critical design review - lafayette college · glv - sub-systems responsibilities of glv can be...
TRANSCRIPT
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Critical Design ReviewLFEV-Y5-2017
Lafayette Formula Electric VehicleYear 5
ECE 492 - Spring 2017
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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System Overview - Top
TSV Packs
TSV Packs
PedalsGLV
TSI
Motor
Controller
Cooling
Panel
Panel
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System Overview - Side
TSV Packs
GLV
TSI
MotorMC
Pedals
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System Overview - System Objectives
● TSI: Provide connection and safety for the power supply of the motor
● GLV: Provide 24V to all systems, excluding the motor
● VSCADA: Provide data acquisition capability, as well as diagnostics
● Cell App: Be able to wirelessly interface with SCADA system
● Cooling: Using 24V, provide constant feedback to SCADA while cooling the motor
● Cabling: Provide safe and consistent connections between subsystems.
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System Overview - System Objectives Cont.
● Interface Control Document: Provide documentation for both hardware and software and interfaces.
● Dyno: Build and prepare Dyno room for testing for all sub-systems
● TSV: Provide 96V to the motor, as well as diagnostic information, and update its charging algorithm
● Physics: Helping TSV team understand relevant research, as well as physical modeling of the car, and developing a cruise control algorithm
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System Overview - High Level System Block Diagram
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System Overview - High Voltage Connections
● 96V● 2/0 Cable
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System Overview - Communication Protocol
● CAN Bus● All sensors have unique ID● All stations jabber
○ Settable period
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System Overview - Safety Loop Faults
● All systems access safety loop● Driver resettable section● Non driver resettable section
Systems announce status on CAN Bus
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System Overview - Interfaces
● Hardware○ Cockpit○ Panels
● Software○ Dash○ Remote Computer○ Cell phone
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Hardware Interfaces - Driver Accessible
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Hardware Interfaces - Driver Inaccessible
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Software Interfaces - LCD Display
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Software Interfaces - Remote Displays
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Software Interfaces - Cell Phone
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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Schedule - TSI
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Schedule - GLV
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Schedule - TSV
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Schedule - VSCADA
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Schedule - Cell App
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Schedule - Cooling
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Schedule - DYNO
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Schedule - Interconnect
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Schedule - Car Physics Investigation
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Schedule - Management
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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Cost Analysis
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TeamAllocated
Budget
Total
Spent
Budget
Remaining
Percentage
Spent
TSI $1,000 $153.61 $846.39 15.36%
GLV $1,000 $275.82 $724.18 27.58%
VSCADA $50 $0.00 $50.00 0.00%
Cell App $125 $0.00 $125.00 0.00%
Controller Cooling $600 $452.92 $147.08 75.49%
Interconnect $1,000 $1122.20 -$122.20 112.20%
Dyno $50 $0.00 $50.00 0.00%
TSV $500 $388.95 $111.05 77.79%
Shipping / Tax /
Misc$1,175 $159.94 $1,015.06 13.61%
TOTAL $5,500 $2,553.44 $2,946.56 46.43%
http://sites.lafayette.edu/ece492-sp17/cost-summary/
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Cost Analysis - Allocated Budget
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Team Allocated Budget
TSI $1,000
GLV $1,000
VSCADA $50
Cell App $125
Controller Cooling $600
Interconnect $1,000
Dyno $50
TSV $500
Shipping / Tax / Misc $1,175
TOTAL $5,500
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Cost Analysis - Current Budget Status
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TeamAllocated
Budget
Total
Spent
Budget
Remaining
TSI $1,000 $153.61 $846.39
GLV $1,000 $275.82 $724.18
VSCADA $50 $0.00 $50.00
Cell App $125 $0.00 $125.00
Controller Cooling $600 $452.92 $147.08
Interconnect $1,000 $1122.20 -$122.20
Dyno $50 $0.00 $50.00
TSV $500 $388.95 $111.05
Shipping / Tax / Misc $1,175 $159.94 $1,015.06
TOTAL $5,500 $2,553.44 $2,946.56
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Cost Analysis - Percentage Spent per Subsystem
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TeamPercentage
Spent
TSI 15.36%
GLV 27.58%
VSCADA 0.00%
Cell App 0.00%
Controller Cooling 75.49%
Interconnect 112.20%
Dyno 0.00%
TSV 77.79%
Shipping / Tax /
Misc13.61%
TOTAL 46.43%
Ideal 71.86%
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Cost Analysis - Percentage Spent Overall
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TeamPercentage
Spent
TSI 15.36%
GLV 27.58%
VSCADA 0.00%
Cell App 0.00%
Controller Cooling 75.49%
Interconnect 112.20%
Dyno 0.00%
TSV 77.79%
Shipping / Tax /
Misc13.61%
TOTAL 46.43%
Ideal 71.86%
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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System States
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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Demo Plan
● 4 Packs● Spin motor● Safety Loop● CAN Bus communication● Cell communication● IMD Fault safety loop
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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VSCADACraig Lombardo & Austin Wiles
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Why Do We Need VSCADA?
