2. Presentation Outline
Summary of Recent Decisions
Specifications
Table
Detailed
Power Budget
Bill of Materials
CAD Models
ME 729 – ADVANCED MACHINE DESIGN
3. Motor System Changes
No changes made to motor or driver
24Vdc 240Vac inverter revised
Type: Modified Sine Wave
Input: 22-30Vdc input
Rated Power: 800W continuous, 1800W peak
Mass: 1.7kg
Size: 267mm x 124mm x 70mm
Gearbox responsibility moved to drivetrain team
http://www.alibaba.com/catalog/11318118/800W_Power_Inverter_12V_220V_230V_240V.html
ME 729 – ADVANCED MACHINE DESIGN
4. Motor System Concepts
DC Motors
AC Motors
Servomotors
Key Advantages:
Features robust driver with
feedback and auxiliary inputs
Torque or velocity control
options
Exact control scheme will be
up to Human Interfaces Team
ME 729 – ADVANCED MACHINE DESIGN
5. Windshield Wipers ?
Disadvantages of adding windshield wipers to our
vehicle:
Weight: Including washer fluid system, total mass is approx 4 kg
Power: We need between 100 and 150 W only for wiper motor
Complexity: Installing wipers and washing system to vehicle will
increase electrical and mechanical complexity
Function: Almost all wiper systems are designed for car
windshields. Considering the shape of our aero body, cleaning of
windshield with wipers is very difficult (size and curved shape)
ME 729 – ADVANCED MACHINE DESIGN
6. Windshield Wipers ?
Alternative solution: Rain X
Advantages:
No extra weight
No power required
Really cheap
Fits our vehicle concept
No increased complexity
It works!
ME 729 – ADVANCED MACHINE DESIGN
7. Windshield Wipers ?
There are many reviews for this
product and they are all
positive. See video…
If you ever drive your car during rain and you haven't discovered Rain-X, you are
probably driving far less safely than you could. Rain-X is an exterior window (windshield,
mirror, rear-window) treatment that causes water to shed from the surface rather than
sheet. I don't know the composition of the product, but it behaves like a silicone wax for
glass. Water beads up and drips off.
Sheeting water on a glass surface, like a windshield, causes significant distortion in the
light/images passing through the glass because it isn't perfectly smooth. Rain-X causes
the water to bead up so that spaces between the beads give you clear vision of what's
ahead. While this is clearly evident during rainstorms, it is UNBELIEVEABLY
DIFFERENT during rainstorms at night. You can actually SEE!
ME 729 – ADVANCED MACHINE DESIGN
8. Windshield Wipers ?
We recommend using Rain X
instead of wiper system.
ME 729 – ADVANCED MACHINE DESIGN
10. Battery - Lithium iron phosphate
(LiFePO4)
• Lithium iron phosphate- LiFePO4
Hybrid characteristics: 1. Safe as the lead acid battery
2. Powerful as the lithium-ion battery
Specifications:
Output voltage (nominal) : 24V
Output current: 30A
Approx Weight: 2.8 kg
Operating time at maximum power: 7 hours
Each cell:
L*W*T = 105*80*27 mm
Weight =0.4 kg
ME 729 – ADVANCED MACHINE DESIGN Source: http://www.powerstream.com/index.html
11. Lithium Iron Phosphate Cell parameters
Nominal voltage 3.2 Volts
Peak voltage 3.65 Volts
Absolute Minimum
2.0 Volts
discharge voltage
CV charge voltage 3.65 Volts 100% charge
CV charge voltage 3.5 Volts 95% charge
Charge Temperature 0°-40°C
Discharge Temperature -10°-60°C
ME 729 – ADVANCED MACHINE DESIGN Source: http://www.powerstream.com/index.html
13. Battery Charger Specifications
ITEM UNIT SPECIFICATION
Rating Input
INPUT V ac 100~240Vac 50/60Hz
Voltage
Rating Input
A 0.3A
Current
Max. input power W 40
OUTPUT Output voltage
V dc 12VDC ~ 17VDC
range
Suit with Battery
Ah 14.4V LI-ION
type
