1. BATTERY PERFORMANCE METER FOR ELECTRIC PROPULSION SYSTEMS Team Members: Ryan Bickham, Dennis Blosser Cody Dinkins, Todd Dutton, Rachel Shively December 11, 2007 Project Sponsor: Patrick Taylor, Ph.D., AMRDEC

2. Operational Concept Characterize UAV electrical propulsion systems –Battery pack and electric motor –Simulate load conditions during a typical mission –Characterize voltage and current to predict amount of time left in battery pack Wind tunnel testing –Determine power needed for various mission conditions –Simulate conditions like banking, climbing, and diving

3. Battery Monitor Features and Applications Requirements NumberRequirementSpec 1.1Physical 1.1.1 Outer enclosure dimensions: The monitor should be of minimum size allowable to retain ease of adjustment Not yet defined 1.2Electrical 1.2.1Operating voltage: The battery monitor shall operate on a voltage of12 V - 36 V 1.2.2Operating current: The battery monitor should draw less than1.5 A 1.3Battery Source 1.3.1Battery type: The battery monitor shall monitor a battery of the typeLi-Ion 1.3.2 Battery capacity: The battery monitor shall monitor a battery of capacity 2000 Ah - 4000 Ah Battery Monitor System Requirements

4. 1.4Output / Feedback Parameters 1.4.1 Voltage level: The battery monitor shall report battery voltage to precision of0.01 V 1.4.2 Current level: The battery monitor shall report current drawn from the battery to precision of0.01 A 1.4.3 Remaining battery capacity: The battery monitor shall report remaining battery capacity to precision of 0.01 Ah or 0.1 Ah 1.4.4 Elapsed mission time: The battery monitor shall report the elapsed time to a precision of0.1 s 1.5Interface 1.5.1Display: The battery monitor shall report parameters by LCD, PC Monitor 1.5.2 Control: If using an LCD, the battery monitor shall report parameters chosen by the user's input by a keypad Battery Monitor System Requirements

5. Mechanical System Requirements Dyno & Mechanical Instrumentation Requirements NumberRequirementSpec 2.1Coupler 2.1.1 The coupler shall transmit power between motor and dynamometer with no slippage 2.1.2The coupler shall be structurally sound and durable 2.1.3 The coupler shall fit the physical limitations of the motormount / motor / dyno systemNot yet defined 2.2Motor Mount 2.2.1 The motor mount must be easily used and adjustable in 6 directions: 3 rotational, 3 translational 2.2.2 The motor mount shall fit within the physical constraints of the table and mount to the provided mounting holesNot yet defined 2.2.3 The motor mount shall hold the motor stationary and in alignment without slippage

6. Mechanical System Requirements 2.3Shield 2.3.1 The shield must prevent shards of a shattering coupler from harming nearby people 2.3.2The shield must be able to absorb energy on order of approx.50 J 2.4Cooling System 2.4.1 The cooling system shall maintain the dynamometer at optimal operation temperature of0 - 50 °C 2.4.2 The cooling water shall meet the physical requirements of the dyno heat exchanger

7. System Diagram – 3 Part

8. 1) Device Under Test Motor –Connected to Dyno by means of coupler Battery –Outputs voltage and current to instrumentation

9. 2) Dynamometer Coupler Water In/Out TSC 401 Conditioner –Torque –Speed DES 310 Power Supply –Excitation TSC 401 Conditioner

10. 3) Instrumentation Battery Monitor –Voltage and current DSP6001 Controller –Torque, speed, and excitation Thermocouples –Monitor water temperature PC –RS 232 from controller DSP6001 Controller

11. BatteryMotor Battery Monitor Coupler Dynamometer DES 301 P/S TS 401 Signal Conditioner DSP6001 Controller PC InOut Thermocouples RS 232 ExcitationTorque Speed Voltage Current Device Under Test Dynamometer Instrumentation System Diagram – Expanded

12. RECENT DEVELOPMENTS Mechanical: Cooling system effectively analyzed and planned: Water quality & pressure information obtained and studied Determined components for procurement Electrical: Made preliminary decision of FPGA for order Outlined other components required for project D/A Converter Misc. circuitry for signal scaling

13. Water Cooling System Water Quality –All requirements are met, including hardness, pH, and iron –Still researching other parameters Pressure –Max input pressure must not exceed 2 bar –Standard faucet pressure ranges from 60 – 80 psi (4.14 – 5.52 bar) –Pressure regulator needs to be purchased

14. Cooling System, Continued Procurement –902H25 Standard 25 PSI Regulator –Thermocouples, K-type –Clear plastic hose –Hose clamps –Pipe fittings, ¾”NPT, 5/8” swagelok with 1/8” T junction for thermocouple

15. Altera Nios II Development Kit, Cyclone II ed. Cost: $995 + additional fees Key Features of Included Components - Nios II Embedded Processor Suitable for a wide range of apps w/o sacrificing performance - Cyclone II 33k Logic Elements 475 I/O pins - Quartus II Software Package Pin Assigner Incremental Design FPGA Development/Evaluation Kit

16. NEXT STEPS Mechanical: Design cooling system Receive motor from AMRDEC Electrical: Audit FPGA design course (MWF 10:10 – 11:00 AM) Begin base design of FPGA Learn Quartus II Development Software Thoroughly investigate Li-ion batteries