kgcoe msd p15263 - rochester institute of technologyedge.rit.edu/content/p15261/public/final...

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KGCOE MSD P15261

Offboard Electric Vehicle Charger

Joseph Droleskey, Tucker Graydon, Brian Hebbard, Christopher Liess

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Index

Customer Project Readiness Package (PRP) 3

Customer Requirements 7

Engineering Requirements 8

Benchmarking 10

Risk Management 12

Morphological Table 15

Functional Decomposition 15

Team Schedule 16

System Layout and Design 27

AC-DC Rectification Subsystem 30

DC-DC Control Subsystem 32

Current Control Subsystem 34

Control and Logic System 35

CAN Communication Subsystem 36

Microcontroller 38

Prototype CAD Design 42

Estimated Bill of Materials 43

References 44

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Multidisciplinary Senior Design

Project Readiness Package

Project Title: Electric Superbike Off-board Charger

Project Number:

(MSD will assign this) P15261

Primary Customer:

(provide name, phone

number, and email) EVT, Josh Jones, Wheeler Law, Derek Gutheil

Sponsor(s):

(provide name, phone

number, email, and amount

of support)

MSD Senior Design department

Preferred Start Term: Spring 2015

Faculty Champion:

(provide name and email) Prof. George Slack, [email protected]

Other Support:

Project Guide:

(MSD will assign this) Slack

EVT, Josh Jones, Derek Gutheil January 2015

Prepared By Date

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Project Information

Overview: The RIT Electric Vehicle Team is a student run organization dedicated to promoting the

viability of electric vehicles through real world demonstrations of electric drivetrains in action. The

team aims to educate people on the principles of electric vehicle design by engaging students in

challenging and rewarding projects that cover a wide variety of academic disciplines. The team’s main

project is to design, build, and race a high performance electric motorcycle for competition in the 2015

eMotoRacing all-electric race series. The current bike is based off of the frame from a 2005 Kawasaki

Ninja ZX6RR, and utilizes two Zero Z-Force 75-7 motors paired with two Sevcon Size6 controllers. In

house engineering includes the design and fabrication of a battery management system, battery

containment modules, structural framing for the mounting of the powertrain, as well as advanced data

collection and analysis software. Based on this, the team is currently in need of a high powered charger

that can charge the bike's battery pack in a reasonable amount of time.

Project Goals: The R.I.T. Electric Vehicle Team proposes a portable off-board charger for an electric super

bike. In order to compete in the E-Moto Racing series, the team requires an efficient and reliable

method of charging the bike's 12 Kwh battery pack. Unlike traditional battery chargers, the superbikes

charger must conform to the J-1772 electric vehicle charging standard.

References:

[1] http://emotoracing.com

[2] http://en.wikipedia.org/wiki/SAE_J1772

[3] https://code.google.com/p/open-evse/wiki/J1772Basics

[4] http://batteryuniversity.com/learn/article/charging_lithium_ion_batteries

Customer Requirements (CR): This list of customer requirements of anticipated activities.

CR # Imp. Customer Need Description

CR1 1 Battery connection Able to safely connect and discount battery.

CR2 1 Power on / off Able to safely power on and power off charger

CR3 4 LCD Display Able to know the charging rates, state of charge,

charging time, etc. CR4 3 Adjustable Able to select voltage and current

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CR5 1 J-1772 standard Able to implement given standard(s)

CR6 3 Communication with the Superbike Able to communicate with the Superbike's BMS

via CAN

CR7 1 Wall connection Able to charge via J-1772 or 120V Wall

connection

CR8 3 Documentation

Every facet of the project must be well

documented with instructions where

necessary

CR9

CR10

Engineering Requirements (ER):

1. Power Requirements

a. The charger must be capable of charging a battery from full discharge to full charge in

no more than 4 hours while using the J-1772 standard charging station

b. The charger must also be capable of operating through standard 120V 15A 60Hz wall

outlets. While in this low power mode, the charger must be capable of charging the

battery in no more than 12 hours

c. The charging system must automatically detect and switch between the low and high

power modes

2. Control Requirements

a. The charger must be able to output voltage and current to within 20% of the nominal

values in either mode. These outputs must also be regulated to within 1% of their set

values

b. The charger must be able to vary voltage and current through both software and a user

interface

3. Communication Requirements

a. Needs to conform to the J-1772 communication protocol for use in high power mode

b. During all modes of operation, the charger must be capable of communicating over

CAN

Constraints: Safety is of the upmost importance. It will be a factor in every aspect of the design. The

batteries on the Superbike that will be charged have a large capacity, and as such, will not be readily

available for testing. The Electric Vehicle Team has access to them and can provide them upon request.

Most EVT members can be made available with a reasonable notice for assistance. EVT members will

also be a regular part of the design process ensuring that their goals are met.

