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


Auxiliary power unit apu

Auxiliary Power Unit (APU)


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


Apu questions

APU Questions?


Sensor button placement

Sensor & Button Placement


Sensor placement

Sensor Placement

1


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


James kast andrew kuharske timothy lenberg daniel taylor

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


Chosen design side

Chosen Design - Side


Heat shielding

Heat Shielding

Exhaust Wrap

Exhaust Shielding


Exhaust questions

Exhaust Questions?


James kast andrew kuharske timothy lenberg daniel taylor

  • Fuse Setup

  • Radiator Mounting Issues


Fuse setup

Fuse Setup

Before

After


Fuse setup1

Fuse Setup

PEU

Rectifier

Fuse

360 V


Radiator

Radiator


Fuse setup and radiator questions

Fuse Setup and Radiator Questions?


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


Project timeline

Project Timeline


Potential problems

Potential Problems

Existing Components

Outsourcing

Weather

Time Constraint


Final questions

Final Questions?


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