Design SolutionsSponsored by: National Science Foundation
Advisors: Abdullah Eroglu, Hosni Abu-Mulaweh, Hossein Oloomi
Team Members: Mitchell Eilerman, Leandra Lee, Charles McIntosh, Josh Weaver, Andres Cobos, Austin Swihart
March 19, 2015
IPFW Electric Vehicle
Project Overview
Electrically powered vehicle with solar recharge
Uses data and equipment from previous senior design
projects
Bipolar DC-DC converter with four quadrant topology
Solar Panel
Mini-Baja frame
Project Overview
Project’s Final Goals:
Reach speed of 10 mph in 15 seconds
time
Achieve Driver Controlled Speed
Design Cooling System
Provide information display
Stay within $1000 budget
Project Diagram
Solar Panel
Battery
Battery
DC-DC Converter
Arduino
DC-DC Converter
Motor
Heat Dissipation
Tra
nsm
issi
on
Subsystems
DC-DC Converter
Control System
Cooling System
Charging System
DC-DC Converter Concepts
Decoupling capacitors
Decoupling capacitors and shielding
Decoupling capacitors, shielding, separate Arduino from MOSFET
drivers, and reduce the length of the wires
Concept 1: Decoupling capacitors
Advantages: Drastically reduces switching noise Relatively simple design
Disadvantages: Consume more space High Cost
+15VConverter
+9VConverter
+5VConverter
+24 V +15 V +9 V +5 V
Concept 2: Decoupling capacitors & shielding
Advantages:
Least expensive solution
No relocation of components
Disadvantages:
Consumes space
System more unwieldy
Wires
Arduino microcontroller
Concept 3: Decoupling capacitors, shielding, separate Arduino from MOSFET drivers, and reduce the length of the wires
Advantages: Less affected by interference from MOSFET drivers May be placed closer to any needed sensors
Disadvantages: There may not be space Longer wires cause additional power loss Longer wires introduce additional noise
MOSFET drivers
Arduino microcontroller
Control System Concepts
Pedal press linear with speed
Pedal press linear with voltage
Two-state system: acceleration and constant speed
Concept 1:Pedal press linear with speed
Advantages:
More accurate control of speed
Pedal scheme relatively easy to learn
Disadvantages:
Significant testing required
Concept 2: Pedal press linear with voltage
Advantages:
Control code already designed for application
Disadvantages:
Harder for driver to control vehicle speed
Concept 3: Two-state system: Acceleration and constant speed
Advantages:
Accelerates at set rate
Easier to maintain speed
Disadvantages:
Cannot directly control acceleration
Steep learning curve
Cooling system
Forced convection by use of fans
Radiator with a water jacket
Fin and fan combination
Concept 1: Forced convection by use of fans
Advantages:
Simple and easily implemented
Reliable, low maintenance and inexpensive
Can affect a large area of components
Free convection changed to forced convection
Can remove variable amount of heat
Disadvantages:
Relies on the ambient air
Concept 2: Radiator with a water jacket
Advantages:
High capacity for heat removal
More easily controlled
Disadvantages:
Components will require a partial disassembly to maintain
Potential safety issues
Requires large amount of energy from batteries
More complicated and more maintenance
Concept 3: Fin and Fan combination
Advantages:
Low maintenance
Localized heat removal
Low cost
Disadvantages:
Relies on ambient air temperature
Charging System Concepts
Use existing 48V booster
Replace booster with 24V booster
Include AC option with either of the previous
ideas
Concept 1: Use Existing 48V booster
Advantages:
No additional purchasing of parts
Allows batteries to reach peak voltage
Disadvantages:
The charge time of the batteries will be increased
Power will be lost
System is dependent on light available
Concept 2: Replace booster with 24V booster
Advantages:
Higher efficiency
Charges the batteries faster
Disadvantages:
Purchase of a new booster is necessary
System is dependent on light available
Concept 3: Include AC option with either of the previous ideas
Advantages:
Charges more quickly if an AC power source available.
Can be charged without light source.
