Transcript Phase 3: Subsystem Design Review Presentation

MSD P15280
RIT HOT WHEELZ
TEST BENCH
AGENDA
❖Review Problem Definition Material
❖Review System Design Material
❖Sub-System Design Review
▪Motor Sourcing
▪Motor Coupling Solutions
▪Heat Transfer Analysis
▪Electrical Testing
▪Sensor Solutions
❖Design Changes
▪Current Dyno Functions
▪Updated Problem Definition Material
▪Plans for Improvements & Changes
PROJECT BACKGROUND
❖ The RIT Hot Wheelz Electric Vehicle Team is a group of all
female undergraduate engineers who come together to
form a team of innovative and creative race enthusiasts.
❖ There focus is an environment of both learning and
teaching with hands-on design and build experience.
❖ Previously, the team has competed in only Imagine RIT
events
❖2012- Electric Dragster Competition ~ 1st Place
❖2013- Electric Endurance Competition ~ 3rd Place
❖2014- Electric Autocross Competition ~ 3rd Place
❖ The team is ready to take their skills to the next level!
❖2016- Formula Hybrid-Electric only
PROJECT STATEMENT
CUSTOMER REQUIREMENTS
Pugh Chart
BENCHMARKING- Example Test Benches
❖ Speed Control Test Bench (Left)
➢ Allows the study of the operation of a servodrive
when a variety of loads are applied to the motor.
➢ Powder Brake to vary motor load
➢ Main Components:
■ Motor Voltage
■ Motor Temperature
■ Load amount and type
❖ Motor Test Bench (Below)
➢ Robust, multi-compatible
➢ Flexibility through modular design
➢ Motor Torque, Power & Efficiency
SELECTED CONCEPT- MECHANICAL
❖ Two mechanical
structures
➢ Mobile Cart to mimic Hot
Wheelz Chassis
➢ Enclosed T-framed
structure to house motors
and moving parts
➢ UI will be located on top
of the T-framed
enclosure.
➢ All pieces are portable
and compact
Above: Preliminary CAD model of a 36in by 30in T-slot
aluminum framing enclosure with two removable
plexiglass panels for access and electrical attachment.
MOTOR SOURCING
❖ Enstroj Emrax 228 Sourced to Vary Load on the Hot Wheelz
Powertrain
➢ AC Electric Motor
➢ 3000-5000 Continuous RPM
➢ 35-55 kW Continuous Motor Power
➢ 240 Nm Max Torque ; 125 Nm Continuous Torque
MOTOR COUPLING SOLUTIONS
Concerns:
❖
❖
❖
❖
Vibration
Durability
Modularity
Safety
MOTOR COUPLING SOLUTIONS
Initial Concept:
❖ Subject Matter Experts
➢ Dr. Ghoneim (vibration)
➢ Prof. Humphrey (power
transmission)
❖ Multi V-Belt
➢ Absorbs vibrations
➢ No slip is not critical
❖ Sheave (Pulley)
➢ Supported by a bearing
on each side
➢ Fully enclosed for safety
HEAT TRANSFER ANALYSIS
❖ Energy Dissipation Method Using Resistor Banks
➢ TE Connectivity Wirewound Resistors
■ Power Rating 2.5kW
❖ Assumptions
➢ Continuous Run Time 10 Minutes
➢ Room Size: 18’ X 18’ X 12’
➢ Initial Temperature is 23 degrees Celsius
➢ Using 14 Resistors to Dissipate 32kW of Power
(Worst Case)
❖ Results
➢ Final temperature of Hot Wheelz Room After
Testing → 146 degrees Celsius (296 degrees
Fahrenheit)
ELECTRICAL MOTOR TESTING
ELECTRICAL TESTING
Equivalent Resistance Analysis
Schematic of Resistive Network
s: Duty Cycle of PWM
ELECTRICAL TESTING
Approximation Analysis
When R1 >> R2,
Relationship could be linearized by
restricting range of s:
SENSOR SOLUTIONS
❖ Voltage Sensor
➢ CR Magnetics - CR5310 - 600
➢ Sensing voltage - 600Vdc
➢ $207.35
-----------------------------------------➢ CR Magnetics - CR4811 - 600
➢ Sensing voltage - 600Vac
➢ $156.97
❖ Current Sensor
➢ Honeywell Sensing and Control CSLA2EL
➢ Sensing current - 550A max AC/DC
➢ $50.00/sensor
❖ Temperature Transducer
➢ Microchip Technology MCP9701A-E/TO
➢ Sensing temperature - Local -10°C ~ 125°C
➢ $0.37/sensor
SENSOR SOLUTIONS
❖ Ultrasonic Proximity Transducer
➢ Sparkfun Ultrasonic Range Finder - LV-MaxSonar-EZ1
➢ Sensing Range - 255 inches (0 to 6.45m) in 1 inch increments
➢ $25.95/sensor
❖ Encoder
➢ ams AS5048 Magnetic Rotary Encoder
➢ Sensing Range - 30mT to 70mT
➢ $6.60/IC
❖ Out of price range:
➢ Torque Transducer
➢ Price upwards of $1,000+ (Acquire data from Hot Wheelz sensors
instead)
UC FLOW DIAGRAM
1. Make connection with computer
1. Obtain test parameters - manual
test or simulated
1. Check interlocks
1. Begin test
1. Collect data
UC FLOW DIAGRAM
Sampling ISR Handles same rate and
sampling from different
Sensors
Interlock/ESTOP Fault
ISR - Automatically
stops Hot Wheelz and
loading motor
Incoming Message
from Computer ISR Interpret message and
execute appropriate
code
CURRENT KGCOE DYNAMOMETER
CURRENT KGCOE DYNAMOMETER-CONTROLS ROOM
UPDATED CUSTOMER REQUIREMENTS
UPDATED ENGINEERING REQUIREMENTS
UPDATED CONSTRAINTS
UPDATED DESIGN CONCEPT
UPDATED DESIGN CONCEPT CONT.
UPDATED DESIGN CONCEPT CONT.
UPDATED DESIGN CONCEPT CONT.
MOTOR COUPLING SOLUTIONS
Current Dyno
A similar system will be adopted for our motor.
UPDATED RISK ASSESSMENT
PROGRESSION TIMELINE
QUESTIONS?
FEEDBACK?
SUGGESTIONS?