Electrical System

Electrical System Overview Main Components

› Batteries Primary (72VDC) Secondary (12VDC)

› Motor Brushed DC

› Motor Controller› DC-to-DC

Converters› Microcontroller› Ignition Switch

› Peripherals (5VDC) Potentiometers Hall Effect Sensors Switches

› Circuit Protection Fuses Diodes Circuit Breakers Optoisolators

› Safety Emergency Stop Kill Switch

Electrical System Functional Overview

System Functions› Store High Voltage (HV) and route current to

electric motor to propel motorcycle› Maintain OEM-type motorcycle battery

voltage used to power microcontroller and motor controller

› Control rear wheel spin and front wheel lift by modifying the throttle input signal to the motor controller

› Isolate HV battery from all HV components for safer operability and serviceability

Electrical System Wiring Diagram

Electrical System SpecificationsInput Peripherals

Spec # Voltage Range Component Type Input Type Wire Count # of MicrocontrollerInputs Needed

# of Components Needed Description Part Number(s) Ref. Spec(s)

S20

0 - 5 VDC

Wheel Speed Sensor Hall Effect Digital 2 1 2 0.4VDC = air gap, 5VDC = blocked by ferro-magnetic material,50 pulses per rotation

21176-0706 (FR WSS)21176-0134 (RR WSS)21007-0166 (FR RLR)21007-0167 (RR RLR)

S2, S11

S21 Accelerator Sensor Assembly Potentiometer Analog 3 0 1 0VDC = closed throttle, 5VDC = wide open throttle (WOT) 13S-85884-00-00 S11

S22(a) Gear Position Sensor(OEM-type) Potentiometer Analog 3 1 1 Tiered levels of voltage designated for each gear position

(i.e. 0.5VDC = 1st, 1.0VDC = 2nd, 1.5VDC = 3rd, etc.) 13151-0045 S11

S22(b) Gear Position Sensor(Magnet type) Hall Effect Digital 2 2 2 Upper sensor trigger = upshift, lower sensor trigger = downshift,

triggered by rising-edge HP620-300 S11

S23 Front Suspension Travel Sensor Potentiometer Analog 3 1 1 0VDC = suspension fully extended, 5VDC = fully retracted CLP-250 S1, S11

S24 Push-Button Switch Digital 2 2 2Button 1) adjusts traction control levels (i.e. 1st push = 10% allowable slip, 2nd push = 5% allowable slip, 3rd push = OFF) Button 2) starts/stops Data Acquisition; Both triggered by rising-edge

3-1437565-0 S11

Output Peripherals

Spec # Voltage Range Component Type Output Type Wire Count # of MicrocontrollerOutputs Needed

# of Components Needed Description Part Number(s) Ref. Spec(s)

S25 0 - 3.3VDC Optoisolator NPN Digital 3 0 1 Optoisolator reduces interference from motor controller to microcontroller. 4N25-000E S10

Microcontroller

Spec # Requirement Quantity Description Part Number(s) Ref. Spec(s)

S26 USB Port 1 Required for data acquisition and programming by a PC.

dsPIC33FJ12GP202 S10

S27 External Interrupts 4 Allow specific digital peripherals (i.e. WSS, to input external trigger for program interrupts.

S28 Throttle Control PWM Output 1 Output PWM for throttle control at fixed frequency of 1000 - 2000 Hz.

S29 Voltage Sample PWM Output 1 Output PWM to sample 12VDC battery voltage every 1 - 2 seconds.

S30 10-bit ADC 1 Required to interpret analog voltages into 1024 unique binary values for the microcontroller to analyze.

Legend

FR = Front VFA = Very Fast Acting RLR = Reluctor Ring

RR = Rear WSS = Wheel Speed Sensor LPF = Low Pass Filter

Electrical System Specifications (cont.)

Power Distribution, Wire Ratings, & Circuit Protection

Spec # Voltage Level Component Wire Count Rating(s) # of Components Needed Description Part Number(s) Ref. Spec(s)

S31

12 VDC(Low Voltage)

Ignition Switch 3 5A, 12VDC 1 Three positions: OFF (0VDC, HV OFF), ACC (12VDC, HV OFF), RUN (12VDC, HV ON) 27005-5137 S10

S32 Kill Switch 2 1A, 12VDC 1MUST be operated without removing either hand from the handlebars, be identifiable by rider and person not sitting on machine, disable the machine's controller, not be a software input, does not act as a General Circuit Breaker. MUST be Normally Closed.

0616-0159 S10

S33 Emergency Stop 2 4A, 230VDC 4

MUST be located behind rider, be operated if machine is on its side, be a red button with a yellow disc of at least 8cm in diameter reading "Emergency" in red or black letters, latch down mechanically once it has been operated, require manual operation to reset it, act as a General Circuit Breaker that interrupts ALL electrical transmission between the batteries by means of a spark-proof circuit breaker, include isolation of pre-charge (ground) circuits. MUST be Normally Closed. Four switches will be used for test bench.

