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

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

3. 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

4. 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

5. Sound Testing
M. Gleddie, 2012

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

7. 7

8. 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

9. Battery Management System

10. 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

11. 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?
Arduino, 2012

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

13. 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

14. 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
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

15. Drive Train Design Process

16. 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

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

18. Motor Selection

19. 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

20. Primary Reduction - Belt
Gates Mectrol 2012
Gates Mectrol 2012

21. 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)

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

23. 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

24. Final Design

25. 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

26. S. Thomas, 2012

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

28. 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

29. 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

30. References
Arduino Mega Photo – Slide 11
Orion BMS – Slide 14

31. Extra Slides

32. Battery Energy Storage System

33. 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.

34. Sound Testing Results
From Fall 2012 Term Report

35. 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

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

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