Project Deliverables: Minimum requirements:

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● All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test

results)

● working prototype

● technical paper

● poster

Additional required deliverables:

● List here, if applicable

Budget Information: List major cost items anticipated, and any special purchasing requirements from the sponsor(s).

Intellectual Property: There are no IP restrictions on this project

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Customer Requirements

CR # Imp. Customer Need

CR1 1 Battery Connection to charger meets safety standards

CR2 1 Power on / off

CR3 4 LCD Display

CR4 3 Adjustable Outputs

CR5 1 J-1772 standard

CR6 3 Communication with the Superbike

CR7 1 Wall Connection

CR8 3 Documentation

CR9 1 Overall Design must be User Safe

CR10 1 Monitoring of battery charging

CR11 1 Adhering to EVT safety protocols

CR # Description

CR1 Able to safely connect and disconnect battery

CR2 Able to safely power on and power off charger

CR3 Able to know the charging rates, state of charge, charging time, etc

CR4 Able to select voltage, current

CR5 Able to implement given standard(s)

CR6 Able to communicate with Superbike's BMS via CAN

CR7 Able to charge via J-1772 or 120V wall connection

CR8 Every facet of project must be well documented with instruction where necessary

CR9 The final implementation must be safe to use even for a person who has never been trained on it

CR10 The charger must monitor the battery status over CAN communication to prevent damage to

battery

CR11 While working on the charger and with the batteries the team must adhere to all the safety

protocols the Electric Vehicle Team has in place and a member of EVT must always be present.

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Engineering Requirements & Specifications (revision 4)

Some features have been omitted since they do not necessarily have engineering metrics to rate success. These features include the user

interface being simple and user friendly, Certain safety implementations such as key switches and emergency stops. These are addressed in

the respected subsystem documentation.

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Specifications

Below are the current specifications for the charger: They currently based on the XALT 63 Ah High Power LIPO Cells in a pack of 25

connected in series. The list will be continuously updated as more data becomes available.

Parameter Min Expected Max Unit Comments

UnderVoltage Lockout 2.6 V Bat. Too low

Charge Current 1 15 50 A Depends on Source

Charge Voltage 25 50 110 V Pack Size dependent

Battery Termination Voltage 4.1 V

Accuracy -1 0 1 %

Battery Overvoltage Threshold 0.1 V

Battery Detection 2.5 2.9 4 V

Battery Detection Timer 333 ms

Start Charging Delay Timer 1 min

Charge Complete Timer 5 min

Safety Timer 2910 35 min Based on Charge Param.

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Benchmarking

PARAMETERS

Required EVT Energica Ego

Charge Rate <4hrs Charge Rate <4hrs 3.5hrs

Cool Rate 40deg C stability Cool Rate 40deg C stability Not Specified

PWR Response 1 sec PWR Response 1 sec Not Specified

Capacity 11.544 kWh Capacity 11.544 kWh 11.7 kWh

Life 1200 CYCLES Life 1200 CYCLES 1200 CYCLES

V/I Reg. Accuracy >99% CFM TBD 90

Output Voltage 50-60V+ 110/220V

Cost <$1000 >$1000

Attached Below is a expanded graph of efficiency and voltage characteristics of other EV Chargers

analyzed by EnergyStar for approval. These values will be used to compare the end product with what

is on the market currently.

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MSD Risk Assessment

ID Risk Item Effect Cause Lik

elih

oo

d

Sev

erit

y

Imp

ort

an

ce

Action to Minimize Risk Owner

Describe the risk briefly What is the effect on any or all of the project deliverables if the cause actually happens?

What are the possible cause(s) of this risk?

L*S What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring?

Who is responsible for following through on mitigation?

1

J-1772 interface unobtainable

The charger will not be usable with J-1772 chargers unless an adapter is manufactured in house

