2013_ESF_-_Univ_of_Kansas_-_JMS13e.docx

University of Kansas, E213

Electrical System Form

FSAE-E2013

University of Kansas - Jayhawk Motorsorts - Electric !eam

"ar #$m%er&

E213

Main "ontact&

Andrew Mertz

"ontact Email&

[email protected]

2013 orm!la "AE Electric

ii

University#ame,$ar#!m%er

&a%leof$ontents

&a%le of $ontents &a%le of $ontents ........................................................................................................................... iii '

(ist of ig!res........................................................................................................................... )

''

(ist of &a%les...................................................................................................................... ***vi

'''

(ist of A%%reviations .......................................................................................................... ***vii

1

"ystem +verview ..................................................................................................................... 2

2

Electrical "ystems .................................................................................................................... 3 2.1

"!tdown $irc!it ............................................................................................................... 3

2.1.1

-escrition/concet.................................................................................................... 3

2.1.2

iring / additional circ!itry ......................................................................................... 3

2.1.3

osition in car ............................................................................................................ 

2.2

'M- ................................................................................................................................... 

2.2.1

-escrition tye, oeration arameters4 ................................................................... 

2.2.2

iring/ca%les/connectors/ .......................................................................................... 5

2.2.3

osition in car ............................................................................................................ 5

2.3

'nertia "witc .................................................................................................................... 5

2.3.1

-escrition tye, oeration arameters4 ................................................................... 5

2.3.2 2.3.3

iring/ca%les/connectors/ .......................................................................................... 5 osition in car ............................................................................................................ 5

2.

6ra7e la!si%ility -evice ................................................................................................... 8

2..1

-escrition/additional circ!itry ....................................................................................... 8

2..2

iring ............................................................................................................................ 8

2..3

osition in car/mecanical fastening/mecanical connection ......................................... 8

2..

iring/ca%les/connectors/ .......................................................................................... 8

2..5

osition in car ............................................................................................................ 8

2.5

9eset / (atcing for 'M- and 6M" .................................................................................... )

2.5.1

-escrition/circ!itry .................................................................................................... )

2.5.2

iring/ca%les/connectors ........................................................................................... )

2.5.3

osition in car ............................................................................................................ )

2.8

"!tdown "ystem 'nterloc7s ............................................................................................. )

2.8.1 -escrition/circ!itry .................................................................................................... ) 2013 orm!la "AE Electric iii

2.8.2

iring/ca%les/connectors ........................................................................................... )

2.8.3

osition in car ............................................................................................................ :

2.)

2.).1

-escrition/circ!itry .................................................................................................... :

2.).2

iring/ca%les/connectors ........................................................................................... :

2.).3

osition in car ............................................................................................................ :

2.:

Meas!rement oints.......................................................................................................... ;

2.:.1

-escrition ................................................................................................................. ;

2.:.2

iring, connectors, ca%les ......................................................................................... ;

2.:.3

osition in car ............................................................................................................ ;

2.;

re<$arge circ!itry .......................................................................................................... ;

2.;.1

-escrition ................................................................................................................. ;

2.;.2

iring, ca%les, c!rrent calc!lations, connectors ......................................................... ;

2.;.3

osition in car .......................................................................................................... 10

2.10

-iscarge circ!itry........................................................................................................... 10

2.10.1

-escrition ............................................................................................................... 10

2.10.2

iring, ca%les, c!rrent calc!lations, connectors .......... Error' (ookmark not )efine)*

2.10.3

osition in car .......................................................................................................... 11

2.11

=> -isconnect =>-4...................................................................................................... 12

2.11.1

-escrition ............................................................................................................... 12

2.11.2

iring, ca%les, c!rrent calc!lations, connectors ....................................................... 12

2.11.3

osition in car .......................................................................................................... 12

2.12

3

&ractive system active ligt ............................................................................................... :

9eady<&o<-rive<"o!nd 9&-"4 ...................................................................................... 12

2.12.1

-escrition ............................................................................................................... 12

2.12.2


2.12.3

osition in car .......................................................................................................... 12

Acc!m!lator ........................................................................................................................... 13 3.1

Acc!m!lator ac7 1......................................................................................................... 13

3.1.1

+verview/descrition/arameters ............................................................................. 13

3.1.2

$ell descrition ........................................................................................................ 13

3.1.3 3.1.

$ell config!ration ..................................................................................................... 13 $ell temerat!re monitoring ..................................................................................... 1


4

3.1.5

Acc!m!lator ins!lation relays ................................................................................... 1

3.1.8

!sing ...................................................................................................................... 15

3.1.)

6attery management system.................................................................................... 18

3.1.:

Acc!m!lator indicator............................................................................................... 18

3.1.;

iring, ca%les, c!rrent calc!lations, connectors ....................................................... 1)

3.1.10

$arging .................................................................................................................. 1:

3.1.11

Mecanical $onfig!ration/materials.......................................................................... 1:

3.1.12

osition in car .......................................................................................................... 1:

3.2 

5

Energy meter mo!nting .......................................................................................................... 1; .1

-escrition ...................................................................................................................... 21

.2

iring, ca%les, c!rrent calc!lations, connectors .............................................................. 21

.3

osition in car ................................................................................................................. 21

Motor controller ...................................................................................................................... 22 5.1

-escrition, tye, oeration arameters ................................................................... 22

5.1.2


5.1.3

osition in car .......................................................................................................... 23

Motor 1............................................................................................................................ 2

8.1.1

-escrition, tye, oerating arameters ................................................................... 2

8.1.2


8.1.3

osition in car .......................................................................................................... 25

8.2

:

Motor controller 2 ............................................................................................................ 23

Motors .................................................................................................................................... 2 8.1

)

Motor controller 1 ............................................................................................................ 22

5.1.1

5.2 8

Acc!m!lator ac7 2......................................................................................................... 1;

Motor 2............................................................................................................................ 25

&or?!e encoder ...................................................................................................................... 28 ).1

-escrition/additional circ!itry......................................................................................... 28

).2

iring.............................................................................................................................. 28

).3

osition in car/mecanical fastening/mecanical connection........................................... 28

Additional (><arts interfering wit te tractive system........................................................... 2) :.1 (> art 1 ............................................................................ Error' (ookmark not )efine)* :.1.1 -escrition ............................................................................................................... 2)


5

:.1.2

iring, ca%les, ......................................................................................................... 2)

:.1.3

osition in car .......................................................................................................... 2)

:.2 ;

(> art 2 ............................................................................ Error' (ookmark not )efine)*

+verall ro!nding $oncet .................................................................................................... 31 ;.1

-escrition of te ro!nding $oncet............................................................................. 31

;.2

ro!nding Meas!rements ............................................................................................... 31

10

irewalls4 ........................................................................................................................... 3

10.1

-escrition/materials................................................................................................ 3

10.1.2

osition in car .......................................................................................................... 3

10.2 11

irewall 1......................................................................................................................... 3

10.1.1

irewall 2......................................................................................................................... 3

Aendi* ............................................................................................................................ 35

University #ame, $ar #!m%er

,

Error' +eference so$rce not fo$n)*

ist of Fi.$res

ig!re 1.1  6loc7 diagram of te tractive system & e section  e rt a in ing t o t e s y s t em o v er vte ie w tracti of ve s y sem t a n d c o n tr ol s y s t e m can %e f o ! nd  ee.r

ig!re 1.2  6loc7 diagram of te control system. 2013 orm!la "AE Electric

7

ig!re 1.3 < ig!re 1.2  6loc7 diagram of te s!tdown system &e section ertaining to te system overview of te s!tdown system can %e fo!nd ere.

ig!re 2.1 < $A- rendering sowing osition in car of => system s!tdown %o* & e section  e rt a in ing t o t e = > s d o!wt n %o* can %eof! nd  ee.r

ig!re 2.2  "cematicB 'M&e section ertaining to te wiring of te 'M- can %e fo!nd ere.