● VSCADA acts as the “brains” of the car● Comprehensive control and monitoring of the subsystems in the LFEV● Dynamometer control to simulate operations of an actual car
○ Physics Modeling● VSCADA displays information to both the driver and developers
○ Driver: limited information○ Developer: extensive information
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VSCADA - Installing Software
1. git clone https://github.com/LafayetteFormulaElectricVehicle/VSCADA.git2. cd VSCADA/3. make install4. ./scada or ./configuration
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VSCADA - Control Flow
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VSCADA - Web Server
● HTTP Web Server● Can query database using endpoints provided by web API● Information sent to Cell in JSON format
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VSCADA - Database Structures
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VSCADA - Database Structures cont.
Criticality Scale
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VSCADA - Database Structures cont.
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VSCADA - Maintenance View
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VSCADA - Drive View
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VSCADA - Charging View
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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Cell AppKemal Dilsiz & Raji Birru
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Cell App - In depth design - Layout
● Customizable Display● Automatically generated generic data availability● ViewPager for multiple display tabs
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Cell App - Landscape Layout
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Cell App - Activity Diagram
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Cell App - In-Depth Design - Data Structures
Dictionary of dictionaries, provides a generic way to locally store data temporarily
Hashcodes
> “tsvcell1voltage”
> “03/03/2017 17:56:34”
newSystem.put(“03/03/2017 17:56:34”, “8.1”);
allSystems.put(“tsvcell1voltage”, newSystem);
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Cell App - Content Diagram
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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TSIChrister Hoeflinger, Jack Plumb,
& Adam Ness
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TSI - System Overview
Safely connect tractive system voltage to motor controller
● Interface with throttle and brake pedals
● Interface with Insulation Monitoring Device (IMD)
● Send voltage, current, and IMD resistance to SCADA
● Control drive state
● Tractive System Measuring Point
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TSI - High Level Block Diagram
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TSI - System State Diagram
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TSI - Circuit Schematic - Throttle Plausibility Overview
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TSI - Circuit Schematic - Throttle Plausibility
● Two separate, linear potentiometers
● Biased 5V apart
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TSI - Circuit Schematic - Throttle Plausibility cont’d
Multiple Failure Modes1. Deviation of more than 10% pedal travel between the sensors1
12017-18 Formula SAE Rules Rev. A
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TSI - Circuit Schematic - Throttle Plausibility cont’d
Multiple Failure Modes2. Open or short circuit condition
which generates a signal outside of the normal operating range (5% - 95% travel).
12017-18 Formula SAE Rules Rev. A
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TSI - Circuit Schematic - Throttle Enable
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TSI - Circuit Schematic - Microcontroller
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TSI - Circuit Schematic - High Voltage Inputs
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TSI - Circuit Schematic - Throttle/Voltage Isolation
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TSI - Circuit Schematic - High Voltage Present Light
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TSI - Box Inventor
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TSI - Box Inventor
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TSI - Box Inventor
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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GLVKyle Phillips, Joe Sluke, & Chris Bennett
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GLV - Sub-Systems
Responsibilities of GLV can be divided into 4 main sub-systems.
1) GLV Power - providing 24V to all the main systems of the vehicle.
1) Safety Loop - serve as the direct means to control the Accumulator Isolation Relays in the
packs (enable/disable of high voltage systems).
1) Vehicle Computer Interface (VCI) - deliver information about GLV Power and the Safety
Loop to the VSCADA computer and route the CANBUS to the VSCADA computer
1) Vehicle User Interface (VUI) - includes physical panels, buttons, switches, screens and lights
on the car, such as the exterior panels and the cockpit panel
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GLV - GLV Power
Requirements:● Provide 24V to all subsystems for 3 hours● Rechargeable battery● Protected from overcharge, overcurrent, overdischarge and overvoltage.