Constant Charge
A 1.8A ( + -0.2A)
current
Constant Voltage V 16.8 ± 0.05
Charge end current A <0.18
Typical charge time hour 4 hours
Max. output power W 30W
15. Electrical Team - Specifications
Sub-system Specification Parameter Value Units
Motor dimension Motor diameter D_motor 0.058 m
Motor length L_motor 0.1334 m
Motor specs Motor power (max) P_motor_max 539.3 W
Motor Torque (max) T_motor_max 3.84 N-m
Motor Torque (continuous) T_motor_continuous 1.03 N-m
Motor speed (rated) N_motor_max 5000 rpm
Output gear ratio GR_motor_out 8.5 -
Driver Width W_driver 0.05475 m
Driver Length L_driver 0.1316 m
Driver Height H_driver 0.175 m
Driver Mass M_driver 0.77 kg
Controller losses P_driver_loss_idle 11 W
Controller losses P_driver_loss_max 29 W
Inverter Width W_inverter 0.124 m
Inverter Length L_inverter 0.267 m
Inverter Height H_inverter 0.07 m
Interter Mass M_inverter 1.7 kg
Inverter Efficiency eta_inverter 0.9
Inverter Rated Power P_inv_continuous 800 W
Inverter Maximum Power P_inv_max 1800 W
Electric power Maximum electric power P_elect_max 750 W
Battery Energy storage E_battery 30 A-hr
recharge rate (time from 80% discharge) t_battery_recharge 4 hr
Battery life (hrs) Life_battery 7 hr
Energy storage E_battery 30 A-hr
Auxiliary devices Power consumption (daytime) P_auxiliary_day 80 W
Power consumption (night) P_auxiliary_night 94 W
Light intensity (front) Intense_light_front 1050 lumen
Light intensity (rear) Intense_light_rear 500 lumen
ME 729 – ADVANCED MACHINE DESIGN
Extras power (iPod, speakers) P_extras 0 W
16. Bill of Material & Mass Table
BOM Dimensions (mm) Mass (kg)
Part Number Description Quantity Length Width Height Weight
E01 Rechargeable Battery 1 189 80 105 2.8
E02 Battery Charger (With Case) 2 117 61 37 0.5
E03 Sensors 2-3 100 20(Dia) 0.2
E04 Microcontroller 1 50 20 10 0.05
E05 Controller circuit board 1 300 200 30 0.5
E06 Headlight 2 113 66 113 1.3
E06 Front Signal 2 80 108 80 0.45
E07 Back Light 2 127 27.5 127 0.68
E20 Motor 1 133.4 58 58 1.38
E21 Motor Driver 1 175.01 131.57 54.75 0.77
E22 Inverter 1 267 124 70 1.7
17. External Motor Interfacing
Mounting to Chassis
Φ “E” (Diameter)= 63 mm
Φ “C” (Hole Dia.) = 4.8 mm Thru
Connecting to Gearbox
Φ “J” (Shaft Dia.) = 9 mm
“K” (Shaft Length) = 20 mm
“P” (Key Height) = 10.2 mm
“R” (Key Width) = 3 mm
“S” (End Clearance) = 3 mm
“T” (Key Length) = 12 mm
Physical Specifications for Systems Integration
58mm square
Y max 133.4 mm
Mass = 1.38 kg
Inertia = 2.2 x 10-5 kg-m2
Source: AKM_Motor_Selection_Guide.pdf
ME 729 – ADVANCED MACHINE DESIGN http://www.danahermotion.com/
20. Head Lamps
PRODUCT SPECIFICATIONS
Light Source LED (Light Emitting Diodes)
Input Voltage 12-48V DC
Current Draw 550 mAmps @ 12 volts
Approx 7W
Lens Polycarbonate – Flood pattern
Dimensions: 112.9 x 112.9 x 65.9 mm
Weight: 1.362 kg
Intensity: 450 lumens
Source:
www.jwspeaker.com
ME 729 – ADVANCED MACHINE DESIGN
21. Front Turn Signal
PRODUCT SPECIFICATIONS
Light Source: Incandescent bulb
Input Voltage 12V
Current Draw 0.69 Amps at 12V;
Approx 8 W
Lens: Polycarbonate
Dimensions: 80 x 80 x 55 mm
Weight: 0.454 kg
Intensity: 75 lumens
ME 729 – ADVANCED MACHINE DESIGN
22. Tail, Stop, Rear Turn Lamps
PRODUCT SPECIFICATIONS
Light Source Light Emitting Diode (LED)
Input Voltage 8V – 28V DC
Current Draw – 12V 0.3 Amps - Stop
0.1 Amps - Tail
2.25 Amps – Turn
Approx 32W
Dimensions: 127 x 127 x 27.5 mm
Weight: 0.68 kg
Intensity: 250 lumens
ME 729 – ADVANCED MACHINE DESIGN
23. CAD models & Drawings
Lithium iron phosphate cell
24. Cell arrangement type-1 (Battery-1) (Finally decided to put this type)
Cell arrangement type-2 (Battery-2)
