Presentation final 4.29

Production Electronics for a Light Weight Electric CarTeam 11Team leader: Mitch Wozniak Team members : Majed Alarawi, Xueyin Shi (Charlotte), Yiqing Zhou (Jack)

Industry Sponsor: Blair Jackson Orison Corporation

Advisors: Scott Schneider, Rebecca BlustIndustry Sponsor: Blair Jackson

Orison Corporation

Advisors: Scott Schneider

Rebecca Blust

School of Engineering Innovation Center1

Outline for Presentation

Introduction System Layout and Components

Status of ComponentsRecommendation

School of Engineering Innovation Center

IntroductionHistory

BackgroundPurpose


History

The Blair Jackson Orison Corporation, (“Orison”) was started by Blair Jackson

The company resides in Troy, OH Orison has developed a prototype of

electric single person vehicle


Background

The Orison light weight vehicle is a 4-wheeled single rider electrical vehicle still in the development stage.

“Big Picture” The client wants to eventually begin manufacturing of this vehicle.

The mechanical design of the car was designed by Blair Jackson. The electrical systems were also developed by Blair Jackson. Blair Jackson wants improvements made to the electrical system.


Purpose / Function

The purpose of this project is to provide a simple functional electrical system to be combined into the electrical vehicle created by Orison.

The function of the electrical system is the heart of the vehicle. It supplies power to all the working components.

The components will improve the use of the vehicle such as lights, speed control, simplicity, and braking.

Team 11 is improving the electrical systems so that manufacturing can be easier and the electrical systems will be improved.


Project SpecificationsRequirements

Deliverables


Functional Requirements Power Distribution PCB must connect directly to the UNO. It

controls voltages to different areas of the vehicle, organizes the wiring of the UNO, and has a transistor circuit to control voltage to the motor controllers.

New Hall Sensors control the throttle. They must be durable and water/dirt repellent.

The digital display is required to be able to display speed, battery life, and direction of the motors.

System of lighting around the vehicle is required to make it easy to drive at night and noticeable to others.

New motor controllers must allow for regenerative braking.


Requirements Continued…

Power distribution PCB must control voltages and be able to send the voltage to the correct components.

Power distribution PCB must fit on the UNO. Power distribution PCB must have an easy to use and water proof plug

for wires. Hall Sensor must be water and dirt proof and must communicate with

UNO. Display must be visible in all weather and must show speed, battery

life, and direction. Lights must be be able to seen during day and night and have a visual

range of 50 feet at night. Motor controllers must provide voltage back to the batteries during

breaking.


Deliverables There are five deliverables that will be accomplished

during the project1. Design of a power distribution circuit2. Research and selection of rotary hall sensors 3. Research and selection of a new digital display for vehicle speed, battery information and vehicle direction4. Selection and testing of new lighting system for headlights and running lights5. Research and test new four-quadrant motor controllers


System OverviewPower Distribution Circuit

Hall SensorsDisplay

LightsMotor Controllers


System Layout

1

2

4

3

5

Legend:Red – PositiveBlack – GroundBlue – I^2cPurple – Multiple Signal


Power Distribution Circuit Section Layout

UNO Criteria for the Power Distribution Circuit Test Results from Multisim (Voltage & Amps) Breadboard Test Results Layout of Circuit in Multisim Layout of Circuit in Ultiboard 3D Visuals of Circuit board Components chosen for Circuit LDO Criteria LDO Matrix LDO Description Explanation of Transistor Circuit Replacement Status of Power Distribution Circuit


Arduino Uno

The Arduino Uno is a microcontroller board based on ATmega328 It has 14 digital input/output pins Operating Voltage 5V Input Voltage (recommended) 7-12V Input Voltage (limits) 6-20V Digital I/O Pins 14 (of which 6 provide PWM output) Analog Input Pins 6 DC Current per I/O Pin 40 mA DC Current for 3.3V Pin 50 mA


Power Distribution Circuit

Power Distribution CircuitCriteria Provide different voltages to components around the vehicle 3.3 volts for display, 9 volts for UNO, and 36 volts in series for

the lights Connectivity to UNO to minimize the complexity of wires Easy cable connection for communication sent from UNO to

front of the Vehicle Pin layout that coheres with the pin layout on the UNO Addition of transistors circuit that steps up voltage from UNO

to motor controllers to consolidate circuits


Testing of the Circuit (Voltage)