IP restrictions/low demand or supply for the interface

1 6 6 Conduct proper research into the ability to purchase this interface

Team

2 Over current

Damaged equipment,

injured

operator/bystander Current regulation does

not work 1 9 9

Researching and developing a

safety mechanism that shuts down

the charger and electrical system

when failure is detected Team

2 Over current

Damaged equipment,

injured

operator/bystander Software fails to detect

current 1 9 9 Debugging code and perform

testing Team

3

Battery management

system fails to cut off the

charge

Batteries

overcharge/lifecycle

decreases

Microcontroller fails to

detect a full

battery/communication

disconnect 3 7 21

Thorough debugging of

code/firmware will be

implemented, a microcontroller that

can effectively communicate with

the BMS will be researched and

purchased. Use test equipment to

ensure that the battery cells will not

exceed or meet 100% capacity Team

4 Input voltage detection Batteries Damaged

Microcontroller/software

fails to detect input

voltage 1 7 7

Thorough debugging of

code/firmware will be

implemented, a microcontroller that

can effectively communicate with

the BMS will be researched and Team

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purchased

5 Damage to charger

Must replace damaged

equipment/increased

cost due to replacement

Improper use,

overheating, system

design, short circuit 2 9 18

Implementation of redundant safety

systems and procedures. Adequate

research and testing to validate

design Team

6 Design Over-Budget Not all components are

obtainable

Lack of oversight,

incorrect parts ordered,

replacement to damaged

parts 2 7 14

Keep a log of desired

items/components, assign an

estimate cost to each system, and

minimize risk 5. Team/Project

Manager

7 Design behind schedule Project deliverables

incomplete

Unforeseen design

complications, Risk 5,

Lack of communication

between team 3 5 15

Team must update/adhere to

schedule on a regular basis and

maintain communication of any

possible complications or FMEA’s Project

Manager/Team

8 System function fails test Function must be

corrected

Inadequate components

within system, not

designed to interface

with other functions 2 6 12

Adequate research will minimize

risks. Having multiple concepts per

subsystem/function will provide a

backup in case system is proven to

fail. Team

9 System overheats Damaged Equipment Inadequate cooling 2 6 12 Add sufficient vents, fans, and heat

sinks. Team

9 System overheats Damaged Equipment Software does not detect

temperature 1 6 6

Debugging code and perform

testing to determine sensor is

recording accurate values Team

10 Battery Cell Detection Damaged Batteries Software does not detect

correct number of cells 1 6 6


testing to determine code is


11 Output Voltage Detection Damaged Batteries Software does not detect

correct output voltage 1 6 6


testing to determine code is


Likelihood scale Severity scale 1 - This cause is unlikely to happen 1 - The impact on the project is very minor. We will still meet deliverables on time and within budget, but it

will cause extra work

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2 - This cause could conceivably happen 4 - The impact on the project is noticeable. We will deliver reduced functionality, go over budget, or fail to

meet some of our Engineering Specifications.

3 - This cause is very likely to happen 9 - The impact on the project is severe. We will not be able to deliver, or what we deliver will not meet the

customer's needs.

“Importance Score” (Likelihood x Severity) – use this to guide your preference for a risk management strategy

Prevent Action will be taken to prevent the cause(s) from occurring in the first place.

Reduce Action will be taken to reduce the likelihood of the cause and/or the severity of the effect on the project, should the cause

occur

Transfer Action will be taken to transfer the risk to something else. Insurance is an example of this. You purchase an insurance

policy that contractually binds an insurance company to pay for your loss in the event of accident. This transfers the

financial consequences of the accident to someone else. Your car is still a wreck, of course.

Accept Low importance risks may not justify any action at all. If they happen, you simply accept the consequences.

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Morphological Table

Functional Decomposition

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Team Schedule

MSD II Schedule (Fall 2151) (updated 8/19/2015)

Class Date Phase Activities Week # Dates Team Members

All

semester

Build/ Test/

Integrate/Modify:

Sub-system &

System Level

Iterative activities throughout

semester

- Build/Test/Integrate/Modify.

Update Test Plan.

- Planning and tracking,

including risk assessment and

problem list

- Logbook updates

- Documentation and upload to

EDGE

Brian Hebbard Chris Liess Tucker Graydon Joe Droleskey

1

Wk 1

Aug 25

(Tues)

Subsystem Level

Prep/Build

Design Completion

(if failed gate

review)

Class:

MSD II Expectations: first 2

weeks and end of semester.

Revisit “Big Picture”.

Point students to purchasing

resources, space requests,

fabrication resources, safety

DeBartolo

MSD I post-mortem, project

planning, problem solving

Project plan walk-through with

Guide

1 8/24/2015

Catch team up on project status and goals, develop weekly meeting time outside of MSD II

Review project documentation



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2

Wk 1

Aug 27

(Thurs)

Online module: Testing

resources (test bench setup)

– equipment procurement,

location, procedures and exit

criteria, responsibilities,

schedule & priorities -- ready

to implement tests. (30 min)

Class:

Test plan walk-through with

Guide (each team member

brings in drafttest plan for

select ER's after watching

module)

3

Wk 2

Sept 1

(Tues)

Subsystem Level

Prep/Build

Design Completion

(if failed gate

review)

Status update, Phase I:

schedule for testing, what will

you demo in weeks 5, 8, and

11? (Revisit at each demo).

Review Team plan for Week 5

Subsystem Demo

Critical Design Review (some

teams - if failed gate review):

finalize design, demo key

functions, updated project

plan, test plan, other action

items

2 8/31/2015

Update schedule. Review progress of hardware, software and firmware development

Update BOM Update BOM Update BOM

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4

Wk 2

Sept 3

(Thurs)

Status update, Phase I:

schedule for testing, what will

you demo in weeks 5, 8, and

11? (Revisit at each demo).

