Presentation final 4.29

Production Electronics for a
Light Weight Electric Car
Team 11
Team leader: Mitch Wozniak
Team members : Majed Alarawi, Xueyin Shi (Charlotte),
Yiqing Zhou (Jack)
Industry Sponsor: Blair Jackson Orison Corporation
Advisors: Scott Schneider, Rebecca Blust
Industry Sponsor: Blair Jackson
Orison Corporation
Advisors: Scott Schneider
Rebecca Blust
School of Engineering Innovation Center
1

Outline for Presentation
Introduction
System Layout and Components
Status of Components
Recommendation

Introduction
History
Background
Purpose

History
 The Blair Jackson Orison Corporation,
(“Orison”) was started by Blair Jackson
 The company resides in Troy, OH
 Orison has developed a prototype of electric
single person vehicle

Background
 The Orison light weight vehicle is a 4-wheeled single rider electrical vehicle
still in the development stage.
 “Big Picture” The client wants to eventually begin manufacturing of this
vehicle.
 The mechanical design of the car was designed by Blair Jackson.
 The electrical systems were also developed by Blair Jackson.
 Blair Jackson wants improvements made to the electrical system.

Purpose / Function
 The purpose of this project is to provide a simple functional electrical system
to be combined into the electrical vehicle created by Orison.
 The function of the electrical system is the heart of the vehicle. It supplies
power to all the working components.
 The components will improve the use of the vehicle such as lights, speed
control, simplicity, and braking.
 Team 11 is improving the electrical systems so that manufacturing can be
easier and the electrical systems will be improved.

Project Specifications
Requirements
Deliverables

Functional Requirements
 Power Distribution PCB must connect directly to the UNO. It controls
voltages to different areas of the vehicle, organizes the wiring of the
UNO, and has a transistor circuit to control voltage to the motor
controllers.
 New Hall Sensors control the throttle. They must be durable and
water/dirt repellent.
 The digital display is required to be able to display speed, battery life,
and direction of the motors.
 System of lighting around the vehicle is required to make it easy to
drive at night and noticeable to others.
 New motor controllers must allow for regenerative braking.
8

Requirements Continued…
 Power distribution PCB must control voltages and be able to send the
voltage to the correct components.
 Power distribution PCB must fit on the UNO.
 Power distribution PCB must have an easy to use and water proof plug
for wires.
 Hall Sensor must be water and dirt proof and must communicate with
UNO.
 Display must be visible in all weather and must show speed, battery
life, and direction.
 Lights must be be able to seen during day and night and have a visual
range of 50 feet at night.
 Motor controllers must provide voltage back to the batteries during
breaking.
9

Deliverables
 There are five deliverables that will be accomplished during
the project
1. Design of a power distribution circuit
2. Research and selection of rotary hall sensors
3. Research and selection of a new digital display for vehicle
speed, battery information and vehicle direction
4. Selection and testing of new lighting system for headlights
and running lights
5. Research and test new four-quadrant motor controllers
10

System Overview
Power Distribution Circuit
Hall Sensors
Display
Lights
Motor Controllers

System Layout
1
2
4
3
5
Legend:
Red – Positive
Black – Ground
Blue – I^2c
Purple – Multiple Signal
12

Power Distribution Circuit Section
Layout
 UNO
 Criteria for the Power Distribution Circuit
 Test Results from Multisim (Voltage & Amps)
 Breadboard Test Results
 Layout of Circuit in Multisim
 Layout of Circuit in Ultiboard
 3D Visuals of Circuit board
 Components chosen for Circuit
 LDO Criteria
 LDO Matrix
 LDO Description
 Explanation of Transistor Circuit Replacement
 Status of Power Distribution Circuit

Arduino Uno
 The Arduino Uno is a microcontroller board based on ATmega328
 It has 14 digital input/output pins
 Operating Voltage 5V
 Input Voltage (recommended) 7-12V
 Input Voltage (limits) 6-20V
 Digital I/O Pins 14 (of which 6 provide PWM output)
 Analog Input Pins 6
 DC Current per I/O Pin 40 mA
 DC Current for 3.3V Pin 50 mA
14

Criteria
 Provide different voltages to components around the vehicle
 3.3 volts for display, 9 volts for UNO, and 36 volts in series for the
lights
 Connectivity to UNO to minimize the complexity of wires
 Easy cable connection for communication sent from UNO to front of
the Vehicle
 Pin layout that coheres with the pin layout on the UNO
 Addition of transistors circuit that steps up voltage from UNO to motor
controllers to consolidate circuits

