Tractive System Interface User Manual ECE492 - Spring 2020

Draft Prepared by: Feng Qiu, Zhengxie Hu, Phillip Harding

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Abstract This document presents general guidelines for using the Tractive System Interface (TSI), as well as the manual for using design tools. To better understand how TSI works, we suggest reading the TSI maintenance manual alone with this. All tools and parts for TSI can be found in AEC 400 and AEC 404.

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Table of Contents 1.Introduction 4 2.Wiring Diagram 4 3.TSI PCB 4

1.The Circuit Board 5 2.PCB Design Software 6 3.Throttle Plausibility 6 4.Programming 6

4.TSI Testing Panel 7 5.Enclosures 8 6.Current Sensor 9 7.IMD 10 8.CAN Isolator 10 9.Cockpit Panel 10 10.Getting Started 11

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1.Introduction This document gives a general guideline for using the TSI system. It also includes common issues you may encounter in using and redesigning the system. For TSI structure and functionalities please read the TSI Maintenance Manual.

2.Wiring Diagram You can find the CarMan wiring diagram here. It provides guidelines for connecting the TSI PCB to other parts of the CarMan. https://sites.lafayette.edu/motorsports/files/2019/12/carmanicd_labled.pdf

3.TSI PCB The TSI PCB is the main printed circuit board we designed using Kicad. You can find the detailed description in the TSI Maintenance Manual. The TSI User Manual mainly focuses on how to use, connect, and design the circuit board.

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Figure 1. TSI PCB Top View

1.The Circuit Board The circuit board is divided into a high voltage part and a low voltage part. The low voltage part has 10 connectors on the top that connect to the rest of the TSI system. The detailed connection is in the Wiring Diagram. Jumper JP2 is a CAN bus terminal resistor jumper. Connector J18 is the microprocessor programming port. The detailed procedure explaining how to program the chip can be found later in the Programming section. Button SW4 is the processor reset button. Pressing the button will reset the program to initial states. For the high voltage side, connector J1 connects to the corresponding high voltage aluminum bar in the high voltage side of the enclosure, which lets high voltage get into the board. Connector J32 contains signals go

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to motor controller and connector J9 connects to precharge relay in the precharge/discharge circuit. JP3 is a connector which is allowed to switch the spinning direction of the motor by a jumper.

2.PCB Design Software The PCB is designed in Kicad. The software can be found on all computers in AEC 400. Original files can be found on TSI website: https://github.com/Lafayette-FSAE/KiCad-TSI

3.Throttle Plausibility The right pedal is the throttle. The throttle is composed of two mechanically linked 5k piston potentiometers. The first (APPS1) is biased from 5-10V, the second (APPS2) is biased from 0- 5V. APPS1 is then then stepped down into the 0-5V range (APPS1_ISO). APPS2 voltage is sent to the microcontroller and sent to the motor controller. For the throttle to be plausible APPS1_ISO and APPS2 need to be between 0.5-4.5V. In addition, the difference between APPS1 and APPS2 needs to be within 0.5V. An implausibility should only occur if a mechanical failure occurs or one of the throttle wires become disconnected.

4.Programming We are using a PIC32MZ2048EFM064 (NOT PIC32MZ2048EFH064!!! double check the device name in MPLAB X IDE to ensure successful programming) for the TSI board. The development environment is MPLab X IDE with Harmony 2.06 extension.

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MPLab should be on every computer in AEC 400. Here is the guide for installing Harmony extension: Tractive System Interface User Manual 6 1. Download harmony 2.06 extension from: https://www.microchip.com/mymicrochip/filehandler.aspx?ddocname=en606317 2. Install the extension on the computer. 3. Open MPLab and click on Tool -> Plugins 4. Active MPLAB@ Harmony Configurator in Available Tab 5. Enjoy

To use the Harmony Configurator, run MPLAB X IDE. In Tool -> embedded you can find the MPlab harmony configurator. Using the configurator you can easily configure the chip and generate basic code. To program the chip, you need to use Pickit3. We have one in AEC 400. To program you need to connect ~MCLR Vcc Vss PGEC and PGED to the Pickit3 and click run in MPLab. Detailed instruction and connection for Pickit 3 can be found here: http://ww1.microchip.com/downloads/en/DeviceDoc/52116A.pdf

4.TSI Testing Panel The TSI Testing board is designed to test pedal, brake, and BOT of TSI in the dyno room. The testing panel should be powered when the TSI PCB is powered and in place in the dyno room. The two switches on the left side can be toggled upward to make APPS1 0 and bias the two APPS so that they are 5V apart respectively. The switch on the right side can be toggled upward to enable Brake Over Travel. Refer to the labels when using the switches. The brake button can be used to test the brake light. The panel voltmeter shows the throttle voltage. When using the testing panel to simulate pedal input, the two potentiometers should be adjusted so that the APPS1 and APPS2 are 5V apart. The four banana jack sockets on the bottom right are APPS1_10, APPS1_RTN, APPS2_5 and APPS2_RTN respectively for you to calibrate the two

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potentiometers to have a 5V bias. Through testing a resistance value combination we know that work is setting RV1’s “hour hand” to 1 and “minute hand” to 10, as well as setting RV2’s “hour hand” to 1 and “minute hand” to 0.

Figure 2. Testing Panel

5.Enclosure The TSI has been incorporated into the CarMan enclosure. Refer to the 2018-2019 user manual for details on the old dyno room enclosure.

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Figure 3. New CarMan Enclosure

6.Current Sensor The current sensor is used for measuring current through the high voltage bus bars. The data sheet and calibration data are provided here: https://sites.lafayette.edu/motorsports/files/2019/04/Current-Sensor-Calibration-Factor-Sheet1.pdf

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7.IMD IMD is used for monitoring the insulation resistance between the HV+ of the TSV and the chassis ground.A pinout for the IMD can be found on the datasheet here under IR155-3204: https://www.bender.de/fileadmin/content/Products/d/e/IR155-32xx-V004_D00115_D_XXEN.pdf The recommended wiring of IMD can be found in this document: https://formula-hybrid.org/wp-content/uploads/Bender-wiring-Rev-1.pdf The main connections that need to be connected are the power and three grounds to the GLV signals, theOKHS used in a 24V relay to control the safety loop and also used in a PMOS transistor to control IMDfault LED. The high voltage side needs to be connected to the corresponding high voltage bus bars.

8.CAN Isolator The CAN Isolator used in the TSI enclosure connects to the CAN signals coming from the motor controller. This is used to ensure the high voltage signal is isolated from the low voltage. This is mounted on din rail and should span the high and low voltage sides of the box. https://advdownload.blob.core.windows.net/productfile/PIS/BB-CANOP/Product%20-%20Datasheet/CANOP_4218ds20181204233352.pdf

9.Cockpit Panel

Figure 4. Cockpit Panel

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10.Getting Started The TSI system is fairly easy to set up. The connectors on the outside of the CarMan box are used to interface with the other subsystems on the car, mainly TSV and the motor. There are several connections on the inside of the CarMan box that will interface with the IMD, Precharge/Discharge Relay, and high voltage bars. The PCB setup was talked about in the TSI Board section above.