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Team #2 Solar Car ProjectSenior Design 2011 - 2012

TABLE OF CONTENTSIntroductionsQualifications and Responsibilities of Design TeamProposed DesignMotor ChoiceStatement of WorkBudget and Schedule Questions

IntroductionPresented by: Patrick BreslendMeet The TeamElectrical Engineers (EE) Shawn Ryster EE-Team LeaderPatrick Breslend C0-Treasurer Greg Proctor - C0-Treasurer Jordan Eldridge EE Tech Lead

Mechanical Engineers (ME) Valerie Pezzullo Secretary Bradford Burke ME-Team Lead Tyler Holes - Media Specialist

AcknowledgementsThe senior design team would like to acknowledge the following individuals and organizations for their contributions to the advancement of this project:

Dr. Michael Frank for administrative and technical guidanceDr. Chris Edrington for electrical engineering technical guidanceDr. Patrick Hollis for mechanical engineering technical guidanceFAMU-FSU College of Engineering for financial contributions to the projectThe Advisory Board

Statement of ProblemMotor ReplacementPV ArrayMPPTHinge/LatchDriver EncasementParking BrakeRegenerative BrakingRear Arm & Rear SuspensionAir Circulation

Intended Use(s) / Intended User(s)Future solar car competitions American Solar Car Challenge Sustainable Engineered Solutions (SES)Increase interest in the community through participation in local eventsGenerate donations from the community and relevant businessesUse of car will almost solely be project team members

SES: Sustainable Engineered SolutionsSolar car will live on with future projects within SESProvide a continuous learning hands on experience for years to comeIntended Use(s) / Intended User(s)Ultimate goal to compete in the North American Solar Challenge

Solar car set up in phases, meant to enter competition in the years to come

Qualities and ResponsibilitiesPresented by: Patrick Breslend

Qualities of Project TeamTeam MemberSkills and Knowledge Jordan Eldridge Photovoltaics, Programming, Control Systems, Electronics, and Testing Patrick Breslend Electrical Simulations, Photovoltaics, and Power Valerie PezzulloDynamic Systems, Control Systems, Vehicle Design, Fluid DynamicsGreg ProctorPhotovoltaics, Power, Electronics, and Electrical SimulationsShawn RysterComputer Programming, Electrical Simulations and Power SystemsBradford BurkeMechanical System, Materials, Vehicle Design and Model ConstructionTyler HolesMechanical System, Vehicle Design, Thermo/Fluid DynamicsResponsibilities of Project TeamTask Assignment Skills and Knowledge Needed3.1: Project ManagementTeam LeadBasic managerial skills, organization skills, and communications abilities3.2:MotorEEPower systems, Simulink simulations, control systems, mechanical devices theory, and circuit theory 3.3: PV ArrayEEPhotovoltaics, Simulink simulations and circuit theory 3.4:Maximum Power Point TrackerEEControls, circuit theory, and Simulink simulations3.5: Latch/HingeMEBasic linkages & materials selection3.6: Driver Encasement (Bubble)MECFD and FEM modeling, fluid dynamics equations, materials selection & design3.7: Parking BrakeMEVehicle design, brake installation, brake testing knowledge3.8: Rear Suspension and ArmMEVehicle design, suspension analysis3.9: Regenerative BrakingMEBasic mechanical & vehicle design3.10: Air circulation METhermodynamicsProposed DesignPresented by: Tyler Holes

Top Level Design

Motor ControllerMotor and Suspension DesignComplications with existing motor New motorLack of funds for new modelFind a less expensive motor that is similarRedesign rear suspension and arm to fit new motor parametersMotorWheelRear SuspensionCarbon Fiber BottomRear Suspension ArmSuspension BracketLatch and Hinge DesignLatch:Attached to right side of carHinge:Attached to left side of car so driver can exit vehicle away from traffic

Higher operational safety

Aerodynamics improved

Able to prop open for maximum solar radiationDriverCarbon Fiber BottomCarbon Fiber TopLatchHingeDriver Encasement (Bubble) DesignSimulations performed on proposed design shapesSphericalAir foilFinal design somewhere in the middle

Material selectionSimilar to polycarbonate beads used in motorcycle visorsShatter resistantHigh level of clarityBubbleCarbon Fiber TopMountAir Circulation System DesignCirculation ducts using lightweight tubing