Testing of the Circuit (Voltage)

Test of the Circuit (Amps)

Breadboard Test
Overall Breadboard9 Volt Regulator Test3.3 Volt Regulator Test
Lighting System Voltage

Layout of Power Distribution Circuit

Layout of Circuit on to the PCB / Engineer Design
 All of the traces (red and green lines) had to be
sized correctly for the amount of current that was
going to pass through. (0.75 mm for large voltage
and current and 0.5 mm for all other traces)
 The traces must be a certain distance apart to
prevent jumping. (.25 mm)
 Pin foot print needed to match exactly with the
UNO.
 Parts with high current and voltage create more
heat. These were designed to be in open areas of
the PCB for heat dispersion.

3D view
Front ViewSide ViewRear View
Top View

Electrical Components
On / off switch
Board to wire Connector
Low drop out voltage regulator (3.3v & 9v)
Power resistance (510 Ω & 220 Ω both 5 Watt rated)
Capacitors (0.1μF or bigger)
Fuse (250 mA)
Circuit Breaker (4 amps)
Pins

Criteria for the Low Drop Out Voltage Regulator
1. Complexity: components are simple to use
2. Functionality: step up or step down voltage
3. Ripple / Noise: fluctuation in voltages
4. Size: component shape size
5. Efficiency: Ability to transform voltage without losses
6. Total Cost: the price of purchasing

LDO Matrix
24
LDO
0
2
4
6
8
10
LDO
SWITCHING
Criteria
Raw Score out of
10 Linear LDO Switching LDO
Complexity 10 10 6
Functionality 8 7 6
Ripple/Noise 10 10 6
Size 9 9 7
Efficiency 7 4 7
Cost 5 5 3
Totals 49 45 36

LDO
 Credible for battery design(enable battery to be used up
to the limit)
 Low noise(no switching needed)
 Small size and simple
 Most frequently used in technology (phone-digital camera-
laptop)
 Less heat loss(no transformer)
 Complexity(amplifier-pass element)
25

Replacing the Transistors from the UNO to the Motor Controllers with a circuit on
the PCB
26
Multisim Circuit
3D VisualPower Distribution Circuit

Status of Power Distribution Circuit
 The circuit has been designed and tested successfully.
 All components were ordered and received.
 Final design in Ultiboard is ready for client approval and is ready to be
sent out to a PCB manufacturer.

Part 2 - Hall Sensors
28
 Criteria
 Matrix
 Test results
 Information
 Status

Criteria
1. Resolution- The more resolution we have the more accurate the hall
sensor
2. Interface- The interface should be suitable to work with the UNO
3. Temperature Range- The temperature range should be large to
withstand all conditions
4. Supply Voltage - It should match what the UNO can provide
5. Price- The team’s budget is limited, the price should be reasonable
Hall Sensors

Hall Sensors
30
Criteria
Raw Score
(out of 10)
AS5048A
Rotary
Sensor
ADS1208
ADS1201
Resolution 8 6 6 8
Interface 8 8 3 3
Temperature Range 10 10 5
5
Supply voltage 6 5 3 3
Price 8 7 7 7
Total 40 36 24 26
Matrix

Hall Sensor
 The DRV5053-Q1 device is a chopper-stabilized
Hall IC that offers a magnetic sensing solution
with superior sensitivity stability over
temperature and integrated protection features.
 The 0 to 2V analog output responds linearly to
the applied magnetic flux density, and
distinguishes the polarity of magnetic field
direction.
31
Information

Hall Sensors
 Tested with LabVIEW
 Hooked into the Breadboard
Power Distribution Circuit to prove
that they work together
 Tested with Multi-meter
 LabVIEW writes information to
excel file
Test Results

Hall Sensor
 Cleaned up test values
 Chart for linear equation for the
hall sensor
 These equations can be used in
RobotC to convert the pulse
width signal to distance
Test Results

Status
 Component has been researched and ordered
 Experiment connecting to the UNO has been completed and failed
 Alternative methods to test the Hall Sensors were done in LabView and
Multi-meter
 We proved that they can work and found out what type of signal is
being used
 Having the knowledge of the signal type and how it works will help in
setting up the Hall Sensors with the UNO
Hall Sensors

