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Group Members: Dan Brownlee
Sean Harriman
Andrew Robison
James Evans
Joshua Doores
𝜎𝑟𝑒𝑣 1/𝑏
𝑁=(
)
𝑎
(𝑓𝑆𝑢𝑡 )2
𝑎=
𝑆𝑒
1
𝑓𝑆𝑢𝑡
𝑏 = − log(
)
3
𝑆𝑒
𝜎𝑟𝑒𝑣 = 𝑀𝑎𝑥𝐵𝑒𝑛𝑑𝑖𝑛𝑔 𝐾𝑡
𝑀𝑎𝑥𝐵𝑒𝑛𝑑𝑖𝑛𝑔 = 𝐹𝑑1 𝑑2
𝑆𝑒 = 𝑆𝑒′ 𝑘𝑎 𝑘𝑏 𝑘𝑐
𝑆𝑒′ = 0.5𝑆𝑢𝑡
−0.265
𝑘𝑎 = 2.7𝑆𝑢𝑡
𝑘𝑏 = .879𝑑 −0.107
𝑘𝑐 = 1 𝑜𝑛𝑙𝑦 𝑏𝑒𝑛𝑑𝑖𝑛𝑔
𝑓 = 0.9
𝑆𝑢𝑡 = 90.6𝑘𝑠𝑖
𝐾𝑡 = 2.14
−0.265
𝑆𝑒 = 0.5𝑆𝑢𝑡 2.7𝑆𝑢𝑡
.879𝑑 −0.107 1 =

3 tests
› Duty cycle testing wheel lift
› Duty cycle testing wheel slip
› Optional Manual throttle input
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
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
Displays Motor and Wheel RPM
Displays Throttle Signal and modified signal
“Driver Prompts” (Ideal points where shifting
should occur)
Two test buttons, one for each duty cycle,
and a switch to allow for manual throttle.
Data transferred via USB from the DAQ to
host computer and exported into excel at
the end of the data cycle.
Micro-controller Specifications
What our Design Needs
Controller Specifications
1
At least 9 inputs
21 I/O Pins
2
4 Analog Inputs
10 A/D inputs
3
5 Digital Inputs
21 I/O Pins
4
3 Interrupt Inputs
1 Interrupt Pin - 8 Processor Exceptions & Software
Traps
5
1 PWM Output
2 PWM Outputs
6
Frequency ~240 KHz
One 7.37 MHz, One 512 KHz
7
Program Memory
12 KB - Flash Memory
8
Data Memory
1 KB RAM
9
2 Timers
3 x 16-bit Timers, 1 x 32-bit
10
Data Communication
Board has USB
11
Additional Controller Spec's:
Operating Voltage of 3-3.6V, some inputs can handle 5V
CPU Speed of 40 MIPS
A/D Converter 10-bit, 4 sample and hold
All unused I/O pins should be configured as outputs and driven low
Interrupt Vector Table (IVT) - 118 Vectors, 7 user priority levels
Input Capture is designed recognize pulses and uses a designated timer
Matlab Code determining the maximum frequency we would need
Master Clear (NC)
Analog Input 1: Front Fork
Sensor - Linear
Potentiometer
Analog Input 2: Throttle –
Linear Potentiometer
Analog Input 3:
Accelerometer, On board
potentiometer, Thermal
Couple?
Input Capture Inputs: Front
Wheel Hall Effect, Rear whee
Hall Effect.
Other I/O Pins: SPI, I2C,
UART (USB)
Output Compare: PWM
Output
Interrupt Pin: Emergency Stop
Button, Mode Button, Data
Output Button
Grayed in Pins can handle 5V.





Any I/O pins not being used should be configured as an output and driven to a
logic low state. Alternately, a 1K-10K ohm resistor connected between VSS
and the unused pin would drive the output low.
VDD and VSS are attached to the board and will be connected to the power
supply at a voltage level according to what the board power spec is. (Can
handle a 9V power supply. Voltage regulators for 3.3V and 5V operation exist)
Not every pin can handle 5V
Some of the pins will be used by the board, for example the external oscillator
inputs.
Configure Timer 2/3 as 2 independent 16-bit timers. Are used by multiple I/O
functions; such as the input capture and output capture.
Link to Visio Block Diagram of Pseudo code



1.) This micro-chip is run on 3.3V, and most of the pins can only handle a
3.3V signal. (Some are 5V tolerant). Do we need to drop the voltage to
the input with a resistor? Does the board have a voltage regulator that
would drop the voltage to the input?
2.) Not sure how the IVT works. Only one interrupt pin, but is it useable
by many interrupts?
3.) Sampling Frequency Determination – Still need to determine at what
frequency we will be sampling our analog inputs.
Software B.O.M and Budget
#
Item
Quantity
Manufacturer
Price per
Total Cost
1
16-Bit 28-pin
Starter Board
1
Micro-chip
N/A
$0.00
2
PicKit2/3 ICD
1
Micro-chip
3
DMPIC33FJ12GP2
02 Microcontroller
1
Micro-chip
N/A
$0.00
4
22AWG Wire
2ft
5
Terminal Wire
Crimps
20
6
5K Resistor
10
7
Complier
Software
1
Micro-chip
N/A
$0.00
8
9
10

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 Suppression 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.

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
Meets all TTXGP safety regulations
Be safely controlled, Serviced, Modified, and Troubleshot
Conform to all TTXGP race regulations
Integrate into an existing rolling chassis
Be ready for integration by the end of winter 2012
Adjustability to be able to be used with multiple frames
Must fit within available club space and be easily stored
Minimize electrical energy consumption
Display drive train and vehicle parameters
Provides Driver Prompts
Maximize Acceleration
Shaft Life
 Bearing Life
 Stress Strain in A-Frame
 Component Compatibility
 Low Pass Filter Operation
 Controller/Micro Capabilities

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