GLV Systems Preliminary Design Report Electrical and Computer - - PowerPoint PPT Presentation

GLV Systems Preliminary Design Report

Electrical and Computer Engineering Class of 2015

Roadmap

• 2013 System Overview
• System Hierarchy
• Subsystem Reports

○ Power ○ Safety ○ VCI ○ TSI

• Budget
• Schedule

Psdgraphics.com

2013 Safety Box

• Pros

○ Functioning safety loop ○ Materials

• Cons

○ Not chassis mountable ○ Large

Source: CDR Presentation 2013

2013 VSCADA Box

• Pros

○ Working Relay system ○ Some Usable Parts

• Cons

○ Not chassis mountable ○ Large ○ Messy Wiring

Source: CDR Presentation 2013

2013 Load Controller

• Pros

○ Many useful materials

• Cons

○ Not chassis mountable ○ Needs better high/low voltage isolation ○ TSAL board

Source: CDR Presentation 2013

2013 GLV Power

• Pros

○ Acts as a good test stand

• Cons

○ Not a battery

Source: CDR Presentation 2013

GLV

GLV Power

VCI / Safety

Driver Controls

TSI

GLV Power Subsystem

• Priority #1 - buying a battery
• Charging and power management
• Cabling, distributing power to different parts
• f the car

Power - Requirements Highlights (End Goal)

• power GLV and other non-tractive systems
• power for >3 hours
• battery protection
• grounding to chassis
• packaging and mounting

Psdgraphics.com

Power - Test Plan Highlights

• Analysis + Inspection

○ System ground, electrical insulation, prohibited insulators, battery type, fusing

• Tests

○ System ground, tractive system power up, GLV failure, battery duration, charge from zero, data measurement

Power - potential battery

24V, 10Ah, NiMH, High Temp Protection, $185

All-battery.com

Power - potential smart charger

12V-24V, NiMH/NiCd, $20, includes temperature sensor

All-battery.com

Power - potential battery

12V, 12Ah, Lead Acid, $49 (would need two)

Digi-Key.com

Power - potential charger

12V, $99, indicator lights

Digi-Key.com

Budget Comparison

$185 + $20 = $205 $49 + $49 + $99 = $196

All-battery.com Digi-Key.com

Power Management

Digi-Key.com LTC4365 Overvoltage/Undervoltage Protection $2 LTC2945 Power Monitor $9 LTC4365 Data Sheet LVR055 PolySwitch $2 Max Currents: 1.2A - 7A options Board $30 Housing $150

Safety Systems Description

• Keeps high level voltage system in a safe state
• Monitors status of the system and provides multiple

shutdown options to both driver and surrounding personnel

• Interacts with each electrical subsystem
• Follows rules presented in SAE International Formula

Hybrid Rules 2015

Shutdown State Analysis

Top Level Overview of the Safety Loop

ref 2012 PDR: slide 12

Basic Components

• Safety Controller
• 1. Start and end to safety loop
• 2. Contains system status LEDs
• Safety Panel
• 1. User access to the safety loop
• 2. 4 ways to shut off the safety loop: one BRB for the

cockpit and one on each side of the car, and the Brake Over-Travel switch

Basic Components Cont.

• BRBs (owned)

1. Push-Rotate (in our case) where pushing opens the shutdown circuit 2. Pushing any of the 3 BRBs separates tractive system for the accumulator

• Master Switch (owned)

1. GLVMS and TSMS are rotary type and direct acting with removable key 2. Disables power to all electrical circuits; all battery power flows through this switch

Safety - Budget

• Budget of $200 needed
• BRBs and Master Switches are

already owned

• $150 dollars required for fuses,

wires, sensors (according to 2013 BOM)

• Could potentially reuse these

materials assuming they are up to spec

Safety - End Goal

• The safety loop will keep the driver and other team

members safe on and off the track

• Maintain safe operating status of the system and shut

down if there are any failures

• Meet the desired specifications and shutdown

appropriate systems when necessary

Safety - Test Plan

• Can demonstrate proper

function by triggering different shutdown protocol

• Follow Table 17 from

the spec pertaining to shutdown priority

TSI

• Tractive System Interface
• Load Controller

○ Connect motor controller to battery pack ○ Keep TSV isolated from the rest of the vehicle

TSI - Requirements Analysis

• Galvanic isolation
• Electrical insulation and layout
• TSMP and GLV GMP
• TSAL
• IMD
• IMD indicator light
• MCS cabling
• Tractive System restart

TSI - 2013 Load Controller

• TSAL PCB

○ Opto-isolator resistor ○ IO Holes ○ Incorrect labeling

• TSMP
• GLV GMP
• IR LEDs
• VSCADA control
• IMD

TSI - What to Expect

• Car ready container
• Electrical insulating barriers
• TSAL circuit board
• MCS cabling

○ High voltage power-lock connectors

• IMD indicator light
• Interfaced with VSCADA
• Tractive system reset

TSI - Test Plan

• TSAL Test
• TSMP and IR Indicator Test
• IMD Safety Loop Test
• IMDT

○ As outlined in Formula EV rules

• VSCADA Interface Test

TSI - Budget

Vehicle Computer Interface (VCI)

• Collect and deliver data from sensors to VSCADA
• The collected data will be converted from the analog to

digital and then formated by the VSCADA team

• Important to coordinate with VSCADA to determine the

appropriate sensors

• In charge of purchasing the sensors

ref Phidgets Inc.

Top Level Overview of the VCI Subsystem

ref GLV Systems PDR page 5

Ready to Drive Sound

• When the car is set to ready to drive mode it must emit

a sound

• Sound needs to be audible

in front of the vehicle in noisy environments

• Modify the amplifier to

meet requirements

VCI - Budget

• Speaker/Amplifier - $50
• Sensors

○ Temperature (x4) - $25 ○ Current (x2) - $30 ○ Voltage (x2)

• $60

○ State of Charge - $6 ○ Rate of Charge - $15 ○ Rate of Discharge - $15

• Container - $150
• Total $330

VCI - End Goal

• Ready to Drive Sound feature is fully

functionable and meets the requirements

• Sensors required by VSCADA are

implemented

• Data is correctly converted from analog to

digital

• Data is delivered to VSCADA

VCI - Test Plan

• RTD Sound Length Test

○ Should last for 1-3 seconds

• RTD Sound Tone Test

○ Tone of 2500-3500 Hz ○ Minimum loudness of 68 db at 2 ft from the car

• Required Sensor test

○ Compare sensors’ output to the specified requirement ○ VSCADA is receiving properly converted data

• Total

○ $1,399

Budget

Budget

Schedule

• User Manual

○ February 12th

• CDR Planned

○ March 5th

• Hardware Purchase

○ March 12th

Questions?