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Malte Marko Daniel MacDonald Stephen Thomas Matthew Gleddie Supervisor: Dr. Lukas Swan Team 1 Electric Trials Motorcycle MECH 4010 Final Presentation December.

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Presentation on theme: "Malte Marko Daniel MacDonald Stephen Thomas Matthew Gleddie Supervisor: Dr. Lukas Swan Team 1 Electric Trials Motorcycle MECH 4010 Final Presentation December."— Presentation transcript:

1 Malte Marko Daniel MacDonald Stephen Thomas Matthew Gleddie Supervisor: Dr. Lukas Swan Team 1 Electric Trials Motorcycle MECH 4010 Final Presentation December 3rd, 2012

2 Outline 2  Problem Definition  Design Process  Final Design  Budget M. Gleddie, 2012 S. Thomas, 2012

3 What Is Trials Motorcycling? 3  Technical  High Torque  Low Speed  High Control  Not a race! S. Manchester, 2012

4 Design Requirements 4 Noise Battery Leads Throttle Response Water Resistance New: Battery Management System! S. Manchester, 2012

5 Sound Testing 5 M. Gleddie, 2012

6 Prototype 2 Sound Requirement 6 91 dB 88 dB 25 % reduction in sound wave pressure

7 7 7

8 Re-Orientation of Leads 8  Side View Power and BMS Leads to Top of Pack Consolidate Wiring Plugs to Single, Central Point.  Top View Messy, Prone to Damage S. Thomas, 2012

9 Battery Management System 9

10 10  Constantly check between cells for over-voltage (3.6V)  Manually turn on/off power supply  Shunt power resistors S. Thomas, 2012

11 Rejected ideas – BMS 11  On-Board BMS  Weight  No need for discharge balancing (Throttle Response)  Arduino Control W/ Relay Power Resistor  Emulates physical charging sequence  Complicated apparatus, high likelihood of user error/malfunction  CCCV power supply shutoff problems Arduino, 2012

12 Battery Management System 12  Final Design: FET Circuit  Limits cell voltages to 3.6V  Dissipates excess current to heat sink  Selectable characteristics

13 Full FET Circuit 13  8 FET circuits in total  Dissipate over- voltage power through back of FET to common heat sink  (Al, finned, 10cm x 40cm)

14 BMS Plan B 14  PreFab Unit  Over-Designed, Expensive - Capable of measuring up to 108 cells connected in series based on configuration. - Performs intelligent cell balancing (passive). - Calculates state of charge (SOC). - Uses professional automotive-grade locking connectors. - Calculates discharge current limit (DCL) and charge current limit (CCL). - Can measure cell voltages between 0.5v and 5.0v. Orion BMS, 2012

15 Drive Train Design Process 15

16 Current Drive Train Problems 16  Motor and shaft mounts are separate  Bent shaft mount – misalignment  Open motor  7:1 reduction  Noise! S. Thomas, 2012

17 Rejected Ideas 17 Goldenmotor.ca Flywheel and Clutch Planetary Gear Reduction Hub Motor One Stage Gear Reduction Clutch Flywheel

18 Motor Selection 18

19 Selected Motor 19  HPM-5000b from goldenmotor.com  5kW  48 V  100 amp continuous  300 amp peak (30 seconds)  Water resistant  Aluminum case, SS shaft  4000 RPM on 48 volts Goldenmotor.ca

20 Primary Reduction - Belt 20 Gates Mectrol 2012

21 Drive Train 21  Primary Reduction  Change ratio to 3:1 (from 1.8:1)  Secondary Reduction  Change ratio to 5:1 (from 7.1:1)  Use lighter 520 chain  Use stock parts

22 Drive Train Bracket 22  Minimize loads  Protect components  Mount to frame TBD Stress calculations Build prototype

23 Controller/Throttle Response 23  Kelly KBL48201 (from department)  48 V  100 amp continuous  200 amp peak (1 minute)  260 amp boost (10 seconds)  Sealed  Torque control, speed control, or a mix S. Thomas, 2012

24 Final Design 24

25 Final Design 25 Final Design ComponentDesign Requirement Met Re-Designed Drive Train 3:1 Toothed Belt  Noise Reduction 5:1 Chained Reduction HPM5000B Motor  Water Resistance BMS FET Circuit  Automated BMS Kelly KBL48201 Controller  Throttle Response  Water Resistance Re-Orientation of Battery Leads  Protection of Cabling

26 26 S. Thomas, 2012

27 Budget 27 Major ItemsCost [$] Motor600 Battery Charger500 Drive Train Components 670 BMS Components630 Miscellaneous150 Controller0 Total2550

28 Goals for the winter term 28 December  Finalize FET circuit  Order Parts  Bracket stress analysis January  Program controller  Assembly February-April  Testing  Fix  Go play in the mud! M. Gleddie, 2012

29 Thank You! 29  Michael Traves  Jon MacDonald  Angus MacPherson  Albert Murphy  Dr. Tim Little  Sebastian Manchester  2011/2012 ETM Design Team  Dr. Lukas Swan  Dr. Julio Militzer

30 References 30  Arduino Mega Photo – Slide 11 http://arduino.cc/en/Main/ArduinoBoardMega2560 http://arduino.cc/en/Main/ArduinoBoardMega2560  Orion BMS – Slide 14 http://www.orionbms.com/products/orion-bms-standard/

31 31 Extra Slides

32 32

33 Existing Prototype 33 Recommendations from 2011/2012 team  Belt on Primary Reduction  Reduce Noise  Waterproofing  Protect Battery leads  Smaller chain

34 Sound Testing Results 34  From Fall 2012 Term Report

35 Battery Energy Storage System 35  48V System  64 Li-Ion Cells  Nominal 3.3V each, 3.6V full charge  Nominal 528 Wh of energy storage

36 FET Characteristics 36  FET Specs:  V1 < V2 < 3.6V  Capable of dissipating 20A at 3.6V (72W)  To be finalized based on VDC

37 37


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