Safe operating temperature range: 40F 95F

Disposable batteriesFan Mounting BracketCarbon Fiber BottomFanAir DuctsParking Brake DesignIndependent of regenerative and disc brakesImplementation on rear wheelParking and emergency situationsRated for 15 incline MotorWheelRear SuspensionCarbon Fiber BottomParking BrakeRegenerative Braking DesignTwo-step system in conjunction with disc brakesUsed for light brakingRecapture as much energy as possibleDisc brakes for additional brakingFirst 50% regenerative brakinglast 50% disk and regenerative brakingDriverSteeringRegenerative BrakesAcceleratorDisc BrakesSolar Array DesignOperate PV array at lower voltage than input voltage of the battery.Boost the voltage up and lower the currentSpace constraints70 modules35 parallel panels consisting of two modules in seriesTotal nominal power of the array = approx. 215 WattsPower of array in charge mode is greater than the quiescent power of the systemPresented by: Shawn RysterSolar Array DiagramPT15-30015.4 VPT15-30015.4 VPT15-300PT15-30015.4 V15.4 V12PT15-30015.4 VPT15-30015.4 VPT15-300PT15-30015.4 V15.4 V3435MPPTBatteriesProposed Motor SolutionPresented by: Shawn Ryster

Current MotorNuGen Motors (SCM-150)Rated Voltage 100V7.5kW peak powerOur motor is badly damaged.$16,000 to replace

Lemco DC Brushed Motor (LEM200-127)Rated Voltage 48VRated Current 215AHigh Torque at low speeds8.55 kW rated power$1900Will need a new motor controller.

Kelly Motor Controller - KDZ48201

Input voltage range 18V 60VOutput voltage 24V-48VMaximum sustained amperage of 80ASupports regenerative braking.$199Statement of WorkPresented by: Shawn Ryster

Task 1: Project Management1.1 - Managerial Duties1.2 - Engineering Responsibilities1.3 - Website1.4 Finance and Fundraising1.1 Managerial DutiesApproach-Schedule tasks to be completed weeklyAssign Engineers to scheduled tasks Conduct weekly meeting to record completion of tasks and assign new tasksOutcome- All engineers will be provided with achievable goalsGroup work ethic assessed weekly Project will move according to proposed schedule

1.2 Engineer DutiesApproach Research assigned tasksDesign and simulate for desired resultsImplementation of design Ensure design parameters are within rangeOutcome Research conducted thoroughlyFind errors in simulation not in implementationTests ensure that tasks meet specification 1.3 - WebsiteApproach Provide current progress on projectSponsor recognitionKeystone for future SESProvide a medium for advertisementOutcome Available information on current and past designsIncreased sponsorship and members for the clubIncrease interest in FAMU/FSU EE/ME departments1.4 - Finance and Fundraising Approach Treasurer will keep budget current.Discuss budget for upcoming tasks with managers.Handle sponsors/donors and coordinate events. In charge of purchase orders and expenditures.Outcome Each task will be properly funded.Well organized finances insure completion of project.Sponsorship will continue into the club.Record of current budget will stimulate response.

Task 2: Motor ReplacementApproach - Research and compare electric motorsConsider budget & electrical constraintsNew motor controller and new rear suspension designMotor and controller testingImplement motor and rear suspension redesignEntire system testedOutcome - Final, verified motor/controller and rear suspension subsystemReady to be integrated congruently with other subsystems

Presented by: Greg ProctorTask 3: PV ArrayObjectives Design panel configuration of array to fit 6 m2. Designed array voltage < battery voltage. Mount solar array to vehicle. Incorporate protective layer over cells.Approach Research irradiation, configuration, mounting, and protection.Simulate researched designs. Implement design that fits parameters. Test that each step is working to specification.Task 4: Maximum Power Point TrackerObjective- Achieve maximum power output

Approach- Build a MPPT to regulate voltage and current to achieve max power

The maximum power point tracker is at its most useful in adverse conditions. Say during a race when you have non-optimal conditions like clouds, rain, etc the MPPT will have to manipulate the current flow and voltage levels to produce the most power. However, during optimal conditions MPPT will not be utilized because power to the system will be abundant. 34MPPT (cont.)Outcome-Design MPPT based on the new motors parameters