ig!re 2.3  $A- rendering sowing location of 'M- %o* & e section  e rt a in ing t o t e loc a t ion o f t e ' M - can %e f o ! nd  e r e.

ig!re 2.  "cematicB 'nertia "witc &e section ertaining to te wiring of inertia switc can %e fo!nd ere.

ig!re 2.5  $A- 9endering sowing 'nertia "witc & e section  e rt a in ing t o t e loc a t ion o f in e rt ia s w it c can %e f o ! nd  e r e.

ig!re 2.8  $A- 9endering sowing 6ra7e ress!re "ensor &e section ertaining to te wiring and osition of te %ra7e ress!re sensor can %e fo!nd ere.

ig!re 2.) $A- rendering sowing 6ra7e la!si%ility -evice Electrical =o!sing & e section  e rt a in ing t o t e loc a t ion o f t e % r a 7 e tylad! es%v ili ice can %e f o ! nd e. e r

ig!re 2.:B "cematic < 'M&e section ertaining to te wiring of te 'M- can %e fo!nd ere.

ig!re 2.;B "cematic < 6M" & e section  e rt a in ing t o t e w ir ingt e of 6 M " can %e f o ! nd  e r e.

ig!re 2.10  $A- 9endering sowing o!sing for 'M- and 6M" &e section ertaining to te location of te 6M" and 'M- can %e fo!nd ere.

ig!re 2.11  $A- rendering sowing reset %!ttons for 'M- and 6M" & e section  e rt a in ing t o t e loc a t ion o f t e 6 M " a n d ' M - can %e f o ! nd  ere.

ig!re 2.12B "cematic  "!tdown "ystem 'nterloc7s

&e section ertaining to te wiring of te s!tdown circ!its can %e fo!nd ere.

ig!re 2.13  $A- rendering sowing tractive and control system master switces & e section  e rt a in ing t o t e loc a t ion o f t e m a s ter s w it c e s a n d s ! t d o w n %! tt o n s can %e f o ! nd  er e.

ig!re 2.1  $A- 9endering of "!tdown switces on roll<oo &e section ertaining to te location of te s!tdown %!ttons can %e fo!nd ere.

ig!re 2.15  $A- 9endering of "!tdown switc on das & e section  e rt a in ing t o t e loc a t ion o f t e s ! t d o w onns %! can tt %e f o ! n d e r e .

ig!re 2.18  iring diagramB &"A( &e section ertaining to te wiring of te &"A( can %e fo!nd ere.

ig!re 2.1)  $A- rendering sowing &ractive "ystem Active (igt & e section  e rt a in ing t o t e loc a t ion o f t e & "A ( can %e f o ! nd  e r e . 2013 orm!la "AE Electric

16

ig!re 2.1:  &"M o!sing and %annana Cac7 connector &e section ertaining to te wiring and o!sing of te meas!ring oints can %e fo!nd ere.

ig!re 2.1;  $A- rendering sowing o!sing for &ractive and $ontrol system Meas!ring oints & e section  e rt a in ing t o t e loc a t ion o f t e m enga so !riints can %e f o ! n d e r e . 2013 orm!la "AE Electric

17

ig!re 2.20B "cematic  re
ig!re 2.21B reoltage vs. &ime & e section  e rt a in ing t o t e va og lte ca lc! lati ons f or t e r e < c a r ge c ir c! it can %e f o ! nd  e r e.

ig!re 2.22B re
D ig!re 2.23  $A- 9endering sowing re
ig!re 2.2 < "cematic of te discarge circ!it &e section ertaining to te wiring of te dis
ig!re 2.25B lot -iscarge >oltage vs. &ime & e section  e rt a in ing t o t e va o g lte ca lc! lation f or t e d is
ig!re 2.28B lot -iscarge $!rrent vs. &ime &e section ertaining to te c!rrent calc!lations for te re
ig!re 2.2)  ig!re sowing sna and loc7 connector for =ig >oltage -isconnect &e section ertaining to te descrition of te =>- can %e fo!nd ere.

ig!re 2.2: $A- 9endering sowing location of =ig >oltage -isconnect & e section  e rt a in ing t o t e oc al t ion o f t e => - can %e f o ! nd  e r e.

ig!re 2.2;  iring -iagram for 9&-" &e section ertaining to te wiring of te 9&-" can %e fo!nd ere.

ig!re 2.30 $A- 9endering sowing location of 9eady
ig!re 3.1  =aiyin (iti!m olymer $ell  Model &e section ertaining to te deiction of te %attery cells can %e fo!nd ere.

ig!re 3.2 Entire Acc!m!lator (eft and 9igt "ides4 & e section  e rt a in ing t o t e co n f ig ! r a t ion o f t ee ry %ce a tt lls can %e f o ! n d e e.r

ig!re 3.3  iring diagram of 6M" &e section ertaining to te config!ration of te 6M" can %e fo!nd ere.

ig!re 3.  1s ac7 wit sacers in %etween te ta%s. & e section  e rt a in ing t o t e w ir ingt e of acc ! m ! lator s y s t e m can %e f o ! n d e r e .

ig!re 3.5  6attery ac7 Model sowing mecanical o!sing &e section ertaining to te mecanical str!ct!re for te acc!m!lator system can %e fo!nd ere.

ig!re 3.8  $A- 9endering sowing mecanical str!ct!re to rotect acc!m!lator system & e section  e rt a in ing t o t e oc al t ion o f e t a cc ! m ! lator s y s t e m can %e f o ! nd  e r e .

ig!re .1  $A- 9endering sowing lacement of Energy Meter &e section ertaining to te location of te energy meter can %e fo!nd ere.

ig!re 5.1  $A- 9endering sowing location of motor controller & e section  e rt a in ing t o t e oc al t ion o f e t m o t or co nt r o ller can %e f o ! nd e. er 2013 orm!la "AE Electric

26

ig!re 8.1  lot of ower vs. 9m for Emra* Motor ($ &e section ertaining to te descrition of te motor arameters can %e fo!nd ere.

ig!re 8.2  lot of tor?!e vs. 9m for Emra* motor ($ & e section  e rt a in ing t o t e d e sc r i t ion o f t e m otor a metaerrs can %e of ! nd  eer.

ig!re 8.3  $A- rendering sowing osition of motor. &e section ertaining to te location of te motor can %e fo!nd ere.

ig!re ).1  iring -iagramB &or?!e Encoder & e section  e rt a in ing t o t e w ir ingt e of t o r ? ! e e n co d er can %e f o ! nd  e r e.

ig!re ).2  $A- rendering sowing &or?!e encoder fi*t!re and lacment &e section ertaining to te location of te tor?!e encoder can %e fo!nd ere.

ig!re :.1  iring diagram of 300> to 12> -$<-$ converter & e section  e rt a in ing t o t e w ir ingt e of 3 0 0> t o 1 2 > - $< - $ co n v e rt er c an %e f o ! nd  e r e. 2013 orm!la "AE Electric

29

University #ame, $ar #!m%er so$rce not fo$n)*

Error' +eference so$rce not fo$n)* Error' +eference

ig!re :.2  $A- 9endering sowing location of 300><12> -$<-$ $onverters &e section ertaining to te location of te 300> to 12> -$<-$ converter can %e fo!nd ere.

ig!re :.3  iring diagram deicting te 12>-$ %attery

& e section  e rt a in ing t o t e w ir ingt e of 1 2>- $ % aett r y can %e f o ! nd  e re.

ig!re :.  $A- 9endering sowing location of 12 > %attery & e section  e rt a in ing t o t e oc al t ion o f e t 1 2> - $ % aertty can %e f o ! nd  ere.

