James kast andrew kuharske timothy lenberg daniel taylor
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James Kast Andrew Kuharske Timothy Lenberg Daniel Taylor. Introduction. Objective: To advance the development of an in house hybrid electric vehicle for use in testing Dr. Dean Edwards' experimental lead acid batteries. Background: Existing platform containing Dr. Edwards’ batteries

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James kast andrew kuharske timothy lenberg daniel taylor

James Kast

Andrew Kuharske

Timothy Lenberg

Daniel Taylor


Introduction
Introduction

  • Objective:

    • To advance the development of an in house hybrid electric vehicle for use in testing Dr. Dean Edwards' experimental lead acid batteries.

  • Background:

    • Existing platform containing Dr. Edwards’ batteries

    • Components from HUMV

  • Specs

    • APU

    • PEU/Motor

    • Exhaust

    • Safety


Accomplishments this semester
AccomplishmentsThis semester

Axels installed

First Battery Isolation Test

Voltage Controlled Fuel Test



Throttle control
Throttle Control

Control Method Options

Mechanical Control

Electrical Control


Microcontroller
Microcontroller

APU Control Scheme Options

  • Linear Organization

  • RTOS Centered

Controller Choice

Familiarity

Analog Inputs


Sensing task
Sensing Task

Check Sensors

Check for Overvoltage

Increment Coulomb Count

Check Charge Parameters

vtaskdelay


I o task
I/O Task

Check Buttons

Decode Buttons

Output LEDs

Update LCD

vtaskdelay


Apu start task
APU Start Task

Connect Kill Switch

Start

vtaskdelay(?)

Altern.

Voltage

Step Up Voltage

Regulate Voltage

Connect


Apu operation task
APU Operation Task

Assess State

+/- Throttle Voltage

vtaskdelay


Apu shutoff task
APU Shutoff Task

Disconnect

Decelerate

Disconnect Kill Switch





Voltage sensor
Voltage Sensor

  • Specifications

    • 500Vdc rated

    • Digital/Analog output

    • Accuracy <= 1%

  • CYHVS500T Sensor

    • 500Vdc rated

    • 4V-5V analog output

    • Accuracy <= 1%

    • -10 C to +70 C

    • Cost ~ $80


Current sensor
Current Sensor

  • Specifications

    • 300 Amp rated

    • Digital/Analog output

    • Accuracy <= 2%

  • LEM HTR 300 Sensor

    • 300 Amp rated

    • 4V analog output

    • Accuracy <= 2%

    • -10 C to +70 C

    • Cost ~ $180


User input
User Input

  • Required User inputs

    • Force APU on

    • Force APU off

    • Regen braking on/off

    • Reset Coulomb count

  • Specifications

    • Minimal distraction

    • Easy to reach

    • Quick to implement/build


Steering wheel
Steering Wheel

  • On Steering Wheel

    • Pros:

      • Easy to reach

      • Won’t have to glance over

    • Cons:

      • Difficult to install


Ground
Ground

  • Ground Next to Driver

    • Pros:

      • Easy to place build

      • Can be easily moved

    • Cons:

      • Driver must look down


Podium
Podium

  • Podium Next to Driver

    • Pros:

      • Easy to reach

      • Adaptable

    • Cons:

      • More materials required


Seat

  • Side of Seat

    • Pros:

      • Buttons are easier to reach

      • Eyes can stay on road

    • Cons:

      • Unconventional setup mayconfuse people

      • Buttons not visible


Decision
Decision

  • Build ground setup first

    • Quick build time gives us more time for testing

  • Build Podium

    • The ground button setup can be placed directly on the podium without much extra work


Sensors and input questions
Sensors and InputQuestions?

  • Work Cited

    • Current Sensor: http://www.lem.com/hq/en/component/option,com_catalog/task,displaymodel/id,70.22.46.000.0/

    • Voltage Sensor: http://www.hallsensors.de/HallVoltage.htm

    • Button: http://www.grainger.com/Grainger/SCHNEIDER-ELECTRIC-Illuminated-Plastic-Operator-6HW87?Pid=search


Exhaust design
Exhaust Design

  • Basic Requirements/Restrictions

  • Design Sketches

    • Pros and Cons

  • Chosen Design

  • Safety - Heat Shielding

  • Questions


Basic requirements restrictions
Basic Requirements/Restrictions

  • Restriction-Clearance

  • Route Exhaust

  • Incorporate Muffler

  • Eliminate Safety Hazards


Design sketches
Design Sketches

Short

Middle

  • Pros – Geometry, Length

  • Cons – Routing

  • Pros – Routing

  • Cons – Geometry, Length, Safety


Design sketches cont
Design Sketches - Cont.

Side

Dual

  • Pros – Routing, Geometry

  • Cons – Length, Safety

  • Pros – Routing

  • Cons – Geometry, Length, Safety


Design sketches cont1
Design Sketches - Cont.

Stack (top view)

Stack (side View)

  • Pros – Routing

  • Cons – Geometry, Location



Heat shielding
Heat Shielding

Exhaust Wrap

Exhaust Shielding




Fuse setup
Fuse Setup

Before

After


Fuse setup1
Fuse Setup

PEU

Rectifier

Fuse

360 V




Cost breakdown
Cost Breakdown

  • Voltage Sensors x2 = $160

  • Current Sensors x2 = $360

  • Micro Controller = $100

  • Exhaust = $350

  • Gear Oil x3 quarts = $27

    Total = $997

    *Prices are an estimate only



Potential problems
Potential Problems

Existing Components

Outsourcing

Weather

Time Constraint



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