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ONR HEV HMMWV

Team Assault and Battery

Team Members: Linnea Anderson, Bryan Blakley, Matthew Braley, Danny George, Slade Klein, Chad Schierman, Matt Shaw, Albert Whetstone

Team Advisors: Steve Beyerlein, Herb Hess

Team Mentors: Brice Quirl, Yu-Chen Lu

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Outline

Background Overview of Project Current State of Affairs Electrical Systems Mechanical Systems Design Options Work Schedule Budget Conclusion

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Background

Team Assault and Battery has received a military grade HMMWV from the U.S. Marines that has been previously converted to a Hybrid Electric Vehicle (HEV). It is currently in a non-running condition due to various subsystem conflicts and possible issues with non-working parts. The focus will be to unify the electric bus to 360V. The next focus is to install monitors and thermal controls to test the performance of the next generation of lead-acid batteries that are currently in development. This will require the implementation of an advanced control and display system. Also we will be working to incorporate aspects of regenerative braking control and advanced battery management systems. The HMMWV will have operational characteristics as close to those of a normal HMMWV as possible.

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Needs-Specifications

Get the HMMWV self propelled Unify the battery bus to 360 VDC Regulate the battery box to 100±20 °F Instrument the battery pack and

vehicle

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Current State of Affairs

Electronics submersed for an extended period of time

Unknown condition of power plant/ engine

24 VDC system requires upgrading No documentation for current systems

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Current State of Affairs

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Overview

Power Plant360V

Drive MotorAC 150

PEU

Battery Pack360V Nominal

Data Acquisition System

Control/Management

Driver Information

24 VDC Auxiliary system

Thermal Managment

DC/DC converter

360

VD

C

Drive PowerSignals

ControlMonitoring

Data Acquisition SignalsMonitor and Control

Sensors

CAN 2.0 Bus Communications

24 VDC

360 VDCInverter Regen

360 VDC for Auxiliary Power

12 VDC Auxiliary System

24 VDC Rail

Data Acquisistion SignalsSensors

12 VDC Rail

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Electrical Systems

Data Acquisition SystemData Storage

Driver Interface

Aux PowerVoltageCurrent Temp

Pedal PositionsThrottle and Brake

Drive PositionForwardReverseNeutral

Main Bus Voltage~360V Nominal

Driver InformationSOC

Engine RPMWater Temp

Driver InputResetEtc.

Battery PackIndividual VoltageIndividual Temp

Pack Current

AC 150OutputsCurrent Voltage

Regenerative varianceEtc.

Mux

or

Sig

nal

Con

ditio

ning

Battery Pack Thermal

ManagementTemp

Heater control

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Electrical Systems - Instrumentation

Alternative 1 – Microcontroller Based

Cons: Extensive development time Expandability issues Task Specific Exponential learning curve

Pros: Less initial cost Distributed computing Task specific Low power

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Electrical Systems - Instrumentation

Alternative 2 – NI PXI Based

Cons: Larger initial cost No sleep mode

Pros: Ready to connect Low development time Highly reconfigurable Extremely expandable Graphical interface capable

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Electrical Systems

Power distribution Buck converter 12V Auxiliary Batteries Vehicle auxiliary systems

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Electrical Systems

Alternator Starting circuit

AC 150 integration Inputs CAN bus

Thermal Management Monitor Control

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Battery Box Configuration Substitute Batteries

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Battery Box Configuration Advanced Lead Acid Batteries

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Thermal Management

Alternative 1 – Fans and Blankets

Cons: Moderate power consumption No active cooling

Pros: Distributed heat source Not dependent on APU for heat source Quick response time Location specific heating Low maintenance

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Thermal Management

Alternative 2 – Engine Heat Transfer

Cons: Engine must be operating Slower response time Less temperature gradient control

Pros: Readily Available Recaptures otherwise lost energy

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Motor Mounting

Requires Battery Box Modification Fabrication of Mechanical Adapters

Environmental protection Torque control Gear reduction

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Work Schedule

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BudgetItem subcategory Estimated Actual

Proposed $30,000.00

AC 150 Retrofit $5,000.00Gear Redux $200.00

radiator $320.00water pump $90.00tubing $100.00radiator fans $150.00heat pads $4,000.00Thermal Blankets $244.00

commercial $1,600.00

Battery Box Modificationmaterials $700.00

NI PXI chassis $18,000.00Touch Screen display $500.00

Power distrobutionDCDC $1,661.00

Cableing $1,000.00Connectors $1,000.00

total in $30,000.00total out $34,565.00difference $4,565.00

Incidentals

Thermal management (Battery Box)

propulsion system

Batteries

Battery Management System

Instrumentation

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Conclusion

Background Overview of Project Current State of Affairs Electrical Systems Mechanical Systems Design Options Work Schedule Budget

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Questions?

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Team Photograph