University #ame, $ar #!m%er (ist of ig!res

;.2

ig!re :.5  iring diagram of 5> to 12> -$<-$ converter & e section  e rt a in ing t o t e w ir ingt e of 1 2 > t o 5> - $ < - $ co er n v can er t %e f o ! nd  e r e.

ig!re :.8  $A- 9endering sowing location of 12><5> -$<-$ $onverter & e section  e rt a in ing t o t e oc al t ion o f e t 1 2 > to 5> -$ < - $ co n v e rt er c an %e f o ! nd  e r e.


***ii

ig!re :.)  iring diagram sown (> f!se %o*es and te gro!nd lane & e section  e rt a in ing t o t e w ir ingt e of (> !se f % o * es and g ro ! nd  la n e can %e f o ! nd  e r e .

ig!re :.:  $A- rendering sow location of (> ro!nd lane. & e section  e rt a in ing t o t e oc al t ion (> f !se % o * es and g r o ! nd  la n e can %e f o ! nd  e r e. 2013 orm!la "AE Electric

333

ig!re :.;  iring diagram for te $M &e section ertaining to te wiring of te $M can %e fo!nd ere.

ig!re :.10  $A- rendering sowing location of te $M o!sing 2013 orm!la "AE Electric

343

& e section  e rt a in ing t o t e oc al t ion o f e t $ M can %e f o ! nd  e r e.


3535

ig!re 10.1  $A- rendering sowing location of firewall &e section ertaining to te location of te firewall can %e fo!nd ere.

=as to %e yerlin7edF

University #ame, $ar #!m%er +eference so$rce not fo$n)*

,,

Error' +eference so$rce not fo$n)* Error'

ist of !a%les

&a%le 1.1 eneral arameters ................................................................................................2 &a%le 2.1 (ist of switces in te s!tdown circ!it ...................................................................3 &a%le 2.2 iring  "!tdown circ!it ....................................................................................... &a%le 2.3 arameters of te 'M-............................................................................................5 &a%le 2. arameters of te 'nertia "witc .............................................................................5 &a%le ).1 &or?!e encoder data ..............................................................................................8 &a%le 2.8 arameters of te &"A( .........................................................................................: &a%le 2.) eneral data of te re

***vii

,,, ist of A%%reviations A$

Alternating $!rrent

A-$

Analog to -igital $onverter

A'9

Acc!m!lator 'solation 9elay

AM"

Acc!m!lator Management "ystem

6M"

6attery Management "ystem

6+&

6ra7e +ver &ravel 6"

6ra7e anic "ystem $A$om!ter Aided -esign $" $ontrol "ystem $"M"

$ontrol "ystem Master "witc

$"M

$ontrol "ystem Meas!ring oints

-$

-irect $!rrent

-

ro!nd a!lt -etection

(>

ro!nded (ow >oltage

'+

eneral !rose 'n!t/+!t!t

=>

=ig >oltage

'M-

'ns!lation Monitoring -evice

(E-

(igt Emitting -iode

(>

(ow >oltage

$M

ower train control mod!le

9&-(

9eady to -rive (igt

9&-"

9eady to -rive "o!nd


383

University #ame, $ar #!m%er +eference so$rce not fo$n)*

Error' +eference so$rce not fo$n)* Error'

&"M"

&ractive "ystem Master "witc

&"M

&ractive "ystem Meas!ring oints


393

1

System /verview

&e electric system of te veicle is divided into two maCor categories. &e tractive system incl!des te motor, te motor controller, main f!ses, A'9s, %atteries and energy monitoring device. &e $ontrol system involves one Ard!ino Mega tat ta7es trottle and %ra7e in!t and sends it to te motor controller, two Ard!ino Megas tat read data from te sensor %an7s of te car and format it, a ras%erry i tat reads te formatted sensor data and erforms calc!lations for traction management and la!nc control and sends it to te Ard!nio Mega in carge of trottle. 'f tere is a sensor error te trottle Ard!ino falls %ac7 to a defa!lt setting tat rovides direct trottle control. 'n addition a s!tdown circ!it on te control system controls te 'M-, AM", 6" and 6+& fa!lt sensing and controls te A'9s tro!g a set of relays. 6loc7 diagrams of te tractive system, control system, and s!tdown system are sown in  ig ! re 1.1, ig!re 1.2, and ig!re 1.3. Ma*im!m &ractive
302. >-$

#ominal &ractive
288. >-$

$ontrol
12>-$,5>-$

Acc!m!lator config!rationB

)2s

&otalAcc!m!latorcaacityB

5117

MotortyeB

ermanente*citatedsyncrono!smotor

#!m%erofmotorsB Ma*im!m com%ined motor ower in 7

&otal1 )5

Table 1.1 General parameters


2

University of Kansas E(E$&9'$, $ar #!m%er

2

2


Electrical Systems

2*1

Sh$t)own "irc$it

2*1*1 escritionconcet &e s!tdown circ!it consists of a milled %oard tat accets in!t from te master switces, s!tdown %!ttons and inertia switc to control te 12> in!t to te A'9s as well as a air of relays. 'n addition te s!tdown circ!it accets in!t from te 'M-, 6M", 6" and %ra7e over travel switc controlled 5> logic circ!itsof !sing a airand of M+"E& to control a air of wic relays is wic control!sing te gro!nd terminal te -$H -$< A'9s transistors indeendently. 'n any fa!lt condition te s!tdown circ!it oens te circ!it to te A'9s !ntil it is reset. All logic systems defa!lt oen wen starting te car !ntil reset. art

!nction

Main "witc for control and tractive
#ormally oen

"!tdown%!ttons"-64

#ormallyoen

'ns!lation Monitoring -evice 'M-4

#ormally oen

6attery Management "ystem 6M"4

#ormally oen

'nertia"witc

#ormallyclosed

'nterloc7s 6ra7eanic"witc

$losedwencirc!itsareconnected #ormally+en

Table 2.1 List of switches in the shutdown circuit 2*1*2 irin.  a))itional circ$itry &e s!tdown circ!it integrates te different sections of te s!tdown system onto one milled %oard located inside of te => s!tdown %o* wit te entire circ!it is sown in ig!re 2.1.2. &e => s!tdown %o* accets in!t from all s!tdown systems and as individ!al o!t!ts for te => -$H and -$< connectors. &is is accomlised %y te => s!tdown %o* carries te direct acting c!rrent from te $"M", &"M", Master %!ttons and inertia switc wile searate relays control te 'M-, 6ra7e la!si%ility, 6ra7e over travel and AM" systems. 'n addition te -$H A'9 as a

software control so tat te motor controller or oter software systems can s!t down te system. Additional feat!res of te => s!tdown system incl!des (E- indicators for all systems involved s!c tat ?!ic7 tro!%lesooting can %e accomlised in te event of fail!re. &otal#!m%erofA'9sB $!rrenterA'9B Additional arts cons!mtion witin te

 0.13A 1.A

s!tdown circ!itB &otal c!rrentB $ross sectional area of te wiring !sedB

1.;2A 0.328 mmG 22 A4

Table 2.2 Wiring – Shutdown circuit 2*1*3 osition in car "ee fig!re 2.1 for $A- rendering.