Review Team plan for Week 5

Subsystem Demo

Critical Design Review (some

teams - if failed gate review):

finalize design, demo key

functions, updated project

plan, test plan, other action

items

Order components.

Order components Order components

5

Wk 3

Sept 8

(Tues)

Build/Test: Sub-

system Level

3 9/7/2015 Prepare team for "Milestone Review" #1

6

Wk 3

Sept 10

(Thurs)

Milestone Review #1

Researched means of reducing overall cost by investing in PCB alternatives.




7

Wk 4

Sept 15

(Tues)

Build/Test: Sub-

system Level

4 9/14/2015

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8

Wk 4

Sept 17

(Thurs)

Ensure that Edge content is up to date, review results from software and hardware testing

9

Wk 5

Sept 22

(Tues)

Build/Test: Sub-

system Level

(Functional Demo)

Sub-System Functional Demo

(key subsystems):

Demonstrate subsystem

functionality

Report out on test results

Updates to project plan,

problem solving, and team

goals for Week 8 demo

5 9/21/2015

Begin building prototype, full-scale DC-DC voltage/current regulation system

10

Wk 5

Sept 24

(Thurs)

Sub-System Functional Demo

(key subsystems):

Demonstrate subsystem

functionality




goals for Week 8 demo

Finish building prototype DC-DC voltage/current regualtion system, begin contstructing test setup



11

Wk 6

Sept 29

(Tues)

Build/Test/

Integrate: Sub-

system & System

Level


Test DC-DC voltage/current regulation system in an isolated test setup, compile and report on test results



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12

Wk 6

Oct 1

(Thurs)

Milestone Review #2

Begin developing software and firmware framework, confirm that the framework allows the Teensy to boot

13

Wk 7

Oct 6

(Tues)

Build/Test/

Integrate: Sub-

system & System

Level

Troubleshooting at the system

integration level: the

subsystems did what they were

supposed to but system doesn’t

work when it’s put together,

OR it works when I put it all

together but not as well as it

should. Open Q&A -

depending on demand, will use

a classroom or Design Center.

7 10/5/2015

Review test/inspection results, address any anomolies/failures, ensure that Edge content is up to date

Purchase capacitors for AC-DC system

Continue developing software and firmware, adding initial menus to the UI

14

Wk 7

Oct 8

(Thurs)

Purchase plexiglass

Continue developing software and firmware, adding menus to the UI. Create PCB for the gate driver

Purchase plexiglass

Wk 8

Oct 13

(Tues)

Fall Break - no class - follow

Monday schedule today - no

MSD

8 10/12/2015

Review test/inspection results, address any anomolies/failures, ensure that Edge content is up to date

Create layout of AC-DC voltage regulation system

Continue developing software and firmware, adding menus to the UI, charge selection menu.

Purchase PVC pipe to use as spacers

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15

Wk 8

Oct 15

(Thurs)

Spec out possible "project box" based on size of the PCB

Start building prototype AC-DC voltage regualtion system

Continue developing software and firmware, adding warning messages and flags

Begin building high current Rev. 2 of the DC-DC voltage/current regulation system, with the test results driving any design changes

16

Wk 9

Oct 20

(Tues)

Build/Test/

Integrate: Sub-

system & System

Level

Preliminary Integrated

System Demo (probably w/o

Customer) (all subsystems,

some integration).

Demonstrate any remaining

subsystem functionality

Demonstrate preliminary

systems integration demo




goals for Week 11 demo with

customer


Finish building prototype AC-DC voltage regualtion system, begin contstructing test setup

Continue developing software and firmware, adding key functions (charge rate, etc)

Finish building high current Rev. 2 of the DC-DC voltage/current regulation system

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17

Wk9

Oct 22

(Thurs)

Preliminary Integrated

System Demo (probably w/o

Customer) (all subsystems,

some integration).

Demonstrate any remaining

subsystem functionality

Demonstrate preliminary

systems integration demo




goals for Week 11 demo with

customer

Milestone Review #3

Purchase container for charger

Test AC-DC voltage regulation system in an isolated (from other subsystems) test setup, compile and report on test results

Develop and ensure that methods of communicating over CAN are robust and functioning properly, load firmware Rev. 1 onto the PIC, test key software functionality, report on results of testing

Mount PCB, relays and other subsystems that aren't on the PCB to the project box

18

Wk 10

Oct 27

(Tues)

Build/Test/

Integrate: System

Level

10 10/26/2015

Develop a user's manual for the charger that can be easily understood

Begin building Rev. 2 of the AC-DC voltage regulation system, with the test results driving any design changes

Continue developing software and firmware, adding remaining features (per ER and CR)

Consult with and assist Brian in developing hardware guidelines for a user's manual for the charger

19

Wk 10

Oct 31

(Thurs)

Consult with and assist Brian in developing software guidelines for a user's manual for the charger

Begin debugging any known non-functional key software/firmware features

Mount lock & key system to the project box

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20

Wk 11

Nov 3

(Tues)

Build/Test/

Integrate: System

Level

11 11/2/2015 Start paper.