Part 3 - Display
35
 Criteria
 Matrix
 Information
 Status

Criteria for the Display
1. Size - The bigger the size, the easier that the customer can see the
information
2. Information on the Board -The board should show multiple information
at the same time
3. Supply Voltage -The voltage should be at 5V
4. Price - The team’s budget is limited, the price should be reasonable

Display Matrix
Criteria
Raw Score
(out of 10
NHD-
0420DZW-
AB5
NHD-2.23-
12832UMB
3
Size 8 8 6
Information on the board 10 10 6
Supply voltage 8 8 8
Price 10 8 10
Total 36 34 30

Display NHD-0420DZW-AB5
 4 lines x 20 character Blue LED display
 3V or 5v power
 4.75mm character height
 Size: 98mm x 60mm
Information

Status of Display
 Other parts of the project were needed before the
display could be integrated so we concentrated on
those parts.
 The other crucial parts should be finished before
the display is worked on.
 The project was not as far along as we thought so
we researched the display, and did not purchase it.
 The display was not ordered.

Part 4 – Lighting System
40
 Head Lights
 Criteria
 Matrix
 Information
 Running Lights
 Matrix
 Information
 Status

Criteria for Lighting System
1. Voltage - The voltage needs to be 12V which is suitable to the circuit.
2. Color of Lens and Lights - The color of rear light should be yellow. The color of
the head light should be white.
3. Number of LEDs - Determines the brightness of the light.
4. Material- The material should be steel.
5. Price- The team’s budget is limited, so the price should be reasonable.

Head Light
42
Criteria
Raw Score
(out of 10)
Black
Motorcycle
Headlight 5"
LED Head Lamp
Double Dual
Lamp
Street
7" LED
Motorcycle
Halogen
Headlight
Voltage 8 8 8 8
Color of lens and lights 8 3 8 3
Number of the LED 10 10 0 6
Material 6 6 3 3
Price 8 7 2 4
Total 40 34 21 24
Matrix

Head Light
Color: Black
Lens Color: Clear
Number of LED: 30
Cable Length: 7 1/2" (19cm)
Voltage: DC 12V
Wattage: 3w/5w
Material:
Steel & Glass Lens
3 wires connection
system.
43
Information

Running Lights
44
Criteria
Raw Score
(out of 10)
1x Rectangle
Reflector
Amber Yellow
LED Rear turn
signal light Car
Clear Lens
Motorcycle
Custom LED
Reflector
Tail Trunk
Rear Fog
Light
Shadow
Clear Lens
ND
Smoke For
Suzuki 05-
06
GSXR1000
LED
Intergrated
Tail Light
Turn
Signals
Brake
Voltage 8 8 8 8
Color of lens and lights 8 8 3 3
Number of the LED 10 9 9 10
Material 6 3 3 3
Price 8 8 8 4
Total 40 36 31 28
Matrix

Running Lights
 Type of Lights : 24 high power LED light clip inside each light
 Size (length x Width x Depth): ~89mm x 39mm × 9.5 mm
 It works at 12 V
 There are three wires: black, blue and red
Black line→ cathode / ground / negative wire
Blue line→ small light (for 50% light) positive wire
Red line→ turn signal or brake light (for 100% light) positive wire
45
Information

Lighting System
 The lighting system was also dependent on the team
finishing other components of the project.
 The parts were ordered and received.
 The parts are ready for installation once the Power
Distribution Circuit is finalized.
 Lights have been tested with the breadboard Power
Distribution Circuit.
Head lightRunning Lights
Status

Motor Controllers
47
 Information
 Status

Kelly KBS-X Brushless Motor Controller
 KBS36051X
 Four quadrant motor control
 Less expensive
 Already programmed
 Client recommended
48

Status of Motor Controllers
 The Motor Controllers were purchased and have been experimented with.
 Research was done to determine the best way to wire the motor controllers
to the motors and the UNO.
 We have been working with the motor controller to get them to turn the
motor but have been unsuccessful.
 We have tried different ways of wiring and changing parameters in the
program both of which have come with no results.

