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Group Members: Dan Brownlee Sean Harriman Andrew Robison James Evans Joshua Doores ππππ£ 1/π π=( ) π (πππ’π‘ )2 π= ππ 1 πππ’π‘ π = β log( ) 3 ππ ππππ£ = πππ₯π΅ππππππ πΎπ‘ πππ₯π΅ππππππ = πΉπ1 π2 ππ = ππβ² ππ ππ ππ ππβ² = 0.5ππ’π‘ β0.265 ππ = 2.7ππ’π‘ ππ = .879π β0.107 ππ = 1 ππππ¦ πππππππ π = 0.9 ππ’π‘ = 90.6ππ π πΎπ‘ = 2.14 β0.265 ππ = 0.5ππ’π‘ 2.7ππ’π‘ .879π β0.107 1 = ο 3 tests βΊ Duty cycle testing wheel lift βΊ Duty cycle testing wheel slip βΊ Optional Manual throttle input ο ο ο ο ο Displays Motor and Wheel RPM Displays Throttle Signal and modified signal βDriver Promptsβ (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 β 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. ο ο ο ο ο 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 ο ο ο 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 β 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 ο Main Components βΊ Batteries ο Primary (72VDC) ο Secondary (12VDC) βΊ Motor ο Brushed DC βΊ βΊ βΊ βΊ Motor Controller DC-to-DC Converters Microcontroller Ignition Switch βΊ Peripherals (5VDC) ο Potentiometers ο Hall Effect Sensors ο Switches βΊ Circuit Protection ο ο ο ο Fuses Diodes Circuit Breakers Optoisolators βΊ Safety ο Emergency Stop ο Kill Switch ο System Functions βΊ Store High Voltage (HV) and route current to electric motor to propel motorcycle βΊ Maintain OEM-type motorcycle battery voltage used to power microcontroller and motor controller βΊ Control rear wheel spin and front wheel lift by modifying the throttle input signal to the motor controller βΊ 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 - 250kΞ© - 250kΞ© for < 300 Volts to earth, 500kΞ© 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 1kΞ©, 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. ο ο ο ο ο ο ο ο ο ο ο 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 ο Bearing Life ο Stress Strain in A-Frame ο Component Compatibility ο Low Pass Filter Operation ο Controller/Micro Capabilities ο 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