Disadvantages:
No longer solely dependent on solar energy
Control system must be developed
Additional space is needed for the system
Cross’s Matrix - DC-DC Converter
DC-DC Converter
Cost x 9 1 9 9
Ease of Design 1 x 1 9 9
Size 9 9 x 9 9
Safety 1 1 1 x 1
Reliability 1 1 1 9 x
0.12 0.20 0.04 0.36 0.28
Cross’s Matrix - Control System
Control System
Cost
Ease
of D
esign
Safe
ty
Mainte
nanc
e
Relia
bility
Cost
Ease
of D
esign
Aesth
etics
Size
Weig
ht
Safe
ty
Mainte
nanc
e
Relia
bility
Ease
of D
esign
Safe
ty
Mainte
nanc
e
Relia
bility
Cost
Ease
of D
esign
Size
Safe
ty
Relia
bility
Ease of Design x 9 9 9
Safety 1 x 1 4
Maintenance 1 9 x 9
Reliability 1 4 1 x
0.05 0.38 0.19 0.38
Cross’s Matrix - Cooling SystemCooling System
Cost
Ease
of D
esign
Safe
ty
Mainte
nanc
e
Relia
bility
Cost
Ease
of D
esign
Aesth
etics
Size
Weig
ht
Safe
ty
Mainte
nanc
e
Relia
bility
Ease
of D
esign
Safe
ty
Mainte
nanc
e
Relia
bility
Cost
Ease
of D
esign
Size
Safe
ty
Relia
bility
Cost x 9 1 1 9 9 4 9
Ease of Design 1 x 1 1 4 9 1 9
Aesthetics 9 9 x 9 9 9 9 9
Size 9 9 1 x 9 9 9 9
Weight 1 4 1 1 x 9 1 9
Safety 1 1 1 1 1 x 1 1
Maintenance 4 9 1 1 9 9 x 9
Reliability 1 1 1 1 1 9 1 x
0.09 0.15 0.03 0.05 0.15 0.23 0.09 0.20
Cross’s Matrix - Charging System
Charging System
Cost
Ease
of D
esign
Safe
ty
Mainte
nanc
e
Relia
bility
Cost
Ease
of D
esign
Aesth
etics
Size
Weig
ht
Safe
ty
Mainte
nanc
e
Relia
bility
Ease
of D
esign
Safe
ty
Mainte
nanc
e
Relia
bility
Cost
Ease
of D
esign
Size
Safe
ty
Relia
bility
Cost x 9 4 9 9
Ease of Design 1 x 4 4 9
Safety 4 4 x 1 4
Maintenance 1 4 9 x 9
Reliability 1 1 4 1 x
0.08 0.20 0.23 0.16 0.34
Design Decisions
Control System
Decision Factors
Line
ar w
/ Spe
ed
Line
ar w
/ Voltage
Acce
l. Pr
ofile Decision
Factors
Fins
& Fan
s
Fans
Water
Jack
etDecision Factors
Deco
uplin
g Cap
acito
rs
Shielding
Dista
nce Ar
duino
Decision Factors
Exist
ing 4
8 V Bo
oster
24 V Boo
ster
Optio
nal A
C So
urce
Engineer
Andres 2.8 3.3 3.1
Austin 3.0 3.0 2.0
Charles 2.8 3.6 2.6
Leandra 3.1 2.3 3.2
Mitch 2.4 3.2 3.0
J osh 3.0 3.6 3.3
Weighted Scores 2.85 3.17 2.87
DC-DC Converter
Line
ar w
/ Spe
ed
Line
ar w
/ Voltage
Acce
l. Pr
ofile Decision
Factors
Fins
& Fan
s
Fans
Water
Jack
etDecision Factors
Deco
uplin
g Cap
acito
rs
Shielding
Dista
nce Ar
duino
Decision Factors
Exist
ing 4
8 V Bo
oster
24 V Boo
ster
Optio
nal A
C So
urce
Engineer
Andres 3.6 3.3 3.1
Charles 2.7 3.3 3.3
Mitch 3.4 3.0 2.6
Weighted Scores 3.23 3.20 3.00
Design Decisions (cont.)
Cooling System
Line
ar w
/ Spe
ed
Line
ar w
/ Voltage
Acce
l. Pr
ofile Decision
Factors
Fins
& Fan
s
Fans
Water
Jack
etDecision Factors
Deco
uplin
g Cap
acito
rs
Shielding
Dista
nce Ar
duino
Decision Factors
Exist
ing 4
8 V Bo
oster
24 V Boo
ster
Optio
nal A
C So
urce
Engineer
Austin 2.9 2.5 2.9
Leandra 3.8 3.2 2.5
J osh 2.9 2.7 2.8
Weighted Scores 3.20 2.80 2.73
Charging System
Line
ar w
/ Spe
ed
Line
ar w
/ Voltage
Acce
l. Pr
ofile Decision
Factors
Fins
& Fan
s
Fans
Water
Jack
etDecision Factors
Deco
uplin
g Cap
acito
rs
Shielding
Dista
nce Ar
duino
Decision Factors
Exist
ing 4
8 V Bo
oster
24 V Boo
ster
Optio
nal A
C So
urce
Engineer
Andres 3.6 3.5 2.4
Charles 3.0 2.7 3.2
Mitch 3.3 3.0 3.2
Weighted Scores 3.31 3.08 2.92
Final Design Decision
Primary Concept Secondary Concept
Control System Pedal press linear with voltage Pedal press linear with speed
DC-DC Converter Decoupling Capacitors between sources Shielding wires leading to Arduino
Cooling System Fins and fans Water jacket
Charging System 48 V booster 24 V booster
Questions?
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