optimization of a 1974 vw electric bug group 16 michael boyle michael labeach andrew magaletti rabei...

Optimization of a Optimization of a 1974 VW Electric Bug1974 VW Electric Bug

Group 16Group 16Michael BoyleMichael BoyleMichael LaBeachMichael LaBeachAndrew MagalettiAndrew MagalettiRabei RabeiRabei Rabei

CustomerCustomer

Andrew ParkAndrew Park Owner of the carOwner of the car Graduate Student Graduate Student

at Florida State at Florida State UniversityUniversity

Dr. HollisDr. Hollis

What is the Problem?What is the Problem?

HillsHills SpeedSpeed RangeRange LightsLights InteriorInterior

Scope and Customer Scope and Customer NeedsNeeds Increase TorqueIncrease Torque Increase SpeedIncrease Speed Increase RangeIncrease Range Distribute Distribute

WeightWeight

QFD ChartQFD Chart

Concept 1 – Add 6 Concept 1 – Add 6 BatteriesBatteries

Components Needed:Components Needed:– 6 12V Deep Cycle Batteries6 12V Deep Cycle Batteries– 24V Field Battery Pack24V Field Battery Pack

Battery Configuration: Series/ParallelBattery Configuration: Series/Parallel Estimated Top Speed: 70mphEstimated Top Speed: 70mph Estimated Range: 55 milesEstimated Range: 55 miles Cost: $530Cost: $530

Components Needed:Components Needed:– AC MotorAC Motor– DC to AC inverterDC to AC inverter

Battery Configuration: SeriesBattery Configuration: Series Estimated Top Speed: 50mphEstimated Top Speed: 50mph Estimated Range: 45 milesEstimated Range: 45 miles Cost: $4000Cost: $4000

Concept 2 – New MotorConcept 2 – New Motor

Concept 3 – New Concept 3 – New controllercontroller

Components Needed:Components Needed:– ControllerController– 10 Batteries10 Batteries

Battery Configuration: Series/ParallelBattery Configuration: Series/Parallel Estimated Top Speed: 65 mphEstimated Top Speed: 65 mph Estimated Range: 70 milesEstimated Range: 70 miles Cost: $2200Cost: $2200

Concept 4 – Lower Concept 4 – Lower Voltage BatteriesVoltage Batteries Components Needed:Components Needed:

– 9 8V Deep Cycle 9 8V Deep Cycle BatteriesBatteries

– 24V Field Battery Pack24V Field Battery Pack

Battery Configuration: Battery Configuration: SeriesSeries

Estimated Top Speed: Estimated Top Speed: 70mph70mph

Estimated Range: 35 Estimated Range: 35 milesmiles

Cost: $840Cost: $840

Concept 5Concept 5

Components Needed:Components Needed:– Advanced DC L91-4003 Series MotorAdvanced DC L91-4003 Series Motor– Kelly Controls KDH09500A Kelly Controls KDH09500A – (10) 12V Deep Cycle Batteries (10) 12V Deep Cycle Batteries

Battery Configuration: Series/ParallelBattery Configuration: Series/Parallel Estimated Top Speed: 80mphEstimated Top Speed: 80mph Estimated Range: 70 milesEstimated Range: 70 miles Hills? - YesHills? - Yes Cost: $2506.86Cost: $2506.86

Decision MatrixDecision Matrix

Decision Matrix

Cost Range Speed Safety Torque ComplexityTotal

Weight % Weight % Weight % Weight % Weight % Weight %

CONCEPT 1 90 0.4 80 0.2 70 0.2 60 0.05 70 0.1 70 0.05 79.5

CONCEPT 2 30 0.4 50 0.2 60 0.2 40 0.05 90 0.1 40 0.05 47

CONCEPT 3 60 0.4 90 0.2 70 0.2 50 0.05 60 0.1 60 0.05 67.5

CONCEPT 4 80 0.4 50 0.2 80 0.2 60 0.05 70 0.1 70 0.05 71.5

CONCEPT 5 40 0.4 90 0.2 95 0.2 30 0.05 80 0.1 30 0.05 64

Optimum DesignOptimum Design

Concept 1Concept 1

Why?Why?

ConclusionConclusion

Boundaries OvercomeBoundaries Overcome– Battery connectionBattery connection– Pre-winding the magnetic field of the Pre-winding the magnetic field of the

motormotor– Series vs. Shunt vs. ACSeries vs. Shunt vs. AC

Future PlansFuture Plans

Regenerative BrakingRegenerative Braking LED LightsLED Lights Battery CageBattery Cage Rob MatthiesRob Matthies Conversion ManualConversion Manual

Questions?Questions?