Assist in developing hardware and software test procedures, taking into consideration ER and CR

Finish debugging known non-functional key software/firmware features, begin debugging known UI issues

Conduct a read-over of the user's manual to ensure that the manual could be easily understood

21

Wk 11

Nov 5

(Thurs)

22

Wk 12

Nov 10

(Tues)

Build/Test/

Integrate: System

Level

Full integrated system demo

with Customer.

System Demo with customer

Report out on final testing vs

ER's



goals for Week 14 prototype

handoff with customer

12 11/9/2015 Continue to develope paper.

Verify via "dry-runs" that developed software and hardware test procedures are robust, testing all key subsystems sufficiently

Begin finalizing software and firmware development

Verify via "dry-runs" that developed software and hardware test procedures are robust, testing all key subsystems sufficiently

23

Wk 12

Nov 12

(Thurs)

Full integrated system demo

with Customer.

System Demo with customer

Report out on final testing vs

ER's



goals for Week 14 prototype

handoff with customer

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24

Wk 13

Nov 17

(Tues)

Verification &

Validation

Submit 75% paper to

myCourses dropbox by today

- will be printed for

Thursday's workshop. 13 11/16/2015

Ensure that Edge content is up to date. Submit 75% paper.

Conduct software tests, cycling through various test procedures to ensure that all features work as intended

Address issues found via software and hardware testing

Conduct hardware tests, cycling through various test procedures to ensure that all features work as intended

25

Wk 13

Nov 19

(Thurs)

Technical Paper Workshop

9am (75% of paper complete)

DeBartolo

KGCOE Ethics Survey in-

class

26

Wk 14

Nov 24

(Tues)

Verification &

Validation

14

11/23/2015 Time delegated for addressing any possible last-minute anomolies/setbacks encountered during previous weeks

Wk 14 Nov 26

(Thurs)

Thanksgiving Break--NO

CLASS Thanksgiving Break

27

Wk 15

Dec 1

(Tues) 15 11/30/2015 Prepare for final presentation

28

Wk 15

Dec 3

(Thurs)

Verification &

Validation

Project complete – hand-off

obligations to Customer are

met

Final demo and customer hand-

off

Work space cleanup

Website complete

Post-mortem: team self-

assessment against norms &

values; objective evaluation of

successes & failures

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29

Wk 16

Dec 8

(Tues)

Project complete – hand-off

obligations to Customer are

met

Final demo and customer hand-

off

Work space cleanup

Website complete

Post-mortem: team self-

assessment against norms &

values; objective evaluation of

successes & failures

Paper complete

(SUGGESTED)

16

12/7/2015 Final Presentations

30

Wk 16

Dec 10

(Thurs) Presentations

Final Project Presentations

Papers due to Design Center

Office

Final Presentation

Exams Dec 14-

18 Gate Review

Gate Review - schedule by

team with guide:

Post mortem

Review EDGE

Check in locker/cart/cubicle to

Design Center Office

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(page inserted for future updates to schedule)

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System Design

Subsystems Covered:

1. Power Switch & Key

2. J1772 Inlet

3. AC/DC Rectifier System

4. Voltage Control System

1. DC-DC Controller

2. Current Limiter

3. Output

5. User Interface

6. MicroController

7. CAN Bus

8. Emergency Systems

1. Relays

2. J1772 Shutoff

9. Temperature Control

10. Programing Interface

1. Power Switch and Key

Both the Key and the Switch are need to turn on the overall charger system. A Master key is utilized to arm the

switch to be toggled on, this is done so that no unauthorized personnel have access to the charger. The switch turns the

power for the logic circuit on so that the user may begin interfacing with the charger.

2. J1772 Inlet

This is the female socket for the J1772 to plug into. A pilot signal from the microcontroller is needed to engage the

plug and allow it to conduct. There is a proximity pin on the line in that the logic circuit pulls its power from. This

proximity line sources approximately 12v.

3. AC/DC Rectifier System

Once the J1772 line has been engaged a differential phase AC current flows to the AC/DC rectifier. The current

design is that of a Vienna rectifier that is known for minimal power loss over transmission. More can be read in that

subsystems documentation.