Test of the Circuit (Amps)Power Distribution Circuit


Breadboard Test

Overall Breadboard 9 Volt Regulator Test3.3 Volt Regulator Test



Lighting System Voltage

Layout of Power Distribution Circuit Power Distribution Circuit


Layout of Circuit on to the PCB / Engineer Design

All of the traces (red and green lines) had to be sized correctly for the amount of current that was going to pass through. (0.75 mm for large voltage and current and 0.5 mm for all other traces)

The traces must be a certain distance apart to prevent jumping. (.25 mm)

Pin foot print needed to match exactly with the UNO.

Parts with high current and voltage create more heat. These were designed to be in open areas of the PCB for heat dispersion.



3D viewFront ViewSide ViewRear View

Top View



Electrical Components

On / off switchBoard to wire ConnectorLow drop out voltage regulator (3.3v & 9v)Power resistance (510 Ω & 220 Ω both 5 Watt rated)Capacitors (0.1μF or bigger) Fuse (250 mA)Circuit Breaker (4 amps)Pins



Criteria for the Low Drop Out Voltage Regulator

1. Complexity: components are simple to use2. Functionality: step up or step down voltage3. Ripple / Noise: fluctuation in voltages 4. Size: component shape size 5. Efficiency: Ability to transform voltage without losses6. Total Cost: the price of purchasing



LDO Matrix


0123456789

10

LDOSWITCHING

LDOSWITCHING

CriteriaRaw Score out of

10 Linear LDO Switching LDO

Complexity 10 10 6

Functionality 8 7 6

Ripple/Noise 10 10 6

Size 9 9 7

Efficiency 7 4 7

Cost 5 5 3

Totals 49 45 36


LDO

Credible for battery design(enable battery to be used up to the limit)

Low noise(no switching needed) Small size and simple Most frequently used in technology (phone-digital

camera-laptop) Less heat loss(no transformer) Complexity(amplifier-pass element)



Replacing the Transistors from the UNO to the Motor Controllers with a circuit on the PCB


Multisim Circuit

3D VisualPower Distribution Circuit

Status of Power Distribution Circuit The circuit has been designed and tested successfully. All components were ordered and received. Final design in Ultiboard is ready for client approval and is

ready to be sent out to a PCB manufacturer.


Part 2 - Hall Sensors


Criteria Matrix Test results Information Status

Criteria

1. Resolution- The more resolution we have the more accurate the hall sensor

2. Interface- The interface should be suitable to work with the UNO

3. Temperature Range- The temperature range should be large to withstand all conditions

4. Supply Voltage - It should match what the UNO can provide5. Price- The team’s budget is limited, the price should be

reasonable

Hall Sensors


Hall Sensors


CriteriaRaw Score(out of 10)

AS5048A Rotary Sensor

ADS1208

ADS1201

Resolution 8 6 6 8Interface 8 8 3 3Temperature Range

10 10 55

Supply voltage 6 5 3 3Price 8 7 7 7Total 40 36 24 26

Matrix

Hall Sensor

The DRV5053-Q1 device is a chopper-stabilized Hall IC that offers a magnetic sensing solution with superior sensitivity stability over temperature and integrated protection features.

The 0 to 2V analog output responds linearly to the applied magnetic flux density, and distinguishes the polarity of magnetic field direction .


Information

Hall Sensors

Tested with LabVIEW Hooked into the Breadboard

Power Distribution Circuit to prove that they work together

Tested with Multi-meter LabVIEW writes information to

excel file

Test Results


Hall Sensor

Cleaned up test values Chart for linear equation for

the hall sensor These equations can be used

in RobotC to convert the pulse width signal to distance

Test Results


Status

Component has been researched and ordered Experiment connecting to the UNO has been completed and

failed Alternative methods to test the Hall Sensors were done in

LabView and Multi-meter We proved that they can work and found out what type of

signal is being used Having the knowledge of the signal type and how it works will

help in setting up the Hall Sensors with the UNO

Hall Sensors


Part 3 - Display


Criteria Matrix Information Status

Criteria for the Display

1. Size - The bigger the size, the easier that the customer can see the information

2. Information on the Board -The board should show multiple information at the same time

3. Supply Voltage -The voltage should be at 5V4. Price - The team’s budget is limited, the price should be

reasonable


Display Matrix

CriteriaRaw Score(out of 10

NHD-0420DZW-AB5

NHD-2.23-12832UMB3

Size 8 8 6Information on the board 10 10 6Supply voltage 8 8 8Price 10 8 10Total 36 34 30