2*2 2*2*1

,M escrition 4tye5 oeration arameters6

&e 'M- !sed is te 6ender A<'someter '9155<3203 and will r!n off te 12> s!ly. &e 'Mindicator ligt is laced on te das of te car and is controlled %y te latcing ortion of te s!tdown circ!it. "!lyvoltagerangeB

10..38>-$

"!ly voltage

12>-$

Environmental temerat!re rangeB

<0..105J$

"elftestintervalB

Alwaysatstart!,tenevery5min!tes

=igvoltagerangeB "et resonse val!eB Ma*.oerationc!rrentB

-$0..1000> 1507 500/>olt4 150mA

Aro*imate time to s!t down at 50L of te 28s resonse val!eB

Table 2.3 Parameters of the !" 2*2*2 irin.ca%lesconnectors &e 'M- is wired !sing 22 A wiring from its location sown in te $A- rendering. &is wiring o

from 6M9" is M22)5; Mill sec wire wit te ins!lation rated to 150 $ and 800>. &e => wires r!n into te acc!m!lator ods after te A'9s. &e ower, (> and $assis gro!nd wires are wired into te control system wiring. &e connector !sed for te 'M- are s!lied %y te man!fact!re and te team made connections are ring terminals to te f!se %loc7 and gro!nd lanes. &e 'M- is wired from te man!fact!rerDs scematics as sown in ig!re 2.2. 2*2*3 osition in car lease refer to fig!re 2.3.

2*3 2*3*1

,nertia Switch escrition 4tye5 oeration arameters6

'nertia"witctyeB

"ensata8<11g

"!lyvoltagerangeB

10..38>-$

"!ly voltageB

12>-$

Environmental temerat!re rangeB Ma*.oerationc!rrentB

<0..105J$ 500mA

&rigger caracteristicsB

8g for 50ms / 11gfor 15ms

Table 2.# Parameters of the nertia Switch 2*3*2 irin.ca%lesconnectors &e inertia switc is wired !sing 22 A wiring from te => "!tdown %o* to te switc and %ac7 o to te %o*. &is wiring from 6M9" is M22)5; Mill sec wire wit te ins!lation rated to 150 $ and 800>. &e wiring will %e connected !sing a =-3<2<)# from 6M9" wit te wires %eing %!ndled into a wiring arness. or a scematic lease refer to  ig ! r e 2. .

2*3*3 osition in car lease refer to  ig ! r e 2. .5

2*7

(rake la$si%ility evice

2*7*1 escritiona))itional circ$itry &e %ra7e la!si%ility section of te s!tdown circ!it ta7es in!t from te E6100 ten asses it tro!g a (M33; comarator to determine if a ard %ra7e is %eing alied. 'n addition to tis data from =&" 200</"2 is also assed into te s!tdown circ!it tro!g a (M33; comarator to determine if a c!rrent a%ove 57 1)A4. After te signals are fed tro!g te comarators tey ass tro!g a A#- gate and into a  %it sift register wit a cloc7 of :.3=z. &e o!t!t of eac %it is fed into a ?!ad #A#- gate s!c tat if te fa!lt condition ersists for fo!r cloc7 cycles .:s4 a fa!lt condition is trown and te A'9s are oened !ntil reset %y te driver. 6ra7e sensor !sedB

E6100 =ig Acc!racyMiniat!re ress!re &ransd!cer

&or?!eencoder!sedB

"trainage

"!ly voltagesB

12>

Ma*im!ms!lyc!rrentsB

5mA

+erating temerat!reB +!t!t !sed to control A'9sB

<0..125 J$ (atc a fa!lt condition and oen a air of relays.

Table 2.$ Tor%ue encoder data 2*7*2 irin. &e %ra7e la!si%ility device is wired !sing 22 A wiring from te =&" 200</"2 to te signal rocessing %oard and ten to te => s!tdown %o*. Additionally te signal from te E6100 is wired !sing 22 A to te => %o*. &is wiring from 6M9" is M22)5; Mill sec wire wit te o

ins!lation rated to 150 $ and 800>.

2*7*3 osition in carmechanical fastenin.mechanical connection lease refer to ig!re 2.8. 2*7*7 irin.ca%lesconnectors &e wiring will %e connected !sing a =-3<2<)# from 6M9" wit te wires %eing %!ndled into a wiring arness.

2*7*8 osition in car 9efer to  ig !er 2 .).

2*8

+eset  atchin. for ,M an) (MS

2*8*1 escritioncirc$itry &e latcing circ!it for te 'M- and 6M" systems are imlemented !sing "9 latces on te s!tdown circ!it %oard. &e - signal is assed tro!g a comarator %!ffer, tro!g an inverter and into te " in of te "9 latc. &e 6M" signals are assed tro!g a air of comarator %!ffers, tro!g an A#- gate and into te " in of te "9 latc. +n te o!t!t of te "9 latc te N terminal fa!lt4 in controls te ligting of te individ!al (E-s wile te ND terminal no fa!lt4 is fed tro!g a ?!ad A#- gate to control te A'9s. 2*8*2 irin.ca%lesconnectors &e latcing circ!it is located in te => s!tdown %o* wit te reset %!ttons and (E- indicators %eing wired s!ing 22 A. &is wiring from 6M9" is M22)5; Mill sec wire wit te ins!lation o

rated to 150 $ and 800>. &e wiring will %e connected !sing a =-3<2<)# from 6M9" wit te wires %eing %!ndled into a wiring arness. &e scematic for te 'M- can %e fo!nd in  ig ! re 2.: . &e scematic for te 6M" can %e fo!nd in ig!re 2.;.

2*8*3 osition in car lease refer to ig!re 2.10 and ig!re 2.11.

2*9

Sh$t)own System ,nterlocks

2*9*1 escritioncirc$itry &e interloc7 section of te s!tdown circ!it consists of two 7eyed master switces tat sit o!tside te car on te assenger side. &e first switc $"M"4 controls te low voltage systems and controls, te second switc &"M"4 ena%les ower to te ig voltage section of te s!tdown circ!it. +nce te &"M" as ower tree emergency s!tdown %!ttons are laced tat carry te c!rrent directly wit one ro!ger at ead level of te driver on eiter side of te veicle and te oter on te das witin reac of te driver. &e two master switces are artO M-<2 from 6M9" and te master %!ttons are model P62 %attery and te => s!tdown %o*. &e &"M" is wired !sing 22 A from te => s!tdown %o* and ret!rns to te s!tdown %o*. &e master %!ttons are wired in series !sing 22 A wire from te => s!tdown %o* and terminating again in te => s!tdown %o*. &is wiring from 6M9" is M22)5; Mill sec wire wit o

te ins!lation rated to 150 $ and 800>. &e wiring will %e connected !sing a =-3<2<)# from 6M9" wit te wires %eing %!ndled into a wiring arness. &e scematic is sown in  ig ! r e 1 2.2.

2*9*3 osition in car lease refer to ig!re 2.13 , ig!re 2.1 , and ig!re 2.15.

2*:

!ractive system active li.ht

2*:*1 escritioncirc$itry &e &ractive system active ligt is te Ecco "ort =ide A (E- wit Am%er (ens. 't is connected directly to a 12 > f!se, and so will %e active as wile te (> system is owered. A switc will also %e incl!ded in te ower line, to allow te ligt to %e deactivated if necessary. "!lyvoltageB

12>-$

Ma*.oerationalc!rrentB

350mA

(am tye owercons!mtionB

(E

6rigtness

100 (!men

re?!encyB

1.5=z

"ize circ!mference * eigt4B

3:.1mm * 22.23mm

Table 2.& Parameters of the TS'L

2*:*2 irin.ca%lesconnectors &e wiring diagram from te &"A( can %e fo!nd in ig!re 2.18. &e (igt is connected !sing 22 ga!ge wire4 directly to te (> f!se %loc7 and gro!nd lane. 't will %e active for as long as te (> system is owered.

2*:*3 osition in car lease refer to ig ! r e 2 .1) .

2*;

Meas$rement oints

2*;*1 escrition &e o!sing will %e made from lastic, wic is a non ositive, => negative, and (> gro!nd. &o access te o!sing and
ig!re

2*;*3 osition in car lease refer to ig!re 2.1;.