4. Voltage Control System

The Rectifier outputs its DC voltage to the control/regulation system. This system is comprised of 3 parts; the

Voltage Regulator, the Current Limiter and the Output socket to the Battery System. The Voltage Regulator utilizes a PWM

controlled buck switch converter that steps the voltage down to a selected level based on user input. This is followed by the

Current Limiter which actively controls current flow based on the user input and in coordination with the voltage level of

the voltage controller. This system is in place to prevent rampant over current from occurring and damaging batteries that

are attached. The current limiter then directs the charge to the output port where the batteries are connected.

5. User Interface

The User Interface is comprised of a Parallax LCD screen that will display the battery statistics as it charges and

any user options that are available at the time. User inputs are selected by use of 4 buttons alongside the screen. The screen

is also capable of auditory alerts and warnings using an on-board piezo speaker element.

6. Microcontroller

The microcontroller in the charger will orchestrate the control systems as well as the communication protocols the

the BMS on the bike. A Teensy 3.1 microcontroller is currently selected and is being tested. A Teensy microcontroller was

selected because it has CAN drivers natively built into its architecture and allows for simple hardware interfacing with the

BMS CAN line. The Teensy also has 24 general GPIO pins all of which have hardware multiplexing so that they can fill

any roll needed.

7. CAN Bus

The BMS CAN bus is interfaced over the built in CAN drivers in the PIC controller. The CAN transceiver

hardware is still necessary to convert the signal into CAN Protocol levels. The signals that are received from the BMS are;

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the battery voltage per cell, the temperature of each cell, and the pressure of each cell. A handshake protocol is also in effect

that regularly checks in to make sure connection is establish and no errors have occurred.

8. Emergency Systems

A number of systems are in place around the charger's design that allow critical systems to be isolated and to

eliminate electrical conductivity in case of an emergency situation. The largest level of isolation is in the form of a set of

relays that isolate the charging lines that are within the charger. At any given moment the AC/DC rectifier and the Voltage

Controller can be isolated and connections to the J1772 and batteries are severed. Research has been done and as of the first

revision solid state relays are the best option. The next level of security is the Emergency Shutoff which cuts the pilot signal

to the J1772 and it ceases to conduct. This is handled by the microcontroller. The most passive system in place for safety is

the ignition system; no user may access the charger unless they have a master key which indicates they have been trained or

are with a trained individual.

9. Temperature Control The temperature control systems monitor the temperature of the high risk systems with a thermistor. If any of the

systems gets within a margin of their critical operating temperatures the microcontroller will disable the charge system and

warn the user of the system overheating. A feedback system will also be in effect to control fans to circulate air around the

components.

10. Programming Interface

This is a female usb port by which the charger's microcontroller may be interfaced with by a computer. If for any

reason the firmware on the microcontroller needs to be changed this allows for ease of access to the system.

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(3) AC-DC Rectification

This design is based on variant of a dual-boost rectifier, called a Vienna rectifier. It has been modified

to be split phase, which is the type of power received by this charger. The main reason this particular

design was selected was for the qualities listed below:

1. Switching loss reduction

2. Power factor = 0.997

3. Total efficiency = 97%

4. Tailored for Industrial/High Power Applications

Schematic Definitions

Gate Drive Transformer: This component turns the inverted gate bipolar transistors (IGBT) on and off

in phase with the line voltage using a PWM cycle of approximately 25kHz.

Q1/Q2: IGBTs used to deliver current from their respective phase to the node between C1/C2 during

the ON period.

C1/C2: Output (offset) capacitors of equal value. When Q1 or Q2 is on they charge linearly via the

central node. The charging of these capacitors will offset +VDC and –VDC.

L1/L2: Represent the input inductors of the rectifier.

+(-)VDC: DC output of rectifier that connected to the DC/DC Regulation from the positive side.

D1-D12: Power Diodes. Current spec is D13940 power diode.

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(3) AC-DC Rectifier Schematic

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(4.1) Voltage Controller Subsystem Support Document

The current subsystem design for the voltage controller is a PWM controlled Buck Switch

converter. Attached is a example circuit diagram where a simple converter is implemented. Previously

voltage was attempted to be regulated utilizing a single branch motor controller however for higher

voltages its effectiveness fell. The PWM controlled buck converter however can handle voltages and

currents around that of the J1772 and the switching style of the converter means it has very low power

loss as a regulator. Looking at the attached circuit the input (V+) is supplied from the AC/DC rectifier

and is a fairly unregulated DC voltage.

The control circuit voltage (VCC) is supplied from the logic power system and the PWM signal

is an output if the microcontroller. The PWM signal is run through a flip flop and the PWM and ~PWM

are ran to the gates of 2 power NMOS devices. The top device allows conduction of V+ through the

inductor and to the batteries. When the top gate shuts off, the bottom turns on and the load goes to

ground. By utilizing a PWM the load can have a voltage modulated across it that sweeps from the input

voltage (100%) to 0V (0%). An ideal modulation frequency is being determined, 100-500 Hz is a good

range and offers steady stage voltages, however higher switching rates have less ripple on the output

and require less filtering.