Criteria for Wiring System
1. Number of Wires – Cables are capable of running 1 to 48 wires for this
application. For this application we needed 20.
2. Protective Coating – A PVC coating is needed to protect the wires from outside
contaminates.
3. Shielding – Important for 2 reasons. It prevents EMI and ESD interference of
the signal and it prevents the wires from easily being pinched.
4. Gauge – It is the thickness of the wire which determines how much voltage
and current can be sent through.
5. Twisted Pairs – Reduces crosstalk for balanced drive applications.
6. Price – Need the above requirements but at a price that is reasonable.

Wiring System
Criteria
Raw Score
out of 10 3M 3600x series Mcmaster-CARR 7741k17 General Cable XLPE/XL-CPE
# of Wires 8 8 7 8
Protective
Coating 6 6 6 6
Shielding 10 10 0 8
Gauge 10 10 7 9
Twisted Pairs 8 8 0 8
Price 5 2 3 2
Totals 47 44 23 41
Matrix

Wiring System
 The wire system was researched and we found the
solution.
 3M Round, Shielded/Jacketed, Disc. Wire Cable 3600x
Series
 We did not purchase it because we were not to that
point in the project.
 You have to buy a set distance of wire, the shortest
being 100ft.
 The price was too much for the bench test.
 We used single wire for the bench test to make it
easier to test different configurations of wires.
Information / Status

Project Management
Budget
Gantt Chart
Recommendation
Conclusion

Budget
 Given $1,000 budget by Blair Jackson
 Company credit card with rules about each
purchase
 Spent total of $550 dollars
 Totally cost to produce the Power Distribution
PCB $78.13
 Total electrical system cost $285.17
 Additional budget was spend on components
for testing
Budget
Number
of Parts
Price of
Part
Shipping
Price
Sales Tax
/ Process
Fee
Total
Price
Deliv
ered(
Y/N)
Total -
Available
Part Name
UNO 1 $34.99 $6.99 $3.04 $45.02y
Hall Sensors 2 $25.00 $0.00 $0.00 $50.00y
Motor Controllers 2 $59.00 $31.00 $0.00 $149.00y
Transistors 10 $0.25 $0.00 $5.00 $7.50y
Circuit Breaker 4 amp 2 $9.25 $0.00 $0.00 $18.50y
Hall Effect Sensor 4 $1.04 $7.00 $0.00 $11.16y
LDO Regulator 3.3v 10 $0.40 $6.99 $0.80 $11.83y
Head Light 1 $24.99 $0.00 $0.00 $24.99y
Circuit Breaker 25 amp 1 $21.73 $0.00 $0.00 $21.73y
Regulator 9v 10 $0.25 $2.67 $5.00 $10.17y $850.00
Running Lights 1 $14.98 $0.00 $0.00 $14.98y
Electronic Parts 1 $8.91 $0.00 $0.00 $8.91y
Conn Recept 20 pos 2 $1.00 $0.00 $0.64 $2.64y
Conn Header 20 pos 2 $0.91 $0.00 $0.00 $1.82y
Conn term female 50 $0.10 $0.00 $0.00 $4.95y
50 pcs 5mmX20mm glass
tube 1 $17.97 $0.00 $0.00 $17.97y
510 OHM resistor 1 $22.83 $0.00 $0.00 $22.83y
easy more 40 pin 1 $25.26 $0.00 $0.00 $25.26y
220 ohm resistor 1 $13.45 $0.00 $0.00 $13.45y
Total Left
Over
$523.51 $326.39School of Engineering Innovation Center
Project Management

Gantt Chart
55
Project Management

Recommendation
 Power Distribution Circuit – Order circuit board from a PCB manufacturer and
test it with the UNO.
 Hall Sensors – Rewrite the RobotC and use the equation derived by LabView
for UNO to understand the signal being sent by the Hall Sensors.
 Display – Get all other components working before working on the display.
Once the system is working take signals that are needed and run them to the
display.
 Head lights – Lighting system is ready to be plugged into the Power
Distribution Circuit as soon as it is complete.
 Motor Controllers – Get the Hall Sensors working with the UNO then try to
hook the Motor Controllers to the UNO.
Project Management

Questions??

Status of the Project
Researched Designed
Parts
Ordered
Parts
Received Assembled Testing Finished
Power Distribution
PCB      In Progress In Progress
Hall Sensors  N/A   In Progress In Progress In Progress
Display  N/A In Progress In Progress In Progress In Progress In Progress
Lighting  N/A   In Progress In Progress In Progress
Motor Controllers  N/A   In Progress In Progress In Progress
59

Presentation final 4.29

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