Display NHD-0420DZW-AB5

4 lines x 20 character Blue LED display

3V or 5v power

4.75mm character height

Size: 98mm x 60mm


Information

Status of Display

Other parts of the project were needed before the display could be integrated so we concentrated on those parts.

The other crucial parts should be finished before the display is worked on.

The project was not as far along as we thought so we researched the display, and did not purchase it.

The display was not ordered.


Part 4 – Lighting System


Head Lights Criteria Matrix Information

Running Lights Matrix Information

Status

Criteria for Lighting System

1. Voltage - The voltage needs to be 12V which is suitable to the circuit.2. Color of Lens and Lights - The color of rear light should be yellow. The

color of the head light should be white.3. Number of LEDs - Determines the brightness of the light. 4. Material- The material should be steel. 5. Price- The team’s budget is limited, so the price should be reasonable.


Head Light



Black Motorcycle Headlight 5" LED Head Lamp

Double Dual Lamp Street

7" LED Motorcycle Halogen Headlight

Voltage 8 8 8 8Color of lens and lights

8 3 83

Number of the LED 10 10 0 6Material 6 6 3 3Price 8 7 2 4Total 40 34 21 24

Matrix

Head Light

Color: BlackLens Color: Clear

Number of LED: 30Cable Length: 7 1/2" (19cm)

Voltage: DC 12VWattage: 3w/5w

Material:Steel & Glass Lens3 wires connection

system.


Information

Running Lights



1x Rectangle Reflector Amber Yellow LED Rear turn signal light Car Clear Lens

Motorcycle Custom LED Reflector Tail Trunk Rear Fog Light Shadow Clear Lens ND

Smoke For Suzuki 05-06 GSXR1000 LED Intergrated Tail Light Turn Signals Brake

Voltage 8 8 8 8Color of lens and lights

8 8 33

Number of the LED 10 9 9 10Material 6 3 3 3Price 8 8 8 4Total 40 36 31 28

Matrix

Running Lights

Type of Lights : 24 high power LED light clip inside each light Size (length x Width x Depth): ~89mm x 39mm × 9.5 mm It works at 12 V There are three wires: black, blue and red

Black line→ cathode / ground / negative wire Blue line→ small light (for 50% light) positive wire Red line→ turn signal or brake light (for 100% light) positive wire


Information

Lighting System

The lighting system was also dependent on the team finishing other components of the project.

The parts were ordered and received. The parts are ready for installation once the

Power Distribution Circuit is finalized. Lights have been tested with the breadboard

Power Distribution Circuit.

Head lightRunning Lights

Status


Motor Controllers


Information Status

Kelly KBS-X Brushless Motor Controller

KBS36051X Four quadrant motor control Less expensive Already programmed Client recommended


Status of Motor Controllers The Motor Controllers were purchased and have been experimented

with. Research was done to determine the best way to wire the motor

controllers to the motors and the UNO. We have been working with the motor controller to get them to turn

the motor but have been unsuccessful. We have tried different ways of wiring and changing parameters in

the program both of which have come with no results.


Criteria for Wiring System

1. Number of Wires – Cables are capable of running 1 to 48 wires for this application. For this application we needed 20.

2. Protective Coating – A PVC coating is needed to protect the wires from outside contaminates.

3. Shielding – Important for 2 reasons. It prevents EMI and ESD interference of the signal and it prevents the wires from easily being pinched.

4. Gauge – It is the thickness of the wire which determines how much voltage and current can be sent through.

5. Twisted Pairs – Reduces crosstalk for balanced drive applications. 6. Price – Need the above requirements but at a price that is reasonable.


