Transcript display


Main Components
› Batteries
 Primary (72VDC)
 Secondary (12VDC)
› Motor
 Brushed DC
›
›
›
›
Motor Controller
DC-to-DC Converters
Microcontroller
Ignition Switch
› Peripherals (5VDC)
 Potentiometers
 Hall Effect Sensors
 Switches
› Circuit Protection




Fuses
Diodes
Circuit Breakers
Optoisolators
› Safety
 Emergency Stop
 Kill Switch

System Functions
› Store High Voltage (HV) and route current to
electric motor to propel motorcycle
› Maintain OEM-type motorcycle battery
voltage used to power microcontroller and
motor controller
› Control rear wheel spin and front wheel lift
by modifying the throttle input signal to the
motor controller
› Isolate HV battery from all HV components
for safer operability and serviceability
Input Peripherals
Spec #
Voltage Range
Component
Description
Part Number(s)
Ref. Spec(s)
21176-0706 (FR WSS)
21176-0134 (RR WSS)
21007-0166 (FR RLR)
21007-0167 (RR RLR)
S2, S11
2
1
2
0.4VDC = air gap, 5VDC = blocked by ferro-magnetic material,
50 pulses per rotation
Accelerator Sensor Assembly
Potentiometer
Analog
3
0
1
0VDC = closed throttle, 5VDC = wide open throttle (WOT)
13S-85884-00-00
S11
Gear Position Sensor
(OEM-type)
Potentiometer
Analog
3
1
1
Tiered levels of voltage designated for each gear position
(i.e. 0.5VDC = 1st, 1.0VDC = 2nd, 1.5VDC = 3rd, etc.)
13151-0045
S11
Gear Position Sensor
(Magnet type)
Hall Effect
Digital
2
2
2
Upper sensor trigger = upshift, lower sensor trigger = downshift,
triggered by rising-edge
HP620-300
S11
Potentiometer
Analog
3
1
1
0VDC = suspension fully extended, 5VDC = fully retracted
CLP-250
S1, S11
Switch
Digital
2
2
2
Button 1) adjusts traction control levels (i.e. 1st push = 10% allowable
slip, 2nd push = 5% allowable slip, 3rd push = OFF) Button 2)
starts/stops Data Acquisition; Both triggered by rising-edge
3-1437565-0
S11
# of Microcontroller
Outputs Needed
# of Components
Needed
Description
Part Number(s)
Ref. Spec(s)
0
1
4N25-000E
S10
Part Number(s)
Ref. Spec(s)
dsPIC33FJ12GP202
S10
S21
S22(b)
# of Components
Needed
Digital
Wheel Speed Sensor
0 - 5 VDC
Input Type Wire Count
Hall Effect
S20
S22(a)
Type
# of Microcontroller
Inputs Needed
S23
Front Suspension Travel Sensor
S24
Push-Button
Output Peripherals
Spec #
Voltage Range
S25
0 - 3.3VDC
Component
Optoisolator
Type
NPN
Output Type Wire Count
Digital
3
Optoisolator reduces interference from motor controller to
microcontroller.
Microcontroller
Spec #
Requirement
Quantity
Description
S26
USB Port
1
Required for data acquisition and programming by a PC.
S27
External Interrupts
4
Allow specific digital peripherals (i.e. WSS, to input external trigger
for program interrupts.
S28
Throttle Control PWM Output
1
Output PWM for throttle control at fixed frequency of 1000 - 2000 Hz.
S29
Voltage Sample PWM Output
1
Output PWM to sample 12VDC battery voltage every 1 - 2 seconds.
S30
10-bit ADC
1
Required to interpret analog voltages into 1024 unique binary values
for the microcontroller to analyze.
Legend
FR = Front
VFA = Very Fast Acting
RLR = Reluctor Ring
RR = Rear
WSS = Wheel Speed Sensor
LPF = Low Pass Filter
Power Distribution, Wire Ratings, & Circuit Protection
Spec #
Voltage Level
S31
Component
Wire Count
Rating(s)
# of Components
Needed
3
5A, 12VDC
1
Ignition Switch
S32
Kill Switch
S33
2
Emergency Stop
1A, 12VDC
2
4A, 230VDC
Part Number(s)
Ref. Spec(s)
Three positions: OFF (0VDC, HV OFF), ACC (12VDC, HV OFF), RUN (12VDC, HV ON)
27005-5137
S10
1
MUST be operated without removing either hand from the handlebars, be identifiable by
rider and person not sitting on machine, disable the machine's controller, not be a
software input, does not act as a General Circuit Breaker. MUST be Normally Closed.
0616-0159
S10
4
MUST be located behind rider, be operated if machine is on its side, be a red button with a
yellow disc of at least 8cm in diameter reading "Emergency" in red or black letters, latch
down mechanically once it has been operated, require manual operation to reset it, act as