Other regulator designs are being pursued, but a PWM Buck Converted seems the most reliable.

The Current limiter is after the Voltage Regulator and will be dynamically related to the voltage

of the regulator and will have a cap to prevent over-current from damaging the components on the

batteries. This component can most likely be handled by a IC from TI or Linear Technologies, it is still

being researched.

The output of the PWM'd voltage can be averaged and filtered with a simple RC filter tuned to

the frequency of the PWM signal.

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(4.2) Current Regulation

A reference voltage will be applied to a leg of a comparator while the other leg is attached to

the load line. The comparator will then respond to a resistor or transistor network to modify the

inbound current to the load. By being able to control the reference voltage with a digitally variable

resistor the current allowed through the load can be controlled by preventing it from drawing the limit

set by a controller.

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(6) Control / Logic Circuit

The microcontroller used is a Teensy 3.1

microcontroller. This board features an Arm

cortex M-4 processor overclocked to 96MHz. It

also has 256 kBytes of on-board flash memory

capable of storing programs to modify its 34

digital I/O pins, which are hardware multiplexed

to allow them to also become analog I/O, SPI,

UART, I2C, CAN or I2S Audio. The Teensy can

be programed using standard AVR .hex loading or

by utilizing the Arduino IDE with small

modifications for compiling for the hardware.

Currently the EVT CAN drivers contain 9

objects that are recognized on the system. And a

total of 13 message IDs that are possible

following the object. The microcontroller in the

charger will act as a single node on the CAN bus

and will have the capability to read any messages

that are status messages or flags from the BMS.

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Figure 1Pilot Signal View

Figure 2 CAN Toplology

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CAN IDs and Messages

Can Gateway Messages

REQUEST_STOP_TRANSMIT 0x10

REQUEST_TRANSMIT_DATA 0x11

REQUEST_NAME_FIRMWARE_VERSION 0x12

REQUEST_DEVICE_DATA_TYPES 0x13

RESET_ALL_DATA_SENDERS 0x20

GTW_UPDATE_NOTIFIER 0x30

GTW_UPDATE_DATA 0x31

GTW_UPDATE_CHECKSUM 0x32

Data Sender Message IDs

ERROR_FLAGS 0x05

NAME_AND_FIRMWARE_VERSION 0x06

DATA_TYPE 0x07

UPDATE_CLEAR_TO_SEND 0x08

UPDATE_CHECKSUM 0x09

DATA_01 0x11

DATA_02 0x12

DATA_03 0x13

DATA_04 0x14

DATA_05 0x15

DATA_06 0x16

DATA_07 0x17

DATA_08 0x18

Device IDs

GTW 0x1

IMU 0x2

BMS_1 0x6

BMS_2 0x7

BMS_3 0x8

BMS_4 0x9

BMS_5 0xA

BMS_6 0xB

BMS_7 0xC

BMS_8 0xD

BMS_9 0xE

BMS_10 0xF

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(6) Microcontroller Pinout and Wiring

Utilizing the Teensy 3.1 microcontroller described

earlier the following wiring diagram was created to display

its integration as the control unit for the system. A pinout

table can be seen below depicting which pins are assigned

each roll for the other subsystems and what they may be

used for. As of the 6th revision there is 3 free Serial

Protocol Interface register (SPI) to be used since the can

transceiver from Linear Technology utilizes TX/RX to

communicate with CAN.

The system can be programed through a micro USB

cable which will be accessible through the exterior. 4 user

input buttons and the LCD screen are accounted for. The

screen chosen, a parallax screen that has built in drivers

and controllers decreases the pins needed to one data pin.

One pin is reading in analog voltages from a thermocouple

within the critical subsystems to detect if the system

temperature rises suddenly or overheats. If this happens

there is a pin utilized to turn on a set of fans to cool down

the components and if an overheating error occurs the

system will shut off. 3 of the systems major relays are

shown on the diagram; 2 are the high voltage relays in the

main current drawing line and one is the relay used to

trigger the pilot signal to tell the J-1772 to conduct.

