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Critical Design Review

Critical Design Review. MACH 1/7. Daniel Bressan David Tran Robbie Banks Amit Kapoor. Overview. Produce an awesome workable RC car from scratch Top speeds of over 100 mph Program GUI interface to control the car from laptop Design mechanical chassis and shell for car. Target Goals.

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Critical Design Review

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  1. Critical Design Review MACH 1/7 Daniel Bressan David Tran Robbie Banks Amit Kapoor

  2. Overview • Produce an awesome workable RC car from scratch • Top speeds of over 100 mph • Program GUI interface to control the car from laptop • Design mechanical chassis and shell for car David Tran

  3. Target Goals • Low: Function Car • Using ECS pre-programmed chip • Driving, with GUI and 900MHz RF • Low end (cutting board) Chassis • Mid: 30-50 MPH • Gate drivers working • High: 100+ MPH • Build own Chassis and Shell David Tran

  4. The Plan v2.0 David Tran

  5. Input • We will build a GUI interface to control the car. • Mouse • Keyboard • Input: • Power from wall • RS-232 Signal for speed • Output: • RS-232 Signal to CPU to control speed and steering • Will start coding as soon as PCB is ordered Amit Kapoor

  6. RF System • Not much changed since PDR • Xtend PKG - 900 MHz • Tested and working Amit Kapoor

  7. Micro Controller David Tran

  8. MSP430 • MSP430-F2616 • Inputs Tx/Rx and digital optical encoder information • Outputs PWM for servo and PWMs for gate driver • MAX232 • Interprets RS-232 signal David Tran

  9. PWM for Sinusoids/Servo • User timers and DAC to generate sinusoid • Pulse widths from sin table • Servo Control David Tran

  10. Power System Daniel Bressan

  11. Power System Daniel Bressan

  12. Power • LiPo 3 cell 11.1 V • Powers motors and everything isolated on that side • LiPo 4 cell 14.8 V • Regulated for: • 3.3 V TLV-1117 33 • 5 V TLV-1117 50 • 9 V LM2940 9.0 Daniel Bressan

  13. Power – Level 2 • 14.8 V, 1Ah LiPo regulated for: • 3.3 V MSP430 • 5 V • Optical Encoder • Max 232 • 9 V RF • 11.1V, 5Ah LiPo Motor side • 5 V • Optoisolater VO0630T (right) • DC motor for Gyroscope • Servo • Transistors Daniel Bressan

  14. Control • Speed Encoders • US Digtial E5 • 32 CPR (cycles per revolution) • Max RPM 60,000 • Sensors • NONE! • Threw out inclinometer and force sensor ideas • Steering • Pre-Built Servo • PWM • Gyroscope Daniel Bressan

  15. Motor – Mamba Monster • Takes three PWM inputs • Max RPM of 60 kHz • Four pole motor • Max input frequency 2kHz • RPMs can be calculated as follows RPM = 120 * f/p p = poles • With our wheels and rotational speed we could achieve a velocity of 700 MPH Robbie Banks

  16. Torque Curves • Constant torque up to the rated frequency • Can go past rated frequency but lose torque Robbie Banks

  17. Motor Driver • Dual Channel Opto-Isolators • Gate Driver • Triple Half-Bridge Driver Robbie Banks

  18. Motor Driver Robbie Banks

  19. Opto-Isolators – VO0630T • Using Opto-Isolator for separation • Powered by a regulator connected to the motor power supply • Takes PWM inputs from microcontroller • Digital Opto-Isolator high-low threshold of .8V • Rise time of 23ns and Fall time of 7ns • Max frequency of 33.3MHz Robbie Banks

  20. Gate Driver – HIP4086 • Three PWM inputs • Amplifies PWM inputs • Dead time setting to prevent shoot through • Disable input signal • Six output signals, three high and three low • Powered directly by the three cell 11.1V LiPo battery Robbie Banks

  21. Triple Half Bridge Driver • Uses six AUIRL1404ZS MOSFETS • High Power NMOS transistors • Continuous drain current of 160A • VGS of 10V • Each source on the MOSFET is connected to the gate driver to ensure a VGS of at least 10V • Powered directly from the three cell 11.1V LiPo battery Robbie Banks

  22. Mechanical • For testing and low level design: • Kitchen cutting board chassis • High level design (after machine shop training): • Chassis and Shell possibly out of acrylic. • ITLL has an acrylic cutter • Will start full designs after PCB is ordered this week Robbie Banks

  23. Division of Labor • Main Changes: • David: mostly software, getting PWMs to work properly • Amit: Learning and teaching us Altium, and software with David • Robbie: Gate Driver and Power • Daniel: Power, and other simple components, helping Robbie Amit Kapoor

  24. Schedule • Changes to Schedule: • Behind on ordering PCB (should finish this week) • Behind on programming GUI, will start as soon as PCB is ordered • Ahead of schedule for gate driver Amit Kapoor

  25. BudgetUsed so far (Parts List) Amit Kapoor

  26. Deliverables • Milestone I • PCB testing (hopefully we’ll have it back) • Working Gate Driver • MSP430 communicating with gate driver • Milestone II • Driving Car • EXPO! • Car going 100+ MPH Amit Kapoor

  27. ANYQUESTIONS? Daniel Bressan

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