properties Diameter: 6.7 in Length: 15in Weight: 54 lbs. Voltage: 96V Amp Rating: 650A Motor efficiency: 89% Peak Power: 50HP Torque: 75 ft/lbs RPM: 7,500

 Takes DC current and outputs AC 3-phase motor  Low Voltage I/O System ◦ Throttle Control  Input Voltage Nominally: 72 – 96V ◦ Runs at 108V (Max 130V)  Serial Communication System

 Serial interface to motor controllers  I2C interface to communicate with BMS  GUI for viewing system status  Active software community to ease software development efforts (existing SDKs, etc.)

Arduino Mega 2560 Clock: 16 MHz I/O: 54 digital, 16 analog inputs Cost: $75

Display - 4D Systems µLCD43 4.3" touch-screen OLED Cost: $220 Inertial Measurement Unit (IMU) - Full ArduPilot Mega 1 kit Cost: $150 Wireless communication - XBee Pro series Cost: $70

 Control loop: ◦ Check BMS – voltage, current ◦ Check motor controller – temperature, rpm ◦ Update display  Use interrupts when system malfunction is detected to shut down the tractive system

 Arduino development software is open- source, which should help with finding code and learning how to code for Arduinos.  Code libraries for LCD display are well- documented and coding tools are included with the display

 Accumulator ◦ Use DC High Powered Load System for  Test the voltage and current as well as the fuses and galvanic isolation relays  Motor Controller ◦ Use AC Load Tester for the motor controller  Motor ◦ Dynamometer  Software ◦ Unit Testing

 Dimensions ◦ Accumulator = (2x) 9” h x 6.3” w x 8.8” d (Ideal) ◦ Motor = 8" diameter, 16" length ◦ Motor Controller = 11” x 9.1” x 4”  Total Weight = 245 lbs. ◦ Accumulator = 110 lbs. ◦ Motor = 120 lbs. ◦ Motor Controller = 15 lbs.  Cost = $12,452 (Need $9,000 more) ◦ Accumulator = $4,752 (72 Cells) ◦ BMS = $2,400 (+ $500) ◦ Motor/Motor Controller = $4,300 ◦ SCADA = $500

BMS SystemSCADATestDeliverablesDue Date 12V Pack Hardware Design & Test Plan Monitor/Display System & Safety Plan SCADA Demo (Monitor)9/28/12 12V Pack Hardware Design & Test Plan Communication with Controller & Safety Plan BMS PCB Layout and Test Plan Safety Plan 10/5/12 12 V Pack Software Design Communication with Controller SCADA - Software Testing SCADA Demo (Controller communication) 10/12/12 12V Pack Construction Communication with the BMS BMS - Software Testing 10/19/12 12V Pack DebugIntegration with the BMS & Controller DC Load Test12V Pack Complete SCADA Demo (BMS Interaction) 10/26/12 96V Pack Construction Wireless Communication AC Load Test96V Pack Complete AC Motor Sim 11/2/12 PDR SCADA - Software Testing ATP (Test Plan)11/9/12 PDR PDR Documents11/12/12

TasksDocumentationTestDue Date Conection to AC MotorSRD (System Requirements Document) AC Load Test2/8 Conection to AC MotorUsers ManualSoftware Testing2/15 SCADA Wireless Communication with Base Users ManualHardware Testing2/22 DebugMaint. Manual3/1 Final Report3/11/12 AssembleATP (Test Plan) QA AuditATP ATR5/10/12

 Mechanical Engineers ◦ Chassis ◦ Brakes/Steering/Suspension ◦ Gas Component  Leave both serial and parallel systems open  Serial system would involve generator  Parallel would involve IC motor  Regenerative Braking  More efficient motor control ◦ Design and build own