2*<

re-"har.e circ$itry

2*<*1 escrition &e re controlls to close te -$H A'9 !tting te veicle into ready to trive mode. 2*<*2

irin.5 ca%les5 c$rrent calc$lations5 connectors

&e wiring diagram of te re
6M9" tye M22)5; Mill sec wire wit te ins!lation rated to 150 $ and 800>. &e scematic for te reR1
E?!ation. 2.1

A lot sowing te re
E?!ation 2.2

9esistor&yeB 9esistanceB

9M"/n53<0008 800

$ontin!o!sowerratingB

50

+verloadowerratingB

200for30sec

>oltage ratingB

1500>

$ross
0.205 mmG

Table 2.( General data of the pre)charge resistor

9elay&yeB

9M"/n))<0028

$ontactarrangmentB

""&

$ontin!o!s-$c!rrentB

30A

>oltage rating

2000>-$

$ross
0.205 mmG

Table 2.* General data of the pre)charge rela+ 2*<*3 osition in car lease refer to ig!re 2.23.

2*10 ischar.e circ$itry 2*10*1 escrition &e discarge circ!it f!nctions %y lacing a 800 resistor in series wit two normally closed relays. &e relays are oened wen te A'9s close to revent wasting ower d!ring nominal oeration of

te veicle. +nce te ower to te A'9s is lost d!ring s!tdown te discarge relays will close allowing te => system to discarge tro!g te 800 resistor.

9esistor&yeB

9M"/n53<00008

9esistanceB

800

$ontin!o!sowerratingB

50

+verloadowerratingB

200for20sec

>oltage ratingB

1500>

Ma*im!me*ectedc!rrentB

0.5A

Average c!rrentB

0.28A

$ross
0.205 mmG

Table 2., General data of the discharge circuit 2*10*2 irin.5 ca%les5 c$rrent calc$lations5 connectors &e wiring of te discarge circ!it is sown in ig!re 2.10.2.1. &e relays are driven from signals o!t of te => s!tdown %o*. All re
M22)5; Mill sec wire wit te ins!lation rated to 150 $ and 800> &e scematic for te dis
E?. 2.3

A lot sowing te re
E?. 2.

2*11 => isconnect 4=>6 2*11*1 escrition &e ig voltage disconnect can %e disengaged %y a sna and loc7 mecanism. &e veicle will contain two of tese ig voltage disconnects located adCacent to te %attery o!sing sideods. &e acc!m!lator system will %e wired in a series config!ration terefore disengaging one of te ig voltage disconnects will disconnect te acc!m!lator system from te ig voltage system. 2*11*2 irin.5 ca%les5 c$rrent calc$lations5 connectors e will %e !sing -e!tsc %rand sna and loc7 connectors, an e*amle is sown in ig!re 2.2). &e -e!tsc %rand connector for 0 ga!ge wire size is rated for a contin!o!s of 300 ams. &e control system will owever ave a ard, te ma*im!m contin!o!s c!rrent te ig voltage system will see is 2)0 A, wic is witin te rating for te connector. 2*11*3 osition in car lease refer to ig!re 2.2:.

2*12 +ea)y-!o-rive-So$n) 4+!S6 2*12*1 escrition &e 9&-" is rod!ced %y a =ella "!ertone 12 > air orn. &e ornDs ower is controlled %y a solid state relay, wic is mani!lated !sing a control signal from te $M Ard!ino to so!nd for one second after te contacts ave engaged. 2*12*2 irin.5 ca%les5 c$rrent calc$lations5 connectors &e 9eady to -rive "o!nd is connected to te 12 > f!se %loc7 and to te gro!nd lane via a solid state relay. &e relay is controlled %y a signal from te ower train control mod!le, wic ca!ses it to so!nd for 1 second wen te car is activated. &e 9eady to -rive so!nd !ses 18 ga!ge wiring, as it as a relatively ig ower drain for te low voltage system. &e wiring scematic is rovided in ig!re 2.2;. 2*12*3 osition in car lease refer to  ig ! r e 2 .30 .

3 3*1

Acc$m$lator Acc$m$lator ack 1

3*1*1 /verview)escritionarameters &e veicle contains two side ods tat contain s!tdown rotection circ!itry, f!sing, -, A'9s, and an acc!m!lator containing 1 cells. Acc!m!lator 1 left side4 and Acc!m!lator 2 rigt side4 are identical, as is everyting in te side ods. Eac acc!m!lator contains fo!r 4 %attery ac7s. Eac ac7 contains 38 cells wired ;s. Eac %attery ac7 as a nominal voltage of 33.3 >. Ma*im!m>oltageB

151.2>-$

#ominal>oltageB

133.2>-$

Minim!m>oltageB

10:>-$

Ma*im!mo!t!tc!rrentB

02Afor15s

Ma*im!mnominalc!rrentB

2:A

Ma*im!mcargingc!rrentB

50A

&otaln!m%ersofcellsB

1

$ellconfig!rationB

38s

&otal$aacityB

255)7

#!m%er of cell stac7s  120>-$



Table 3.1 !ain accumulator parameters

3*1*2 "ell )escrition &e cell tye cosen for te electric car is te =aiyin liti!m olymer o!c cell. 't as dimensions of 100 mm * 120 mm * 8.35 mm. &e weigt of eac cell is 150 g, and for all te cells in one acc!m!lator is 21.8 7g. &e following ta%le lists all te arameters for te cell. &e =aiyin %rand cell is deicted in  ig ! r e 1. 3.

$ell Man!fact!rer and &ye $ellnominalcaacityB

=aiyin  (iti!m olymer o!c $ell 8A

Ma*im!m>oltageB

.2>

#ominal>oltageB

3.)>

Minim!m>oltageB

2.:>


88.8$for15s

Ma*im!m nominal o!t!t c!rrentB

50$


5$

Ma*im!m $ell &emerat!re discarging4

50J$

Ma*im!m $ell &emerat!re carging4

55J$

$ellcemistryB

(iti!molymer

Table 3.2 !ain cell specification 3*1*3 "ell confi.$ration &ere are a total of 1 cells in Acc!m!lator 1 left side4, as well as in Acc!m!lator 2 rigt side4. Eac acc!m!lator contains fo!r 4 %attery ac7s. Eac ac7 contains 38 cells wired ;s. Eac %attery ac7 as a nominal voltage of 33.3 >. &e scematic for te cells is sown in ig!re PP of. Every ac7 of  cells is monitored %y one 14 6M" mod!le, and is disc!ssed in 3.1.. 't is attaced via a 1/:V self
cells. All )2 series %atteries containing  cells in arallel4 from %ot acc!m!lators are monitored %y te one 6M" system. 3*1*8 Acc$m$lator ins$lation relays &e Acc!m!lator ins!lation relays are &yco %randed single ole single trow ig voltage contactors. &ey are contained in te safety circ!itry %o*, along wit te f!sing, -, and te s!toff circ!it. &ere are 2 relays er acc!m!lator %o*, 1 connected to te => ig side, and 1 to te ig voltage negative side. &ese are normally oen tye relays and only ever engaged wen te car is oerational and no errors are fo!nd. At any time tere is an error for te 6M", s!tdown circ!it or safety interloc7 switc, te relays will dis
&yco

$ontactarragmentB

""&

$ontino!s-$c!rrentratingB

500A

+verload -$ c!rrent ratingB

200Afor 10 sec

Ma*im!moerationvoltageB

;00>-$

#ominalcoilvoltageB

12>-$

#ormal (oad switcingB

Ma7e and %rea7 ! to 500 A

Ma*im!m (oad switcing

1 times at 2000 A

Table 3.3 -asic ' data

3*1*9 F$sin. &e rimary tractive system f!se is a 6!ssman (Q<250"'. &is f!se is rated %elow te ma*im!m c!rrent defined for te 0 ga!ge ca%le !sed for te tractive system and is designed wit a 10s delay at 500L overc!rrent. &is f!se is selected to rovide te safety re?!ired %!t remain fle*i%le if small amo!nts of overc!rrent occ!r. Additionally fill o!t te following ta%leB !setyeB

