Sponsor: National Science Foundation IPFW Electric Vehicle Sponsor: National Science Foundation Advisors: Dr. Hosni Abu-Mulaweh, Dr. Abdullah Eroglu, Dr. Hossein Oloomi Team Members: Mitchell Eilerman, Josh Weaver, Andres Cobos, Austin Swihart, Charles McIntosh, and Leandra Lee February 12, 2015

Introduction From Will convert preexisting vehicle into electric vehicle Motor will be powered by two batteries Solar panel will recharge batteries Project is funded by the NSF (National Science Foundation) An NSF strategic goal: “Transform the frontiers of science and engineering” to Maybe add NSF information

High-Level Schematic of Electric Vehicle

The Back Story 2007-2008 senior design team built go-cart sized vehicle for 2008 Illinois Baja Challenge 2014 senior design team designed a controller system for new electric vehicle + We will integrate the control system with the existing go-cart to produce IPFW’s first working electric vehicle. Add picture of Baja and control system

Requirements/Specifications A solar panel will charge the batteries, the batteries will power the motor, and the motor will run the car. Add block diagram for panel to batteries to car – Mitch will add block diagram

Table 1: Project Specifications Requirement Type Speed to Achieve Solar Panel to Battery charge time Torque Required Weight Specific Value 10mph in 15 sec 16 hours 5N-m Under 400lbs Table including specifications

A Simulink simulation will be included with the final design. The vehicle must have a cooling system that keeps all of its parts within their operable temperature ranges.

Given Parameters Two 12V UB12500 batteries will power our vehicle Charging system will be run by Kyocera Photovoltaic Module, Model # KC85T. The HPM5000B brushless motor made by Golden Motors will power our vehicle. Current system provides 5N-m of torque

Table 2: Baja Characteristics Will use existing Baja buggy chassis, suspension, & gear train Table 2: Baja Characteristics Baja statistics in chart.

DC-DC converter with bi-directional four quadrant topology. Converter power board with control traces and power traces Completed power board with heat sinks, cooling fans, and inductor Converter statistics below in a table. Schematic of converter power board complete with control traces, seen in red, and power traces, seen in blue

Design Variables Hardware Control System/Interface: Regulate speed & torque DC-DC Converter: Interfaced with the motor and batteries We will need to add shielding to the DC-DC converter because there is a high amount of noise at high currents Arduino Mega 2560 Microcontroller

Current combustion engine shaft to CVT transmission Design Variables Hardware Cont. Display: Motor speed, battery power remaining, temperature, and operating time remaining Motor Coupling: Electric motor coupled to existing Baja transmission Motor shaft Current combustion engine shaft to CVT transmission

Baja gearbox (high/low/reverse) & sprocket system Design Variables Baja gearbox (high/low/reverse) & sprocket system Operating Conditions Speed: Speed varies according to driver input Forward and Reverse Mode: Operates in forward and reverse mode according to the drivers selection. Polaris gearbox

Limitations & Constraints – Timeframe Concept Selection Brainstorming Problem Formulation Timeframe Design must be completed by May 2015 Project must be completed by December 2015 “Each project must be sufficiently complex, yet simple enough to be accomplished within the allocated time …” – Lecture 1 of course PowerPoint Detail Design

Limitations & Constraints – Results Design Budget of $1,000 Possible Design Costs: Cooling System Coupling System Display System Reserve Fund

Limitations & Constraints – Resources Funds Previously Selected Components Existing Baja Frame from previous design HEIGHT: 66.5 in WEIGHT: 180 lb AVERAGE JOE & PLAIN JANE cdc.gov FRAME DRIVER MOTOR BATTERIES SOLAR PANEL COOLING SYSTEM COUPLING 51” 34” Constraint Factor Lab Door Frame Width of EV < 36 in Existing EV Frame (Baja) Cooling System Placement Weight of Coupling Systems Total Weight of EV minimal Drawing showing area for batteries and motor

Additional Considerations Safety systems must be included with vehicle. Brake, suspension, and steering. Electrical connections. Cooling system

Additional Considerations IEEE Standards Life expectancy

Additional Considerations Operational limits. Uncertainty.

Questions?