a General Circuit Breaker that interrupts ALL electrical transmission between the batteries
by means of a spark-proof circuit breaker, include isolation of pre-charge (ground) circuits.
MUST be Normally Closed. Four switches will be used for test bench.
C22-PVT60P-K11
S10
12 VDC
(Low Voltage)
Description
S34
Wire Diameter
-
22AWG
-
Follow the 10x normal current rule for microcontroller inputs and outputs, multi-strand.
-
S10
S35
Fuse
2
10A
1
Protect the microcontroller, motor controller, and relays from overcurrent.
-
S10
S36
Circuit Routing
-
-
-
Twist all pairs of wires, if feasible, to reduce EMI.
-
S10
-
S5
1N5349BG
S10
1N4001
S5
1N4004
S5
S37
Microcontroller Undervoltage Protection
1
-
1
Automatically shut down when the microprocessor input voltage falls below 9VDC. This
prevents inaccurate microcontroller outputs from out-of-range supply voltages.
S38
Microcontroller Overvoltage Protection
2
5W, 12VDC
1
Install a Zener diode at the VDD input of the microcontroller to prevent overvoltage
damage if improper voltage levels are applied.
S39
Contactor Coil Suppresion Diode
2
1A, 50VDC
1
S40
Contactor Coil Suppresion Diode
2
1A, 400VDC
2
S41
Wire Diameter
-
4AWG
-
6AWG for Current < 300A, 4AWG for 300A < Current < 450A, 4AWG-2AWG for 450A <
Current < 500A, 2AWG-1/0 for 500A < Current < 650A
-
S10
-
S10
Due to large amounts of energy stored in the motor coils during operation, a voltage spike
of several hundred volts is generated when the breaker is turned OFF. This diode
surpresses this spike which protects the connected motor controller and DC-DC
converters. Cathode (i.e. banded end) MUST face positive voltage!
S42
Wire Insulation Resistance
-
250kΩ
-
250kΩ for < 300 Volts to earth, 500kΩ for > 300 Volts, test insulation resistance using at
least 100VDC
S43
General Circuit Breaker
2
400A, 72VDC
2
MUST open circuit when control voltage is switched OFF (relay, solenoid switch).
MUST not be substituted with over-current trip switches but be controlled by Emergency
Stop switch (i.e. relay, solenoid contactor)
SOL-72V-400A
S10
S44
Fuses
2
400A (VFA), 80VDC
1
MUST be easily accessible, be as close as possible to battery, be used for ALL electrical
cables, be rated according to the diameter of the individual conductors, be fast burn type.
ANN400
S10
S45
Pre-charge Resistor
2
1kΩ, 10W, 72VDC
2
Due to the large amount of internal DC capacitance of the motor controller,
the pre-charge resistor helps to prevent arcing at each contactor.
MIS-PRE-1KT
S5
S46
Motor Controller
4
450A, 72VDC
1
Throttle input Pins 2 and 3 are reprogrammable using the serial port and a PC. Set up this
controller to accept a 0 - 5VDC input from the Accelerator potentiometer. Actual allowable
input voltage range for Pins 2 or 3 is 0.15 - 4.90 VDC.
AXE 7245
S10
S47
72VDC-to-12VDC Converter
4
124W, 9A (continuous)
10A (peak)
1
Converter MUST isolate both 72VDC and 12VDC power and ground circuits.
PST-DC/7212-9 72/12
S5
72 VDC
(High Voltage)
Legend
FR = Front
VFA = Very Fast Acting
RLR = Reluctor Ring
RR = Rear
WSS = Wheel Speed Sensor
LPF = Low Pass Filter
Bill of Materials
Item
Component
# of Components Needed
Part Number
1
72VDC Battery
1
(supplied)
2
DC Motor
1
(supplied)
3
Motor Controller
1
(supplied)
4
LPF (PWM adjustment)
1
-
5
25Hz LPF (1 resistor, 1 capacitor)
1
-
6
Normal Diode
2
6A06
7
Zener Diode
1
1N4742
8
Relay
1
275-001
9
12VDC-to-5VDC Converter
1
LM317
10
10A 12VDC Fuse
1
270-1093
11
12VDC Battery
1
UPG 42511
12
dsPIC33FJ12GP202
1
-
13
100k Resistor
2
-
14
10k Resistor
1
-
15
3.3k Resistor
1
-
16
1k Resistor
1
-
17
PMOS MOSFET
1
IRF9530-ENP
18
NMOS MOSFET
1
IRF9530-ENN
*Only includes parts not listed in the System Specifications to prevent redundancy.
Return
Front WSS Mounting Location
Rear WSS & RLR Mounting Location
Return
Solenoid Circuit Breaker
Return
Motor Controller
Return
Front Suspension Linear Potentiometer
Return
DC Motor (supplied)
Motor Curves @ 72VDC
Return