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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 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 Input Peripherals Spec # Voltage Range Component Description Part Number(s) Ref. Spec(s) 21176-0706 (FR WSS) 21176-0134 (RR WSS) 21007-0166 (FR RLR) 21007-0167 (RR RLR) S2, S11 2 1 2 0.4VDC = air gap, 5VDC = blocked by ferro-magnetic material, 50 pulses per rotation Accelerator Sensor Assembly Potentiometer Analog 3 0 1 0VDC = closed throttle, 5VDC = wide open throttle (WOT) 13S-85884-00-00 S11 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 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 Potentiometer Analog 3 1 1 0VDC = suspension fully extended, 5VDC = fully retracted CLP-250 S1, S11 Switch Digital 2 2 2 Button 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 # of Microcontroller Outputs Needed # of Components Needed Description Part Number(s) Ref. Spec(s) 0 1 4N25-000E S10 Part Number(s) Ref. Spec(s) dsPIC33FJ12GP202 S10 S21 S22(b) # of Components Needed Digital Wheel Speed Sensor 0 - 5 VDC Input Type Wire Count Hall Effect S20 S22(a) Type # of Microcontroller Inputs Needed S23 Front Suspension Travel Sensor S24 Push-Button Output Peripherals Spec # Voltage Range S25 0 - 3.3VDC Component Optoisolator Type NPN Output Type Wire Count Digital 3 Optoisolator reduces interference from motor controller to microcontroller. Microcontroller Spec # Requirement Quantity Description S26 USB Port 1 Required for data acquisition and programming by a PC. 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 Power Distribution, Wire Ratings, & Circuit Protection Spec # Voltage Level S31 Component Wire Count Rating(s) # of Components Needed 3 5A, 12VDC 1 Ignition Switch S32 Kill Switch S33 2 Emergency Stop 1A, 12VDC 2 4A, 230VDC Part Number(s) Ref. Spec(s) Three positions: OFF (0VDC, HV OFF), ACC (12VDC, HV OFF), RUN (12VDC, HV ON) 27005-5137 S10 1 MUST 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 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 12 VDC (Low Voltage) Description 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 - S5 1N5349BG S10 1N4001 S5 1N4004 S5 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. 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. S39 Contactor Coil Suppresion Diode 2 1A, 50VDC 1 S40 Contactor Coil Suppresion Diode 2 1A, 400VDC 2 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 - S10 Due 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! S42 Wire Insulation Resistance - 250kΩ - 250kΩ for < 300 Volts to earth, 500kΩ for > 300 Volts, test insulation resistance using at least 100VDC S43 General Circuit Breaker 2 400A, 72VDC 2 MUST 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 1 Throttle 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 72 VDC (High Voltage) Legend FR = Front VFA = Very Fast Acting RLR = Reluctor Ring RR = Rear WSS = Wheel Speed Sensor LPF = Low Pass Filter 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. Return Front WSS Mounting Location Rear WSS & RLR Mounting Location Return Solenoid Circuit Breaker Return Motor Controller Return Front Suspension Linear Potentiometer Return DC Motor (supplied) Motor Curves @ 72VDC Return