6!ssman(Q<250"'

$ontino!sc!rrentratingB

250A

Ma*im!moeratingvoltage &ye of f!seB

300>-$ "low 6low

'2tratingB

1500A2sat50>-$

'nterr!t $!rrent ma*im!m c!rrent at wic te f!se can interr!t te c!rrent4

100000A

Table 3.# -asic fuse data A ta%le of all te comonents tat te f!se rotects as well as contin!o!s c!rrent ratings are sown in &a%le 3.5

$omonentB 9ineartM100-P K'(+>A$ E>200 1/0 A EP9A- P(E 1000 >olt "ielded $a%le

3*1*:

$ontin!o!sc!rrentrating 300A 500A 33;A

(attery mana.ement system

&e 6M" system we ave selected to !se is Ele7tromot!sD 6attery Management "ystem. &e system is a distri%!ted tye system were te %attery mod!les are ysically aart from te main control !nit. &e control !nit will %e laced !nder te seat and owered %y te 12 > low voltage system. &is 6M" system can monitor a voltage range of 2<5 >-$ and can %e rogrammed e*actly to te tye of %atteries !sed. (iti!m olymer as a ma*im!m voltage of .2 > and minim!m of 3.0 >, wic will %e rogrammed into te control !nit. &e cell temerat!re caa%ilities of te 6M" system can detect a range of temerat!res from 0J< 80J $. &is can %e canged to reflect different tyes of cells in te software C!st as te voltages were. or liti!m olymer cells te minim!m allowed temerat!re is 0J$ and te ma*im!m is 50J$. &ese temerat!res can %e adC!sted to fit o!r needs, and if an over temerat!re event ta7es laces it disa%les te A'9 and te cells will ave to cool down %efore tey can %e !sed. Eac 6M" mod!le will monitor  cells connected in arallel. +ne %attery ac7 will ave ; 6M" mod!les on it, as sown in te scematic in  ig ! re 3 . 3&e cells are arranged in a 38s config!ration for eac acc!m!lator. =alf te cells are located in te left acc!m!lator od, and te oter alf in te rigt one. &e 6M" control !nit watces over )2 %atteries. &ere are fo!r data lines tat r!n from te control !nit to te cells. &ere is a ositive and negative transmit line, and ositive and negative receive line. &e transmit air connects to te ositive most %attery terminal,

wile te negative connects to te negative most %attery terminal. &en in %etween eac of te mod!les tere is a single data line r!nning from ci to ci, comleting te data line loo. &e wiring diagram for te 6M" is rovided in ig!re 3.3. 'f a series error occ!rs cell over voltage, cell over c!rrent, cell over temerat!re, etc.4 te 6M" will trow an error, wic is assed onto te s!tdown circ!it telling it tat te 6M" is not active. &e s!tdown circ!it will ten ave te A'9s disengage. rom ere te 6M" can %e oo7ed ! to a com!ter to fig!re o!t te error for tro!%lesooting. 3*1*; Acc$m$lator in)icator &e acc!m!lator indicator is located wit oter indicators on te s!tdown %o*. &is indicator is and (E- tat gets !lled to gro!nd tro!g a 8:0  resistor connected directly from te 6M" control !nit. 'n addition tere is a carging indicator tat !ses te same set! as te acc!m!lator indicator and is also mo!nted on te s!tdown %o*. 3*1*< irin.5 ca%les5 c$rrent calc$lations5 connectors &e car is e?!ied one )5 7 motor, wic limits te ma*im!m draw at f!ll carge to 250 A. &e wiring is sized for ! to 300 A contin!o!s. &e liti!m olymer o!c %atteries are connected togeter wit WV diameter al!min!m t!%ing see ig!re PP4. &e t!%ing as a cross
-e!tsc"!erA"=-contact,

$ontin!o!sc!rrentratingB

300A

$ross
)0mmG

Ma*im!moeratingvoltageB

Z>-$

&emerat!re ratingB

1)5 J$

ire connects te following comonentsB

6attery ac7 to 6attery ac7, and 6attery ac7 to s!tdown %o*.

Table 3.$ Wire data of "eutsch/ (0 mm

3*1*10 "har.in. &e entire acc!m!lator %ot left and rigt sides4 will %e carged !sing te El$on $ 2500 $arger wic as a ma*im!m voltage of 308 >. &e carger is e*ternally located and %e on site to carge te acc!m!lators. &e carger is connected to te side od via a de!tsc connector. en carging te acc!m!lators te car and 6M" will %e t!rned on to monitor te entire rocess and rovide data a%o!t te rocess. 'f tere is a fa!lt d!e to over carging a cell, ten te 6M" will iss!e a fa!lt and te s!tdown circ!it will dis
El$on$2500$arger

Ma*im!mcargingowerB

3.37

Ma*im!mcargingvoltageB

308>


10A

'nterface wit acc!m!lator

$A#<6!s, direct connect.

'n!tvoltageB

120/230>A$

'n!t c!rrentB

20 A

Table 3.& General charger data

3*1*11 Mechanical "onfi.$rationmaterials

&e %attery ac7 tat was constr!cted to old te cells, was designed wit safety and f!nctionality in mind. 't was designed to old 38 (iti!m<olymer cells sec!rely as well as rovide minimal effect on te %attery od[s str!ct!ral integrity. Kevlar was cosen d!e to its ligt weigt, non
3*2

Acc$m$lator ack 2

\ 3*2*1 /verview)escritionarameters "ame as Acc!m!lator 1, see "ection 3.1.1 a%ove. 3*2*2 "ell )escrition "ame as Acc!m!lator 1, see "ection 3.1.2 a%ove. 3*2*3

"ell confi.$ration

"ame as Acc!m!lator 1, see "ection 3.1.3 a%ove. 3*2*7 Acc$m$lator ins$lation relays "ame as Acc!m!lator 1, see "ection 3.1. a%ove. 3*2*8 F$sin. "ame as Acc!m!lator 1, see "ection 3.1.5 a%ove. 3*2*9 (attery mana.ement system "ame as Acc!m!lator 1, see "ection 3.1.8 a%ove. 3*2*: Acc$m$lator in)icator "ame as Acc!m!lator 1, see "ection 3.1.) a%ove. 3*2*; irin.5 ca%les5 c$rrent calc$lations5 connectors "ame as Acc!m!lator 1, see "ection 3.1.: a%ove. 3*2*< "har.in. "ame as Acc!m!lator 1, see "ection 3.1.; a%ove. 3*2*10 Mechanical "onfi.$rationmaterials "ame as Acc!m!lator 1, see "ection 3.1.10 a%ove. 3*2*11 osition in car "ee fig!re 3.1.12.1 3*3*1 (oth Acc$m$lators Ma*im!m>oltageB

302.>-$

#ominal>oltageB

288.>-$

Minim!m>oltageB

218>-$


02Afor15s

Ma*im!mnominalc!rrentB

2:A


50A

&otaln!m%ersofcellsB

2::

$ellconfig!rationB

)2s

&otal$aacityB

5117

#!m%er of cellstac7s 120>-$

Table 3.( -oth accumulator parameters

:

1*1*1 University #ame5 "ar #$m%er 3*2*1 "ame as Acc!m!lator 1, see "ection 3.1.1 a%ove.

/verview)escritionarameters

1*1*2 "ell )escrition "ame as Acc!m!lator 1, see "ection 3.1.2 a%ove. 1*1*3 "ell confi.$ration "ame as Acc!m!lator 1, see "ection 3.1.3 a%ove. 1*1*7 Acc$m$lator ins$lation relays "ame as Acc!m!lator 1, see "ection 3.1. a%ove. 1*1*8

F$sin.