Battery Choice● 24V, LiFeP04 (Lithium Iron Phosphate Battery), 10Ah. ● Internal battery management system ● Lightweight (2.63 kg)
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GLV - Safety Loop
Requirements: ● Drive the coils of the Accumulator Isolation Relays (AIRs) with 24V● Trippable by VSCADA, TSI, Cooling Controller, TSV● Trippable internally and externally by E-STOP Big Red Buttons.
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GLV - Safety Loop - Components
Switch Description Effect
Circuit Breaker A basic resettable circuit breaker
Powers Cooling
System, Dashboard,
VSCADA, and TSI
GLVMS Grounded Low Voltage Master Switch
BRBLS Big Red Button Left Side
BRBRS Big Red Button Right Side
Cooling System Fault Switch Allows Cooling System to trigger fault
24V to Accumulator
Isolation Relays
IMD Switch Insulation Monitoring Device, triggers fault if HV and GLV are galvanically
isolated
PACKMAN Fault Control Allows PACKMAN board on any pack to trigger a fault
SCADA Relay Allows SCADA computer to trigger fault
MRESET (Latching) Exterior Master Reset Button
BRB (Car Dash) Driver accessible Big Red Button
Inertia Switch Driver accessible Inertial switch, opened by a 6g+ collision.
CPR(Latching) Driver accessible Collision Protection Reset Latching Relay.
TSVMS Tractive System Voltage Master Switch
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GLV - Safety Loop
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GLV - Vehicle User Interface (VUI)
Requirements:● Design panels for dyno room● Design panels for interior and exterior of vehicle ● Provide interface for VSCASA
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GLV - Exterior Panel
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GLV - Cockpit Panel
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GLV - Vehicle Computer Interface (VCI)
Requirements: ● GLV Battery State of Charge Monitoring● CAN2USB Interface ● I²C Bus ● UART Bus ● Safety Loop Monitoring
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GLV - Safety Loop Monitoring
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GLV - High-Level System Design
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GLV - Physical Layout
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GLV - Physical Layout
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GLV - Physical Layout
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GLV - Physical Layout
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GLV - Box Design
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GLV - Break Out Board (BOB)
Last year’s BoB shortcomings:● Did not address VCI requirements (safety loop, temp, current monitoring…)● Inadequate number of relays used ● Inadequate containment of safety loop circuit
Our proposed changes:● Add opto-isolators for safety loop monitoring ● Add more relays and move more of safety loop on board ● Use I2C capable chips to relay temp and current readings to SCADA● Connect TSI and VSCADA via UART for throttle control ● Add DAC and ADC chips to connect VSCADA and Huff Box.
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GLV - BoB High Level
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GLV - BoB Layout
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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Controller
Cooling SystemXingyuan Guo & Yi Han
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Cooling System
Major Goal:
● Cool the motor controller, provide information to SCADA, shut
system down when necessary using safety loop.
Objectives:
● Automatic fan, pump speed control; as well as manual override
● CAN interface
● Safety loop interface● Mechanical design
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Cooling System - Overall Electrical Connections
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Cooling System - Water Cooling Layout
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Cooling System - Compatibility and Independence
● 24 VDC
● Koolance products (compatible with dyno, easy to
integrate)
● Run independently
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Cooling System - Automatic Speed Control w/ Manual Override
Overall Process101
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Cooling System - CAN Bus Interface
Oscilloscope
displaying 2 types of
data frames
(Through stackable
CAN shield using
MCP2515 CAN
controller)
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● Open the safety loop when fluid temperature is too high
Cooling System - Safety Loop
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Roadmap
1. System Overview2. Schedule3. Cost Analysis4. System States5. Demo in Dynamometer Room6. Vehicle Supervisory Control and Data Acquisition (VSCADA)7. Cell App8. Tractive System Interface (TSI)9. Grounded Low Voltage (GLV)10.Controller Cooling System11.System Test Plan
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System Test
Plan Greg Flynn
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System Testing - Overview
● 7 Major tests○ Accumulator integration○ Accumulator charging○ CAN Bus link○ Safety loop○ Cruise Control○ 24h endurance test○ Shutdown
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System Testing - Accumulator Integration
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System Testing - Accumulator Charging
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System Testing - CAN Bus link
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System Testing - Safety Loop
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System Testing - Cruise Control
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System Testing - 24h Endurance Test
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System Testing - Shutdown
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TSV Packs
TSV Packs
PedalsGLV
TSI
Motor
Controller
Cooling
Panel
Panel
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