Wiring System

CriteriaRaw Score out of 10 3M 3600x series Mcmaster-CARR 7741k17 General Cable XLPE/XL-CPE

# of Wires 8 8 7 8Protective Coating 6 6 6 6

Shielding 10 10 0 8

Gauge 10 10 7 9

Twisted Pairs 8 8 0 8

Price 5 2 3 2

Totals 47 44 23 41


Matrix

Wiring System The wire system was researched and we found

the solution. 3M Round, Shielded/Jacketed, Disc. Wire Cable

3600x Series We did not purchase it because we were not to

that point in the project. You have to buy a set distance of wire, the

shortest being 100ft. The price was too much for the bench test. We used single wire for the bench test to make it

easier to test different configurations of wires.


Information / Status

Project ManagementBudget

Gantt ChartRecommendation

Conclusion


Budget

Given $1,000 budget by Blair Jackson Company credit card with rules about

each purchase Spent total of $550 dollars Totally cost to produce the Power

Distribution PCB $78.13 Total electrical system cost $285.17 Additional budget was spend on

components for testing

BudgetNumber of Parts

Price of Part

Shipping Price

Sales Tax / Process Fee

Total Price

Delivered(Y/N)

Total - Available

Part NameUNO 1 $34.99 $6.99 $3.04 $45.02yHall Sensors 2 $25.00 $0.00 $0.00 $50.00yMotor Controllers 2 $59.00 $31.00 $0.00 $149.00yTransistors 10 $0.25 $0.00 $5.00 $7.50yCircuit Breaker 4 amp 2 $9.25 $0.00 $0.00 $18.50yHall Effect Sensor 4 $1.04 $7.00 $0.00 $11.16yLDO Regulator 3.3v 10 $0.40 $6.99 $0.80 $11.83yHead Light 1 $24.99 $0.00 $0.00 $24.99yCircuit Breaker 25 amp 1 $21.73 $0.00 $0.00 $21.73yRegulator 9v 10 $0.25 $2.67 $5.00 $10.17y $850.00Running Lights 1 $14.98 $0.00 $0.00 $14.98yElectronic Parts 1 $8.91 $0.00 $0.00 $8.91yElectronic Parts 1 $13.45 $0.00 $0.00 $13.45yElectronic Parts 1 $25.26 $0.00 $0.00 $25.26yConn Recept 20 pos 2 $1.00 $0.00 $0.64 $2.64yConn Header 20 pos 2 $0.91 $0.00 $0.00 $1.82yConn term female 50 $0.10 $0.00 $0.00 $4.95y50 pcs 5mmX20mm glass tube 1 $17.97 $0.00 $0.00 $17.97y510 OHM resistor 1 $22.83 $0.00 $0.00 $22.83yeasy more 40 pin 1 $25.26 $0.00 $0.00 $25.26y220 ohm resistor 1 $13.45 $0.00 $0.00 $13.45y

Electronic Parts 1 $22.09 $0.00 $0.00 $22.09yTotal Left Over

$523.51 $326.39School of Engineering Innovation Center

Project Management

Gantt Chart


Project Management

Recommendation

Power Distribution Circuit – Order circuit board from a PCB manufacturer and test it with the UNO.

Hall Sensors – Rewrite the RobotC and use the equation derived by LabView for UNO to understand the signal being sent by the Hall Sensors.

Display – Get all other components working before working on the display. Once the system is working take signals that are needed and run them to the display.

Head lights – Lighting system is ready to be plugged into the Power Distribution Circuit as soon as it is complete.

Motor Controllers – Get the Hall Sensors working with the UNO then try to hook the Motor Controllers to the UNO.


Project Management

Questions??


Status of the Project

Researched DesignedParts Ordered

Parts Received Assembled Testing Finished

Power Distribution PCB þ þ þ þ þ In Progress In Progress

Hall Sensors þ N/A þ þ In Progress In Progress In Progress

Display þ N/A In Progress In Progress In Progress In Progress In Progress

Lighting þ N/A þ þ In Progress In Progress In Progress

Motor Controllers þ N/A þ þ In Progress In Progress In Progress


Presentation final 4.29

Documents

Transcript of Presentation final 4.29