"ame as Acc!m!lator 1, see "ection 3.1.5 a%ove. 1*1*9 (attery mana.ement system "ame as Acc!m!lator 1, see "ection 3.1.8 a%ove. 1*1*: Acc$m$lator in)icator "ame as Acc!m!lator 1, see "ection 3.1.) a%ove. 1*1*; irin.5 ca%les5 c$rrent calc$lations5 connectors "ame as Acc!m!lator 1, see "ection 3.1.: a%ove. 1*1*< "har.in. "ame as Acc!m!lator 1, see "ection 3.1.; a%ove. 1*1*10 Mechanical "onfi.$rationmaterials "ame as Acc!m!lator 1, see "ection 3.1.10 a%ove.

7 7*1

Ener.y meter mo$ntin. escrition

&e energy meter will %e mo!nted in te rear section of te rigt %attery %o* !sing zi ties. &e zi ties will %e attaced to te !ll wit inserts %onded to te car%on fi%er of te %attery %o*.

7*2

irin.5 ca%les5 c$rrent calc$lations5 connectors

&e 1/0 ga!ge wire from te %atteries will %e connected to te =>H terminal !sing te mating connector. &e energy meter will %e connected to te 1/0 A ca%le from te motor controller !sing a 1/0 A l!g. -ata for tese connection can %e fo!nd in te ta%le %elow. iretyeB

$!rrent ratingB

1/0AEP9A-P(E1000>olt"ielded $a%le

33;A

1*1*9 (attery mana.ement system "ame as Acc!m!lator 1, see "ection 3.1.8 a%ove. 1*1*: Acc$m$lator in)icator "ame as Acc!m!lator 1, see "ection 3.1.) a%ove. 1*1*; irin.5 ca%les5 c$rrent calc$lations5 connectors "ame as Acc!m!lator 1, see "ection 3.1.: a%ove. 1*1*< "har.in. "ame as Acc!m!lator 1, see "ection 3.1.; a%ove. 1*1*10 Mechanical "onfi.$rationmaterials "ame as Acc!m!lator 1, see "ection 3.1.10 a%ove. Ma*im!moeratingvoltageB &emerat!re ratingB

1000> )0?$ to 150?$

&a%le .1  iring information

$alc!lations are rovided in E?!ations .1 and .2 %elow. Ma*im!m contin!o!s owerB E?!ation .1 Ma*im!m rated owerB

E?!ation .2

1*1*9 (attery mana.ement system "ame as Acc!m!lator 1, see "ection 3.1.8 a%ove. 1*1*: Acc$m$lator in)icator "ame as Acc!m!lator 1, see "ection 3.1.) a%ove. 1*1*; irin.5 ca%les5 c$rrent calc$lations5 connectors "ame as Acc!m!lator 1, see "ection 3.1.: a%ove. 1*1*< "har.in. "ame as Acc!m!lator 1, see "ection 3.1.; a%ove. 1*1*10 Mechanical "onfi.$rationmaterials "ame as Acc!m!lator 1, see "ection 3.1.10 a%ove.

7*3

osition in car

lease refer to  ig ! r e . .1


8 8*1


Motor controller Motor controller 1

8*1*1 escrition5 tye5 oeration arameters &e motor controller ta7es a 300 >-$ in!t from te %atteries and converts it to a tree ase A$ o!t!t for te motor. &e fre?!ency is controlled %y te digital in!t from te trottle encoder. MotorcontrollertyeB

9M"M100

Ma*im!mcontino!sowerB

507

Ma*im!mea7owerB

1007for2min

Ma*im!m'n!tvoltageB

380>-$

+!t!tvoltageB

250>A$

Ma*im!m contin!o!s o!t!t c!rrentB

120A

Ma*im!mea7c!rrentB

220Afor2min

$ontrolmetodB

Analogsignal

$oolingmetodB

ater

A!*iliary s!ly voltageB

12>-$

Table $.1 General motor controller data

&e dataseet for te M100 can %e fo!nd in aendi* 11.5.1.1. 8*1*2 irin.5 ca%les5 c$rrent calc$lations5 connectors &e motor controller is connected to te %atteries and te motor !sing sielded 1/0 ga!ge ca%les. iretyeB


$!rrent ratingB

33;A


1000>


)0?$ to 150?$

&a%le 5.2  iring information 8*1*3 osition in car lease refer to ig!re 5.1.

8*2

Motor controller 2

&e tractive system will %e imlemented !sing a one motor and one motor controller.


9 9*1

8


Motors Motor 1

9*1*1 escrition5 tye5 oeratin. arameters &e motor !sed is a ermanently e*citated syncrono!s motor Emra* %rand and is also li?!id cooled. &e motor controller connects to te motor controller via a 3 ase A$ in!t. Additionally fill o!t ta%leB Motor Man!fact!rer and &yeB

EnstroC EM9AP ($

Motorrincile

syncrono!s,ermanentlye*citated

Ma*im!mcontin!o!sowerB

507

ea7 owerB

1007 for 5s

'n!t voltageB

300>A$

#ominalc!rrentB

1)0A

ea7 c!rrentB

330A

Ma*im!mtor?!eB

1;5#m

#ominaltor?!eB

100#m

$oolingmetodB

ater

Table &.1 General motor data

A lin7 to te dataseet for te Emra* ($ can %e fo!nd ere.

A lot of ower vs. 9m is sown in ig ! re 8 .1 , and a lot of tor?!e vs. 9m is sown in ig!re 8.2.

&e ma*im!m contin!o!s tor?!e co!ld not %e acieved d!ring testing d!e to limitations in te test e?!iment. &e rated ma*im!m contin!o!s tor?!e is 235 #m and te ma*im!m instantaneo!s tor?!e is 3)0 #m for 10 seconds.

9*1*2 irin.5 ca%les5 c$rrent calc$lations5 connectors &e motor is connected to te %atteries and te motor !sing sielded 1/0 ga!ge ca%les.

iretyeB


$!rrent ratingB

33;A


1000>


)0?$ to 150?$

&a%le 8.2  iring information &e dataseet for te => ca%les can %e fo!nd in aendi* 11.8.1.2. 9*1*3 osition in car lease refer to ig!re 8.3.

9*2

Motor 2

&e tractive system will %e imlemented !sing a one

: :*1

; +verallro!nding$oncet

!or@$e enco)er escritiona))itional circ$itry

&e tor?!e encoder !sed is a standard rotary otentiometer. $anges in o!r s!lied 5> will %e detected %y a micro
&or?!e encoder man!fact!rer and tyeB

$&" Electrocomonents

&or?!eencoderrincileB

otentiometer

"!ly voltageB

5>

Ma*im!ms!lyc!rrentB

1mA

+erating temerat!reB Used o!t!tB

<30..105 J$ 0<5>

Table (.1 Tor%ue encoder data :*2 irin. &e wiring diagram is sown in  ig ! r e )1.. &e diagram sows te interconnection of te critical low ower s!ly and gro!nd. &eir wires are connected to a dedicated sensor %o* in te front of te car were a microcontroller !ts te sensor data onto a $A# %!s for logging. &e signal wires are ten assed on to te $M mod!le for act!al ower control.

:*3

osition in carmechanical fastenin.mechanical connection

 ig !r e ) sows .2 te way in wic a -
;

A))itional >-arts interferin. with the tractive system

&e (> system is comrised mainly of 3 searate %o*es $M, ront and 9ear sensors4. -ata is gatered %y a sensor grid attaced to eac weel and rocessed %efore %eing sent %ac7 to te $M mod!le.