Boost converter pwm 35Task 5: Hinge/Latch systemApproach Apply without affecting integrity of bodyResearch parameters and materialsInstallation and testingOutcomes Locked and unlocked from inside or outsideTop will stay latched to bottomAllow top to be lifted from one side for easy entering/exitingLid can be propped up at set angles for optimal solar irradiation and maximum chargePresented by: Valerie PezzuloTask 6: Driver Encasement(Bubble)Approach Research materials and companies to shape the bubbleDesign desired bubble shapeSimulate airflow over bubble to calculate dragCAD and CFD/FEM programs: Pro-Engineer and ComsolMount the bubble to the lidOutcomes Driver and electrical components will be shielded from outside environment.Task 7: Parking BrakeApproach Research types of parking brakes and installation techniquesOrder parts based on parameters and researchTest the brake while car is parked on inclined surfaceTest the effectiveness of brake during emergency stopsOutcomes Parked on an inclined surface without the possibility of rollingReduce the stopping distance required during emergency stopsTask 8: Regenerative BrakingApproach Make the brake system into a two step braking processCheck the specifications of regenerative brake in the motorMeasure the travelling distance of the brake pedal and modify it to allow more time for regenerative brakeTesting to ensure mechanical brakes engage when we want them to.Testing to measure energy generated from regenerative brakeOutcomes More efficient braking system which generates more energyLess use of mechanical brakes and parts

Presented by: Bradford BurkeTask 9: Rear ArmApproach Light, stiff connection for rear tire Must allow tire to rotate freely

Outcomes Rear tire will be perpendicular to the groundArm will not be able to move or rotate at any connection point to the car or suspensionTask 9 (cont.): Rear SuspensionApproach Must provide enough stiffness to keep car balanced Allow the tire to move due to changes in terrain without affecting the driverOutcomes The car will maintain its balance while the car is in motion

Task 10: Air CirculationApproach Use the least amount of electrical energy to move airChannel air from outside of car inside

Outcomes Make the car more comfortable to operate for the driverMaintain a safe temperature range to operate electrical components efficientlyBudget and SchedulePresented by: Jordan EldridgeBudgetTotal Estimated Cost Parts, Labor, and Overhead $206,155.60

Total Parts/Equipment $15,495.00

Total Personnel With Overhead $190,660.60

Budget cont.PersonnelNameEffort(hr/week)Base Pay(per hour)Total (per week)Total (per semester)Entire Project CostPatrick Breslend12$30.00$360.00$5,760.00$11,520.00Bradford Burke12$30.00$360.00$5,760.00$11,520.00Jordan Eldridge12$30.00$360.00$5,760.00$11,520.00Tyler Holes12$30.00$360.00$5,760.00$11,520.00Valerie Pezzullo12$30.00$360.00$5,760.00$11,520.00Greg Proctor12$30.00$360.00$5,760.00$11,520.00Shawn Ryster12$30.00$360.00$5,760.00$11,520.00Overhead (45%)Personnel + Expenses$86,635.00Team Total84$210.00$2,520.00$40,320.00$80,640.00Budget cont.Total Expenses$5,995.00ExpensesMechanical ExpensesAmountElectrical ExpensesAmountBearings$500.00Ribbon Wire$100.00Chain/Belt$200.00Solar cell Solder$90.00Labor to machine parts$2,000.00Solder Irons x2 $120.00Nuts, Bolts, Screws, Washers$300.00Solder Iron Tips x 4$40.00Hinges/latches$600.00Mounting Tape$100.00Rods$300.00Wire$125.00Extra/Spare Parts$600.00Connectors$20.00PV cell protection$800.00Sub Total$4,500.00Sub Total$1,495.00EquipmentITEMAmountMaterials$2,500.00Electric Motor$2,000.00Bubble fabrication and delivery$2,000.00Rear suspension/Motor Mount$1,500.00MPPT$1,500.00Motor Controller$1,500.00Total Equipment$9,500.00Schedule - Electrical Major MilestoneEstimated Task CompletionPV Array Research11/1/2011PV Array Mounting1/4/12PV System Test3/26/12Full PV Integration with Protection4/12/12MPPT Research/Design12/7/11MPPT Purchase/Assembly1/30/11MPPT Implementation/Testing2/23/12Motor ResearchCOMPLETEDMotor Purchase11/15/11Motor Installation 1/5/12Motor Integration/Testing4/12/12Schedule - MechanicalMajor MilestoneEstimated Task CompletionLatch/Hinge Research11/10/11Latch/Hinge Fabrication and Install12/1/11Driver Encasement(Bubble) Research11/20/11Bubble Fabrication/Installation1/15/12Parking Brake Research12/18/12Parking Brake Installation/Testing1/12/12Air Circulation Research1/15/11Air Circulation Implementation 2/25/12Rear Suspension Research11/15/11Rear Suspension Installation 12/30/11Regenerative Braking Tuning 4/15/12Gantt Chart

Gantt Chart (cont.)

Gantt Chart (cont.)

Gantt Chart (cont.)

QUESTIONS