IPFW Electric VehicleSponsor: National Science Foundation

Advisors: Dr. Hosni Abu-Mulaweh, Dr. Abdullah Eroglu, Dr. Hossein Oloomi

Team Members: Mitchell Eilerman, Josh Weaver, Andres Cobos, Austin Swihart, Charles McIntosh, and Leandra Lee

February 12, 2015

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Introduction• Will convert preexisting vehicle into electric

vehicle• Motor will be powered by two batteries• Solar panel will recharge batteries

• Project is funded by the NSF (National Science Foundation)

• An NSF strategic goal: “Transform the frontiers of science and engineering”

From

to

2

Solar Panel

Battery

Battery

DC-DC Converter

Arduino

DC-DC Converter

Motor

Heat Dissipation

Tra

nsm

issi

on

High-Level Schematic of Electric Vehicle

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The Back Story• 2007-2008 senior design team built go-cart sized vehicle for 2008 Illinois Baja

Challenge• 2014 senior design team designed a controller system for new electric vehicle

• +

•

• We will integrate the control system with the existing go-cart to produce IPFW’s first working electric vehicle. 4

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Requirements/Specifications

• A solar panel will charge the batteries, the batteries will power the motor, and the motor will run the car.

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Requirement Type

Speed to Achieve

Solar Panel to Battery charge

timeTorque

Required Weight

Specific Value 10mph in 15 sec 16 hours 5N-m Under

400lbs

Table 1: Project Specifications

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• A Simulink simulation will be included with the final design.• The vehicle must have a cooling system that keeps all of its parts

within their operable temperature ranges.

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Given Parameters

• Two 12V UB12500 batteries will power our vehicle• Charging system will be run by Kyocera Photovoltaic Module, Model #

KC85T.• The HPM5000B brushless motor made by Golden Motors will power

our vehicle.• Current system provides 5N-m of torque

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• Will use existing Baja buggy chassis, suspension, & gear train

Weight (lb) Length (in) Width (in) Height (in)310 67 34 58

Power (hp) Weight (lb) High Low10 59 38.88 66.312

8.64 14.7362.46 4.19

Baha Characteristics

Engine Final Gear Ratio

Table 2: Baja Characteristics

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DC-DC converter with bi-directional four quadrant topology.

Converter power board with control traces and power traces

Completed power board with heat sinks, cooling fans, and inductor

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Design Variables• Hardware

• Control System/Interface: Regulate speed & torque• DC-DC Converter: Interfaced with the motor and batteries

Arduino Mega 2560 Microcontroller

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Design Variables• Hardware Cont.

• Display: Motor speed, battery power remaining, temperature, and operating time remaining

• Motor Coupling: Electric motor coupled to existing Baja transmission

Motor shaft

Current combustion engine shaft to CVT transmission

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Design Variables

• Operating Conditions• Speed: Speed varies according to

driver input• Forward and Reverse Mode:

Operates in forward and reverse mode according to the drivers selection.

Baja gearbox (high/low/reverse) & sprocket system

Polaris gearbox

• Timeframe • Design must be completed by May 2015• Project must be completed by December 2015

Concept Selection

Brainstorming

Problem Formulation

“Each project must be sufficiently complex, yet simple enough to be accomplished within the allocated time …”

– Lecture 1 of course PowerPoint

Detail Design

Limitations & Constraints – Timeframe

Limitations & Constraints – Results

• Design Budget of $1,000• Possible Design Costs:

• Cooling System• Coupling System• Display System• Reserve Fund

Cooling System Coupling System Display Interface Emergency Fund

• Funds• Previously Selected Components• Existing Baja Frame from previous design

51”

34”

HEIGHT:

66.5 in

WEIGHT: 180 lb

AVERAGE JOE

& P

LAIN

JANE

cdc.gov

Constraint Factor

Lab Door Frame Width of EV < 36 in

Existing EV Frame (Baja)

Cooling System Placement

Weight of Coupling Systems

Total Weight of EV minimalFRAME

DRIVERMOTOR

BATTERIES

SOLAR PANEL

COOLING SYSTEMCOUPLING

Limitations & Constraints – Resources

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Additional Considerations

• Safety systems must be included with vehicle.• Brake, suspension, and steering.• Electrical connections.• Cooling system

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Additional Considerations

IEEE Standards

Life expectancy

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Additional Considerations• Operational limits.• Uncertainty.

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Questions?