;*1

300> to 12> "-" "onverter*

;*1*1 escrition +nce te => contactors switc on, ower for te (> system is rovided %y tis converter. $onverter man!fact!rer and tyeB

>icor Micro 6ric7 >300$12$1506(4

"!lyvoltageB

1:03)5>

$!rrent (imitB

18.3 A

+erating temerat!reB +!t!t>oltage9angeB

<55..100 J$ <0.518.1>

Table *.1 4 to L4 con5erter data ;*1*2 irin. an) "a%les &e 300 > to 12 > converter draws its ower from te 300 > line tat tells te ig voltage control %oard wen te ig voltage system as activated. en tis occ!rs, te control %oard switces te 12 > %attery off and te 300 > to 12 > converter on. &e converter ten s!lies ower directly to te 12 > f!se %o*. 't is connected via te control %oard4 to %ot te 12 > f!se %o* and gro!nd lane !sing 18 ga!ge wiring. A wiring scematic for te 300> to 12 > -$<-$ converter can %e fo!nd in ig!re :.1. ;*1*3 osition in car lease refer to ig!re :.2.

;*2

12 > (attery

;*2*1 escrition &e %attery is needed to activate te => contactors. &e 300 > to 12 > converter will %e set to rovide an o!t!t voltage sligtly a%ove 13.3 >. &is so!ld maintain te carge on te 12 > %attery.

6attery man!fact!rer and tyeB !llcargevoltageB Am =o!rs A=4B

6raille  13.3> 2.33

Table *.2 12 4 -atter+ "ata

&e dataseet for te 12> %attery can %e fo!nd in aendi* 11.:.2.1. ;*2*2 irin. an) "a%les &e 12 > %attery is connected to te =ig voltage control %oard and te gro!nd lane via 18 ga!ge wiring. &e wiring diagram for te 12>-$ %attery is sown in ig!re :.3. ;*2*3 osition in car lease refer to ig!re :..

;*3

12> to 8> "-" "onverter

;*3*1 escrition &is converter will so!rce ower to most of te sensors. &e maCority of sensors on te veicle re?!ire a 5 >-$ s!ly. $onverter man!fact!rer and tyeB

$astle $reations $$ 6ec 10A 8" "witcing 9eg!lator

"!lyvoltageB

525.2>

+!t!t >oltageB

5.1 >

Ma*im!m contin!o!s c!rrent drawB

)A

Table *.3 4 to L4 con5erter data

&e lin7 to te dataseet is availa%le in aendi* 11.:.3.1. ;*3*2 irin. an) "a%les &e wiring diagram of te 12> to 5> -$<-$ converter can %e fo!nd in  ig !r e :. .5

&is converter draws its ower via 18 ga!ge wiring4 from te 12 > f!se %o* and s!lies ower via 18 ga!ge wire4 to te 5 > f!se %o*. &e 12 > and 5 > ower rails !se te same gro!nd lane, so %ot sides of te converter are connected to it.

;*3*3 osition in car lease refer to ig!re :.8.

;*7

> F$se (oesBro$n) lane

;*7*1 escrition &wo f!se %o*es are imlemented one wit 12 f!ses for 12 > ower, one wit 8 f!ses for 5 > ower4. &ese f!se %o*es ave no gro!nd lane, so instead an e*ternal gro!nd lane consisting of a coer late attaced to te dividing wall tat searates te motor controller from te (> systems4 will %e imlemented. ;*7*2 irin. an) "a%les &e 12 > draws ower from te ig voltage control %oard via 18 ga!ge wiring and delivers ower to te tractive system active ligt, te ready to drive so!nd, and te 12 > to 5 > converter all via 18 ga!ge4. &e 5 > f!se %loc7 delivers ower to te two trottle encoders, te %ra7e ress!re transd!cer, te front sensor %o*, and te $M all via 22 ga!ge wiring4. &e gro!nd lane is connected to virt!ally every system in te car via wiring of te same ga!ge as tat systemDs ower line. &e wiring of te (> f!se %o*es and te gro!nd lane is sown in ig!re :.). ;*7*3 osition in car lease refer to ig!re :.:.

;*8

ower-train "ontrol Mo)$le 4"M6*

;*8*1 escrition &e $M contains an Ard!ino wit $A# f!se %loc7 and gro!nd lane. 't receives $A#<6!s data from te front sensor %o* as well as a secial dedicated trottle line, all via 22 ga!ge wires. inally, te $M sends control signals directly to te motor controller via 22 ga!ge wires.

&e wiring diagram for te $M is sown in ig!re :.;. ;*8*3 osition in car lease refer to ig ! r e : .10 .

< <*1

/verall Bro$n)in. "oncet escrition of the Bro$n)in. "oncet

&e cassis will %e made entirely of car%on fi%er. or areas of te cassis tat are witin 100 mm of te tractive system comonents or (> comonents tere will e*ist secial connections to gro!nd te cassis to te (> system and testing will %e erformed to ens!re a resistance of less tan 5 +ms. &o f!rter red!ce te resistance more intermittent connections to te (> system gro!nd can %e made. &e rear
<*2

Bro$n)in. Meas$rements

&e meas!rements will %e ta7en witin 100 mm of any tractive system comonent or (> comonent on te car%on fi%er cassis and to ass m!st %e ave less tan 5 +ms of resistance to (> gro!nd. or anodized metals te resistance m!st %e less tan 300 m+ms to (> gro!nd witin 100 mm of any tractive or (> comonent.


10 irewalls4

10 Firewall4s6 10*1 Firewall 1 10*1*1 escritionmaterials &e seat %ac7 is to %e !sed as te firewall. &e seat %ac7 is comosed of car%on fi%er wic will acieve te re?!ired scratc and !nct!re resistance to meet U(;<>0 standards. &e seat %ac7 will %e coated in gold reflective tae to imrove te fire resistance. &e firewall will %e cond!ctive and sorted to te low voltage gro!nd tro!g te cassis. &e dataseet for te gold reflective tae can %e fo!nd in aendi* 11.10.1.1 10*1*2 osition in car lease refer to ig!re 10.1.

10*2 Firewall 2 +nly one firewall is needed to rotect te driver from te tractive system, wic is encas!lated %eind te seat.


11 Aen)i 11.5.1.1  M100 Motor $ontroller -ataseet availa%le at te following lin7B tt B // www.rineartmotion.com/rod!cts.tml &e section ertaining to te M100 motor controller can %e fo!nd ere.

11.8.1.1  Emra* motor ($ -ataseet availa%le at te following lin7B tt B // www. enstr oC. si/ Electr ic < r od!ct s/ emr a*
11.8.1.2  => $a%les -ataseet availa%le at te following lin7B ttB// www.camca%le.com/rod!ct/e*rad<*le<1000
&e section ertaining to te => ca%les can %e fo!nd ere.

11.10.1.1 -ataseet for old 9eflective &a !sed as firewall -ataseet availa%le at te followng lin7B http://www .gra inge r.c om / Gra inge r/RE FLEXI TE -Re fle c tive -Ta pe - 4LGL6

& e section  e rt a in ing t o t e r e f le c t iv e t a  e can % e f o ! nd  e r e .

11

11.:.1.1  300> to 12> -$<-$ converter -ataseet availa%le at te following lin7B ttB//cdn.vicorower.com/doc!ments/dataseets/ds]300vin to 12> -$<-$ converter can %e fo!nd ere.

11.:.2.1  12> 6attery -ataseet availa%le at te following lin7B ttB//www.%raille%attery.com/inde*./%raille/rod!ct]%atteries/g &e section ertaining to te 12 > %attery can %e fo!nd ere.

11.:.3.1  12> to 5> -$<-$ converter -ataseet availa%le at te following lin7B ttB//www.dimensionengineering.com/dataseets/"a%ertoot2*12.df & e section  e rt a in ing t o t e 1 2 > t o 5> - $< - $ c o n v er t er can %e f o ! nd  e r e.

2013_ESF_-_Univ_of_Kansas_-_JMS13e.docx

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