Electrical Design

Electrically assisted human powered vehicle

Presentation Outline Summary of Recent Decisions Specifications Table Detailed Power Budget Bill of Materials CAD Models ME 729 – ADVANCED MACHINE DESIGN

Motor System Changes No changes made to motor or driver 24Vdc  240Vac inverter revised Type: Modified Sine Wave Input: 22-30Vdc input Rated Power: 800W continuous, 1800W peak Mass: 1.7kg Size: 267mm x 124mm x 70mm Gearbox responsibility moved to drivetrain team http://www.alibaba.com/catalog/11318118/800W_Power_Inverter_12V_220V_230V_240V.html ME 729 – ADVANCED MACHINE DESIGN

Motor System Concepts DC Motors AC Motors Servomotors Key Advantages: Features robust driver with feedback and auxiliary inputs Torque or velocity control options Exact control scheme will be up to Human Interfaces Team ME 729 – ADVANCED MACHINE DESIGN

Windshield Wipers ? Disadvantages of adding windshield wipers to our vehicle: Weight: Including washer fluid system, total mass is approx 4 kg Power: We need between 100 and 150 W only for wiper motor Complexity: Installing wipers and washing system to vehicle will increase electrical and mechanical complexity Function: Almost all wiper systems are designed for car windshields. Considering the shape of our aero body, cleaning of windshield with wipers is very difficult (size and curved shape) ME 729 – ADVANCED MACHINE DESIGN

Windshield Wipers ? Alternative solution: Rain X Advantages:  No extra weight  No power required  Really cheap  Fits our vehicle concept  No increased complexity  It works! ME 729 – ADVANCED MACHINE DESIGN

Windshield Wipers ? There are many reviews for this product and they are all positive. See video… If you ever drive your car during rain and you haven't discovered Rain-X, you are probably driving far less safely than you could. Rain-X is an exterior window (windshield, mirror, rear-window) treatment that causes water to shed from the surface rather than sheet. I don't know the composition of the product, but it behaves like a silicone wax for glass. Water beads up and drips off. Sheeting water on a glass surface, like a windshield, causes significant distortion in the light/images passing through the glass because it isn't perfectly smooth. Rain-X causes the water to bead up so that spaces between the beads give you clear vision of what's ahead. While this is clearly evident during rainstorms, it is UNBELIEVEABLY DIFFERENT during rainstorms at night. You can actually SEE! ME 729 – ADVANCED MACHINE DESIGN

Windshield Wipers ? We recommend using Rain X instead of wiper system. ME 729 – ADVANCED MACHINE DESIGN

General Circuit Diagram

Battery - Lithium iron phosphate (LiFePO4) • Lithium iron phosphate- LiFePO4  Hybrid characteristics: 1. Safe as the lead acid battery 2. Powerful as the lithium-ion battery Specifications:  Output voltage (nominal) : 24V  Output current: 30A  Approx Weight: 2.8 kg  Operating time at maximum power: 7 hours Each cell: L*W*T = 105*80*27 mm Weight =0.4 kg ME 729 – ADVANCED MACHINE DESIGN Source: http://www.powerstream.com/index.html

Lithium Iron Phosphate Cell parameters Nominal voltage 3.2 Volts Peak voltage 3.65 Volts Absolute Minimum 2.0 Volts discharge voltage CV charge voltage 3.65 Volts 100% charge CV charge voltage 3.5 Volts 95% charge Charge Temperature 0°-40°C Discharge Temperature -10°-60°C ME 729 – ADVANCED MACHINE DESIGN Source: http://www.powerstream.com/index.html

Battery battery chargers System  Lithium ion Charging  Rating Input Voltage: 100-240Vac, 50/60 Hz  Typical Charging time: 4 hours  Weight:500g  Size: 117*61*37 mm (for casing only) Source: http://www.powerstream.com/index.html

Battery Charger Specifications ITEM UNIT SPECIFICATION Rating Input INPUT V ac 100~240Vac 50/60Hz Voltage Rating Input A 0.3A Current Max. input power W 40 OUTPUT Output voltage V dc 12VDC ~ 17VDC range Suit with Battery Ah 14.4V LI-ION type Constant Charge A 1.8A ( + -0.2A) current Constant Voltage V 16.8 ± 0.05 Charge end current A <0.18 Typical charge time hour 4 hours Max. output power W 30W

Power Budget Operational Power Motor Inverter Losses Driver Losses Headlight  Motor: 500W Front Turn Signal Rear Lighting - Stop Rear Lighting - Turn Rear Lighting - Tail  Lights: 2% 1% 1% 1% 0%  Headlight: 7.2W 5% 8%  Front Turn: 8.3W  Rear Stop: 3.6W  Rear Turn: 27W 82%  Rear Tail: 1.2W  Losses:  Inverter: 51.3W  Driver: 13W Motor Inverter Losses Driver Losses  Total: 612W 2% 9% Motor Efficiency  Motor: 500W  Inverter Loss: 51.3W 89%  Driver Loss: 13W ME 729 – ADVANCED MACHINE DESIGN