Pin # Function/ Assignment

0 Heartbeat LED

1 Error LED

2 -

3 CAN TX

4 CAN RX

5 Gate PWM

6 Gate PWM

7 -

8 -

9 Exit Button

10 LCD RX

11 Enter Button

12 Right Button

13 Up Button

14 Termocouple

15 Pilot Relay (8.2)

16 AC Relay (8.1)

17 DC Relay (8.1)

18 Fan Enable

19 -

20 -

21 -

22 -

23 -

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Start Menu

Charging

Operation

(See next

figure)

Slow

Charging

User Options

Charge Menu

Fast Charging

Selectable

User Options

(screen

settings,

units)

Exit

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Prototype CAD Design

1. J-1772 Charging Station

2. MSD P15261 Fast Charger

3. EVT Motorcycle Battery

4. Standard J-1772 Cable

5. Emergency Shutoff Button

6. Key lock / Power Switch

7. LCD Display

8. User Interface, Directional Buttons

1

3

2

4

5

6

7 8

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Subsystem Bill of Materials (BoM)

Component Size Model Cost/unit Total Site

AC-DC system

Mosfet/IGBT 600 V, 50 A NGTB50N60FWG $2.38 $4.76 http://goo.gl/l954ba

Diode 600 V, 50 A 512-RHRG5060_F085 $3.91 $46.92 http://goo.gl/Ovu3dB

Capacitor (for Vripple) 10000 uF DCMC103T200CJ2D $35.35 $141.40 https://goo.gl/tCaeKr

Gate Driver 50kHz-100kHz PA0185NLT $3.00 $3.00 http://goo.gl/n5N8oJ

DC-DC System

Power MOSFET 300V, 88A,

40mOhm IXTH 88N30P $9.53 $133.42 http://goo.gl/Gmf9yS

Gate Driver 6-60V, 1.7A DRV8301 $2.5 $10 http://goo.gl/4y3z9p

DC Relay 600VAC, 90A CWU2490 $98.77 $98.77 http://goo.gl/VHBCIN

AC Relay 600VAC, 90A D2490 $85.19 $85.19 http://goo.gl/qzJ1gS

J1772 Connector N/A DSIEC2f-EV32S-NC $98 $98 http://goo.gl/TwhikR

Misc.

Parallax LCD 4x20 Characters 27979 $42.99 $42.99 http://goo.gl/y6iBUz

J-1772 Cable 10 Gauge wire 1033 $141 $141 https://goo.gl/V2T6WR

Buttons SPST contact

Buttons 30-101 $4.76 $23.8 http://goo.gl/yjwV8C

J-1772 Plug Female plug 1034 $65 $65 https://goo.gl/chHm7c

Fans 12V DC Fan FAD1-04010CSMW11 $2.5 $5 http://goo.gl/FkjAUg

PWM Driver 16 Channel, 12 bit PCA9685PW,112 $2.35 $2.35 http://goo.gl/vXZNGV

E-Stop Button SPST E Stop A165E-02 $20.87 $20.87 http://goo.gl/MZBR0a

Key Switch Key Switch Y101132C203NQ $11.73 $11.73 http://goo.gl/tQVCYk

High-Efficiency PWM

Power Driver 14.4 V/V, +/- 3 A

input DRV594 $28.22 $28.22 http://goo.gl/xIbCtt

Acrylic Sheet 18 in. X 24 in. 1AG2123A $21.37 $21.37 http://goo.gl/YPVJpR

Battery Wire, Ultra

Flexible, 6 Gauge, Red 10 Feet 6948K91 $17.50 $35.00 http://goo.gl/TV165a

Battery Wire, Ultra

Flexible, 6 Gauge,

Black 10 Feet 6948K91 $17.50 $35.00 http://goo.gl/TV165a

Husky 37 in. Mobile Job

Box 50 Gallon 209261 $64.00 $64.00 http://goo.gl/gZCsmo

Total: $1117.79

http://www.mcmaster.com/#6948K91

http://www.mcmaster.com/#6948K91

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References

1. http://publications.lib.chalmers.se/records/fulltext/184817/184817.pdf

2. http://www.ixys.com/Documents/AppNotes/IXAN0001.pdf

3. https://www.energystar.gov/ia/products/downloads/Electric_Vehicle_Scoping_Report.pdf?0544-2a1e

4. http://www.microchip.com/wwwproducts/Devices.aspx?product=PIC18F46K22

5. https://eewiki.net/display/microcontroller/CAN+Example+-+ATmega32M1+-+STK600

6. http://www.vicorpower.com/documents/application_notes/an_ConstantCurrent.pdf

http://publications.lib.chalmers.se/records/fulltext/184817/184817.pdf

http://www.ixys.com/Documents/AppNotes/IXAN0001.pdf

https://www.energystar.gov/ia/products/downloads/Electric_Vehicle_Scoping_Report.pdf?0544-2a1e

http://www.microchip.com/wwwproducts/Devices.aspx?product=PIC18F46K22

https://eewiki.net/display/microcontroller/CAN+Example+-+ATmega32M1+-+STK600

http://www.vicorpower.com/documents/application_notes/an_ConstantCurrent.pdf