Senior Design Team 2008 UCEM Power Train Sponsor: UConn Electric - - PowerPoint PPT Presentation
Senior Design Team 2008 UCEM Power Train Sponsor: UConn Electric Motorsports Club Team: Zachary Ahearn, Waleed Hussain, Dennis Basar, Spencer Arnold Advisor: Sung-Yeul Park Our Sponsor The UConn Electric Motorsports Team (UCEM) is a
Sponsor: UConn Electric Motorsports Club Team: Zachary Ahearn, Waleed Hussain, Dennis Basar, Spencer Arnold Advisor: Sung-Yeul Park
that designs and builds an electric, open-wheeled formula style race car
○ Evaluating the performance of a preselected motor and battery system, both individually and as a completed, integrated system ○ Developing an embedded system to display real-time information about the power train ○ Assisting the ME senior design team on integrating a cooling system for the full power train
○ Battery Management System (BMS) → Dennis Basar ○ Battery and Battery Charger → Waleed Hussain ○ Motor and Motor Drive → Spencer Arnold ○ Embedded System → Zachary Ahearn
○ A majority of the first semester will be devoted to researching and understanding the choices of the previous years Senior Design teams
○ High Voltage Training ○ Electric Safety Courses ○ Standard Operating Procedures are written and submitted for review ■ Proper PPE will be worn when working with the battery ■ In this case, Arc Flash Cat 2 PPE
Battery:
battery must not exceed 80kW.
any two points must not exceed 300VDC.
Battery Management System (BMS)
every cell to ensure they remain in maximum and minimum cell voltage levels.
temperatures of at least 20% of the cells, to ensure the temperature stays below 60°C
*All of the rules are covered in the FSAE rulebook found on their site
thermistors
maximum 289V DC
Contactor
temperatures Battery Thermistors ⇨ Thermistor Module ⇨ CANBUS ⇨ Microcontroller
○ A thermistor expansion module, as well as 3 banks of thermistors will add the additional monitoring that we need ○ Not using the bank directly connected to the BMS, due to incompatibility
○
Thermistors will not be in the way of their cooling system, however we must ensure the temperatures we’re reading are accurate across the entire battery array
BMS Electric Load
Microcontroller/ Laptop
Battery System
system
○ Max voltage ○ Capacity ○ Charge time ○ Amperage ○ Temperature ○ How these change as the state of charge (SOC) changes
○ Voltage ○ Capacity ○ Discharge time ○ Amperage ○ Temperature ○ How these change as the state of charge (SOC) changes
○ According to the FSAE rules and our sponsors guidelines, the circuit “Must be charged to 90% within 5 seconds and discharge to 60V in under 5 seconds.”
mind.
○ Battery provide up to 268 Volts DC, and 360 Amps ○ Maximum power draw must be limited to 80kW
○ Max Voltage: 320 VDC ○ Max Current: 320 Amps ○ Max Power: 80kW ○ Continuous torque output of 80 Nm, with a peak of 140 Nm (59 and 103 ft-lbs.) ○ Lightweight, at only 9.4 kg (~21 lbs.)
H300
○ Allows for Field Oriented Control (FOC) ○ Offers CAN protocol in order to interface with rest of electrical system. ○ Allows for regenerative braking
○ Needs to be tested under dyno load, and tested with a temporary 3KW chiller ■ Torque and speed tests, both under and not under load ■ Chiller will be used until the ME’s cooling system is complete ○ Using EmDrive software and physical hardware, we can modify the parameters of the motor and control its various functions
○ Wall provides 208V 3-phase AC ○ Plugs into AC source to control voltage and current ○ AC source connects to voltage rectifier circuit to output 268V to motor
Microcontroller System
Temporary Chiller
Motor System
Final Design
Microcontroller System Cooling System
Precharge/ Discharge Circuit
○ State of Battery Charge ○ Throttle Level ○ Forward/Reverse
○ BMS uses a very common set of CAN addresses under the OBDII protocol, while
closely with them to create a system that can integrate both of our ideas
○ Single-board computer running Raspbian Linux ○ 1.4GHz ARM processor, 1GB RAM ○ Four USB 2.0 ports, used to connect to the motor controller and BMS ○ DSI display port to connect a small screen, as well as HDMI for prototyping
○ Converts between RS232 and USB, allowing for CAN signals to be directly read or written to ○ Up to 1Mbps baud rate ○ Developed by the same company who made the ORION ○ Creates a virtual serial port, that can be interfaced directly with the USB port of the microcontroller or a laptop (for use with BMS software)
Embedded System Proposal
CANdapter LCD Display BMS Motor Controller
motor
○ One full loop water cooling system, still in the design/simulation phase ○ Must work closely with them in the spring semester to help implement into the full power train
make will not interfere with their cooling system
○
Gantt Chart
Budget
Component Qty. Unit Price Total Price Raspberry Pi 3B Kit 1 $45.99 $45.99 Arduino Mega 2560 1 $14.99 $14.99 Micro SD Card, 32GB 1 $5.32 $5.32 20x4 Char. LCD Screen 1 $7.99 $7.99 Quick Disconnect W/ Pins 2 $6.75 $11.50
1 $40.00 $40.00 Grand Total $127.29
○ Update our plans and timeline as we progress ○ Keep in close contact with our sponsor ○ Attend weekly meetings
○ Repairs too expensive, so we created our own rectifier to test the motor
and motor
○ They need our help to help connect the electrical side of the cooling system ○ Their design is currently unfinalized, so we need to be prepared for things changing