1. Sponsor: National Science Foundation
IPFW Electric Vehicle
Sponsor: National Science Foundation
Advisors: Dr. Hosni Abu-Mulaweh, Dr. Abdullah Eroglu, Dr. Hossein Oloomi
Team Members: Mitchell Eilerman, Josh Weaver, Andres Cobos, Austin Swihart, Charles McIntosh, and Leandra Lee
February 12, 2015

2. Introduction
From
Will convert preexisting vehicle into electric vehicle
Motor will be powered by two batteries
Solar panel will recharge batteries
Project is funded by the NSF (National Science Foundation)
An NSF strategic goal: “Transform the frontiers of science and engineering” to
Maybe add NSF information

3. High-Level Schematic of Electric Vehicle

4. The Back Story
senior design team built go-cart sized vehicle for 2008 Illinois Baja Challenge
2014 senior design team designed a controller system for new electric vehicle +
We will integrate the control system with the existing go-cart to produce IPFW’s first working electric vehicle.
Add picture of Baja and control system

5. Requirements/Specifications
A solar panel will charge the batteries, the batteries will power the motor, and the motor will run the car.
Add block diagram for panel to batteries to car – Mitch will add block diagram

6. Table 1: Project Specifications
Requirement Type
Speed to Achieve
Solar Panel to Battery charge time
Torque Required
Weight
Specific Value
10mph in 15 sec
16 hours
5N-m
Under 400lbs
Table including specifications

7. A Simulink simulation will be included with the final design.
The vehicle must have a cooling system that keeps all of its parts within their operable temperature ranges.

8. Given Parameters Two 12V UB12500 batteries will power our vehicle
Charging system will be run by Kyocera Photovoltaic Module, Model # KC85T.
The HPM5000B brushless motor made by Golden Motors will power our vehicle.
Current system provides 5N-m of torque

9. Table 2: Baja Characteristics
Will use existing Baja buggy chassis, suspension, & gear train
Table 2: Baja Characteristics
Baja statistics in chart.

10. DC-DC converter with bi-directional four quadrant topology.
Converter power board with control traces and power traces
Completed power board with heat sinks, cooling fans, and inductor
Converter statistics below in a table. Schematic of converter power board complete with control traces, seen in red, and power traces, seen in blue

11. Design Variables Hardware
Control System/Interface: Regulate speed & torque
DC-DC Converter: Interfaced with the motor and batteries
We will need to add shielding to the DC-DC converter because there is a high amount of noise at high currents
Arduino Mega 2560 Microcontroller

12. Current combustion engine shaft to CVT transmission
Design Variables
Hardware Cont.
Display: Motor speed, battery power remaining, temperature, and operating time remaining
Motor Coupling: Electric motor coupled to existing Baja transmission
Motor shaft
Current combustion engine shaft to CVT transmission

13. Baja gearbox (high/low/reverse) & sprocket system
Design Variables
Baja gearbox (high/low/reverse) & sprocket system
Operating Conditions
Speed: Speed varies according to driver input
Forward and Reverse Mode: Operates in forward and reverse mode according to the drivers selection.
Polaris gearbox

14. Limitations & Constraints – Timeframe
Concept Selection
Brainstorming
Problem Formulation
Timeframe
Design must be completed by May 2015
Project must be completed by December 2015
“Each project must be sufficiently complex, yet simple enough to be accomplished within the allocated time …”
– Lecture 1 of course PowerPoint
Detail Design

15. Limitations & Constraints – Results
Design Budget of $1,000
Possible Design Costs:
Cooling System
Coupling System
Display System
Reserve Fund

16. Limitations & Constraints – Resources
Funds
Previously Selected Components
Existing Baja Frame from previous design
HEIGHT: 66.5 in
WEIGHT: 180 lb
AVERAGE JOE
& PLAIN JANE
cdc.gov
FRAME
DRIVER
MOTOR
BATTERIES
SOLAR PANEL
COOLING SYSTEM
COUPLING
51”
34”
Constraint
Factor
Lab Door Frame
Width of EV
< 36 in
Existing EV Frame (Baja)
Cooling System Placement
Weight of Coupling Systems
Total Weight of EV
minimal
Drawing showing area for batteries and motor

17. Additional Considerations
Safety systems must be included with vehicle.
Brake, suspension, and steering.
Electrical connections.
Cooling system

18. Additional Considerations
IEEE Standards
Life expectancy

19. Additional Considerations
Operational limits.
Uncertainty.

20. Questions?