C22-PVT60P-K11 S10

S34 Wire Diameter - 22AWG - Follow the 10x normal current rule for microcontroller inputs and outputs, multi-strand. - S10

S35 Fuse 2 10A 1 Protect the microcontroller, motor controller, and relays from overcurrent. - S10

S36 Circuit Routing - - - Twist all pairs of wires, if feasible, to reduce EMI. - S10

S37 Microcontroller Undervoltage Protection 1 - 1 Automatically shut down when the microprocessor input voltage falls below 9VDC. This prevents inaccurate microcontroller outputs from out-of-range supply voltages. - S5

S38 Microcontroller Overvoltage Protection 2 5W, 12VDC 1 Install a Zener diode at the VDD input of the microcontroller to prevent overvoltage damage if improper voltage levels are applied. 1N5349BG S10

S39 Contactor Coil Suppresion Diode 2 1A, 50VDC 1Due to large amounts of energy stored in the motor coils during operation, a voltage spike of several hundred volts is generated when the breaker is turned OFF. This diode surpresses this spike which protects the connected motor controller and DC-DC converters. Cathode (i.e. banded end) MUST face positive voltage!

1N4001 S5

S40

72 VDC(High Voltage)

Contactor Coil Suppresion Diode 2 1A, 400VDC 2 1N4004 S5

S41 Wire Diameter - 4AWG - 6AWG for Current < 300A, 4AWG for 300A < Current < 450A, 4AWG-2AWG for 450A < Current < 500A, 2AWG-1/0 for 500A < Current < 650A - S10

S42 Wire Insulation Resistance - 250kΩ - 250kΩ for < 300 Volts to earth, 500kΩ for > 300 Volts, test insulation resistance using at least 100VDC - S10

S43 General Circuit Breaker 2 400A, 72VDC 2MUST open circuit when control voltage is switched OFF (relay, solenoid switch).MUST not be substituted with over-current trip switches but be controlled by Emergency Stop switch (i.e. relay, solenoid contactor)

SOL-72V-400A S10

S44 Fuses 2 400A (VFA), 80VDC 1 MUST be easily accessible, be as close as possible to battery, be used for ALL electrical cables, be rated according to the diameter of the individual conductors, be fast burn type. ANN400 S10

S45 Pre-charge Resistor 2 1kΩ, 10W, 72VDC 2 Due to the large amount of internal DC capacitance of the motor controller,the pre-charge resistor helps to prevent arcing at each contactor. MIS-PRE-1KT S5

S46 Motor Controller 4 450A, 72VDC 1Throttle input Pins 2 and 3 are reprogrammable using the serial port and a PC. Set up this controller to accept a 0 - 5VDC input from the Accelerator potentiometer. Actual allowable input voltage range for Pins 2 or 3 is 0.15 - 4.90 VDC.

AXE 7245 S10

S47 72VDC-to-12VDC Converter 4 124W, 9A (continuous)10A (peak) 1 Converter MUST isolate both 72VDC and 12VDC power and ground circuits. PST-DC/7212-9 72/12 S5

Legend

FR = Front VFA = Very Fast Acting RLR = Reluctor Ring

RR = Rear WSS = Wheel Speed Sensor LPF = Low Pass Filter

Electrical System Bill of Materials (BOM*)

Bill of Materials

Item Component # of Components Needed Part Number

1 72VDC Battery 1 (supplied)

2 DC Motor 1 (supplied)

3 Motor Controller 1 (supplied)

4 LPF (PWM adjustment) 1 -

5 25Hz LPF (1 resistor, 1 capacitor) 1 -

6 Normal Diode 2 6A06

7 Zener Diode 1 1N4742

8 Relay 1 275-001

9 12VDC-to-5VDC Converter 1 LM317

10 10A 12VDC Fuse 1 270-1093

11 12VDC Battery 1 UPG 42511

12 dsPIC33FJ12GP202 1 -

13 100k Resistor 2 -

14 10k Resistor 1 -

15 3.3k Resistor 1 -

16 1k Resistor 1 -

17 PMOS MOSFET 1 IRF9530-ENP

18 NMOS MOSFET 1 IRF9530-ENN

*Only includes parts not listed in the System Specifications to prevent redundancy.

Wrap-Up

Feasibility Analysis

Risk Assessment

Questions?

Electrical System Wiring Diagram

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Electrical System Wiring Diagram

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Front WSS Mounting Location Rear WSS & RLR Mounting Location

Electrical System Wiring Diagram

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Solenoid Circuit Breaker

Electrical System Wiring Diagram

ReturnMotor Controller

Electrical System Wiring Diagram

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Front Suspension Linear Potentiometer

Electrical System Wiring Diagram

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DC Motor (supplied) Motor Curves @ 72VDC