Malte MarkoDaniel MacDonald

Stephen ThomasMatthew Gleddie

Supervisor: Dr. Lukas Swan

Team 1 Electric Trials Motorcycle

MECH 4010 Final PresentationDecember 3rd, 2012

2Outline

Problem Definition

Design Process

Final Design

Budget

M. Gleddie, 2012S. Thomas, 2012

3What Is Trials Motorcycling?

TechnicalHigh TorqueLow SpeedHigh ControlNot a race!

S. Manchester, 2012

4Design Requirements

Noise

Battery LeadsThrottle Response

Water Resistance

New: Battery ManagementSystem!

S. Manchester, 2012

Sound Testing5

M. Gleddie, 2012

6Prototype 2 Sound Requirement

91 dB

88 dB

25 % reduction insound wave pressure

77

8Re-Orientation of Leads

Side View

Power and BMS Leads to Top of Pack

Consolidate Wiring Plugs to Single, Central Point.

Top View

Messy, Prone to Damage

S. Thomas, 2012

S. Thomas, 2012

Battery Management System

9

10Battery Management System

Constantly check between cells for over-voltage (3.6V)

Manually turn on/off power supply

Shunt power resistors

S. Thomas, 2012

11Rejected ideas – BMSOn-Board BMS

Weight No need for discharge balancing (Throttle Response)

Arduino Control W/ Relay Power Resistor

Emulates physical charging sequence

Complicated apparatus, high likelihood of user error/malfunction

CCCV power supply shutoff problems Arduino, 2012

12Battery Management System

Final Design: FET CircuitLimits cell voltages to 3.6VDissipates excess current to heat sinkSelectable characteristics

13Full FET Circuit

8 FET circuits in totalDissipate over-voltage power through back of FET to common heat sink (Al, finned, 10cm x 40cm)

14BMS Plan BPreFab UnitOver-Designed, Expensive

- Capable of measuring up to 108 cells connected in series based on configuration.- Performs intelligent cell balancing (passive).- Calculates state of charge (SOC).- Uses professional automotive-grade locking connectors.- Calculates discharge current limit (DCL) and charge current limit (CCL).- Can measure cell voltages between 0.5v and 5.0v.

Orion BMS, 2012

Drive Train Design Process

15

16Current Drive Train Problems

Motor and shaft mounts are separate

Bent shaft mount – misalignment

Open motor

7:1 reduction

Noise!

S. Thomas, 2012

17Rejected Ideas

Goldenmotor.ca

Flywheel and ClutchPlanetary GearReduction

Hub MotorOne Stage Gear Reduction

ClutchFlywheel

18Motor Selection

0

100

200

300

400

500

600

700

800

900

5:110:1

15:120:1

25:130:1

35:140:1

2 kW Motor Profile

19Selected Motor

HPM-5000b from goldenmotor.com5kW48 V100 amp continuous300 amp peak (30 seconds)Water resistantAluminum case, SS shaft4000 RPM on 48 volts

Goldenmotor.ca

20Primary Reduction - Belt

Gates Mectrol 2012

Gates Mectrol 2012

21Drive Train

Primary ReductionChange ratio to 3:1 (from 1.8:1)

Secondary Reduction Change ratio to 5:1 (from

7.1:1) Use lighter 520 chain Use stock parts

22Drive Train BracketMinimize loadsProtect componentsMount to frame

TBDStress calculationsBuild prototype

23Controller/Throttle ResponseKelly KBL48201 (from department)48 V100 amp continuous200 amp peak (1 minute)260 amp boost (10 seconds)SealedTorque control, speed control, or a mix

S. Thomas, 2012

Final Design

24

25Final Design

Final Design Component Design Requirement Met

Re-Designed Drive Train

3:1 Toothed Belt Noise Reduction

5:1 Chained Reduction

HPM5000B Motor Water Resistance

BMS FET Circuit Automated BMS

Kelly KBL48201 Controller Throttle Response Water Resistance

Re-Orientation of Battery Leads Protection of Cabling

26

S. Thomas, 2012

27Budget

Major Items Cost [$]

Motor 600Battery Charger 500

Drive Train Components

670

BMS Components 630

Miscellaneous 150Controller 0Total 2550

28Goals for the winter termDecemberFinalize FET circuitOrder PartsBracket stress analysis

JanuaryProgram controllerAssembly

February-AprilTestingFixGo play in the mud!

M. Gleddie, 2012

29Thank You!

Michael TravesJon MacDonaldAngus MacPhersonAlbert MurphyDr. Tim LittleSebastian Manchester2011/2012 ETM Design TeamDr. Lukas SwanDr. Julio Militzer

30References

Arduino Mega Photo – Slide 11 http://arduino.cc/en/Main/ArduinoBoardMega2560

Orion BMS – Slide 14 http://www.orionbms.com/products/orion-bms-standard/

31

Extra Slides

32Battery Energy Storage System

33Existing Prototype

Recommendations from 2011/2012 teamBelt on Primary ReductionReduce NoiseWaterproofingProtect Battery leadsSmaller chain

34Sound Testing Results

From Fall 2012 Term Report

35Battery Energy Storage System

48V System64 Li-Ion CellsNominal 3.3V each, 3.6V full chargeNominal 528 Wh of energy storage

36FET Characteristics

FET Specs:V1 < V2 < 3.6VCapable of dissipating 20A at 3.6V (72W)To be finalized based on VDC

37Battery Energy Storage System