Electrical Team - Specifications Sub-system Specification Parameter Value Units Motor dimension Motor diameter D_motor 0.058 m Motor length L_motor 0.1334 m Motor specs Motor power (max) P_motor_max 539.3 W Motor Torque (max) T_motor_max 3.84 N-m Motor Torque (continuous) T_motor_continuous 1.03 N-m Motor speed (rated) N_motor_max 5000 rpm Output gear ratio GR_motor_out 8.5 - Driver Width W_driver 0.05475 m Driver Length L_driver 0.1316 m Driver Height H_driver 0.175 m Driver Mass M_driver 0.77 kg Controller losses P_driver_loss_idle 11 W Controller losses P_driver_loss_max 29 W Inverter Width W_inverter 0.124 m Inverter Length L_inverter 0.267 m Inverter Height H_inverter 0.07 m Interter Mass M_inverter 1.7 kg Inverter Efficiency eta_inverter 0.9 Inverter Rated Power P_inv_continuous 800 W Inverter Maximum Power P_inv_max 1800 W Electric power Maximum electric power P_elect_max 750 W Battery Energy storage E_battery 30 A-hr recharge rate (time from 80% discharge) t_battery_recharge 4 hr Battery life (hrs) Life_battery 7 hr Energy storage E_battery 30 A-hr Auxiliary devices Power consumption (daytime) P_auxiliary_day 80 W Power consumption (night) P_auxiliary_night 94 W Light intensity (front) Intense_light_front 1050 lumen Light intensity (rear) Intense_light_rear 500 lumen ME 729 – ADVANCED MACHINE DESIGN Extras power (iPod, speakers) P_extras 0 W

Bill of Material & Mass Table BOM Dimensions (mm) Mass (kg) Part Number Description Quantity Length Width Height Weight E01 Rechargeable Battery 1 189 80 105 2.8 E02 Battery Charger (With Case) 2 117 61 37 0.5 E03 Sensors 2-3 100 20(Dia) 0.2 E04 Microcontroller 1 50 20 10 0.05 E05 Controller circuit board 1 300 200 30 0.5 E06 Headlight 2 113 66 113 1.3 E06 Front Signal 2 80 108 80 0.45 E07 Back Light 2 127 27.5 127 0.68 E20 Motor 1 133.4 58 58 1.38 E21 Motor Driver 1 175.01 131.57 54.75 0.77 E22 Inverter 1 267 124 70 1.7

External Motor Interfacing  Mounting to Chassis Φ “E” (Diameter)= 63 mm Φ “C” (Hole Dia.) = 4.8 mm Thru  Connecting to Gearbox Φ “J” (Shaft Dia.) = 9 mm “K” (Shaft Length) = 20 mm “P” (Key Height) = 10.2 mm “R” (Key Width) = 3 mm “S” (End Clearance) = 3 mm “T” (Key Length) = 12 mm  Physical Specifications for Systems Integration 58mm square Y max 133.4 mm Mass = 1.38 kg Inertia = 2.2 x 10-5 kg-m2 Source: AKM_Motor_Selection_Guide.pdf ME 729 – ADVANCED MACHINE DESIGN http://www.danahermotion.com/

Motor (AKM23D/S20360) Specifications Performance  Tps = 3.84 N-m  Tms = 0 N-m  Tcs = 1.16 N-m  Tcr = 1.03 N-m  ωk = 3020 rpm  ωr = 5000 rpm  ωmax = 6540 rpm Source: AKM_Motor_Selection_Guide.pdf ME 729 – ADVANCED MACHINE DESIGN http://www.danahermotion.com/

Driver (S20360) Specifications Source: S200SelectionGuide_L100_Oct_07.pdf ME 729 – ADVANCED MACHINE DESIGN http://www.danahermotion.com/

Head Lamps PRODUCT SPECIFICATIONS  Light Source LED (Light Emitting Diodes)  Input Voltage 12-48V DC  Current Draw 550 mAmps @ 12 volts  Approx 7W  Lens Polycarbonate – Flood pattern  Dimensions: 112.9 x 112.9 x 65.9 mm  Weight: 1.362 kg  Intensity: 450 lumens Source: www.jwspeaker.com ME 729 – ADVANCED MACHINE DESIGN

Front Turn Signal PRODUCT SPECIFICATIONS  Light Source: Incandescent bulb  Input Voltage 12V  Current Draw 0.69 Amps at 12V;  Approx 8 W  Lens: Polycarbonate  Dimensions: 80 x 80 x 55 mm  Weight: 0.454 kg  Intensity: 75 lumens ME 729 – ADVANCED MACHINE DESIGN

Tail, Stop, Rear Turn Lamps PRODUCT SPECIFICATIONS  Light Source Light Emitting Diode (LED)  Input Voltage 8V – 28V DC  Current Draw – 12V 0.3 Amps - Stop  0.1 Amps - Tail  2.25 Amps – Turn  Approx 32W  Dimensions: 127 x 127 x 27.5 mm  Weight: 0.68 kg  Intensity: 250 lumens ME 729 – ADVANCED MACHINE DESIGN

CAD models & Drawings Lithium iron phosphate cell

 Cell arrangement type-1 (Battery-1) (Finally decided to put this type)  Cell arrangement type-2 (Battery-2)

 Cell arrangement type-3 (Battery-3)  Cell arrangement type-4 (Battery-4)

• Battery charger

Electrical Design

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Electrical Design Presentation Transcript