Kevin Lomeli provides a summary of his consulting project with Lit Motors. He oversaw the reorganization and overhaul of the C-1 electric motorcycle prototype to prepare it for the TechCrunch Disrupt competition in September 2012. This included evaluating the team's capabilities, defining functional requirements, specifying hardware and software components, developing a work plan and budget for the summer, and demonstrating a working proof-of-concept vehicle by September. The focus of Kevin's work was redesigning the control moment gyroscope system and integrating it with the upgraded vehicle and landing gear systems to achieve safe, self-stabilized operation for the competition deadline.

1. KEVIN LOMELI
Mechanical Engineering
Consulting Project:
Lit Motors
1

2. ABOUT MYSELF
2

3. International Traveller
Hobbyist
Photographer
3

4. Rebuilt ’67 Mustang in HS
4

5. INVERTED
PENDULUM
Y I enjoy developing
mechantronic
side-projects
X
ø
Arduino based project
5

6. BSME MSME
6

7. Matrix Technologies Control system design & validation
Consultancy for Biotech Automation
First job out
of college
7

8. Stumbled upon Lit & decided to provide
consultation to develop the project and
company
A lean startup, striving to
disrupt the automotive
industry with an efficient
and safe EV.
8

9. THE IDEA
+ =
The C-1
A fully enclosed and self-stabilized electric motorcycle. 200
mile range per charge. 120MPH top speed. Low drag.
Extremely efficient
9

10. THEORY
10

11. GYROSCOPES
Referred to as a “controlled moment gyroscope” or “CMG”
Spin
Ω MMAX = ά Ω IG
IG(disk) = (m r2)/2
𝛕
M
α Output
Input
IG Moment of Inertia (kg m2)
α Precession Angle (rad)
Ω Flywheel Spin Speed (rad/s)
𝛕 Applied Torque (Nm)
M Righting Moment (Nm)
11

12. Ω
G1
𝛕
α
One gyro for stabilization is too big!
If we run two mirrored gyros, it (theoretically)
simplifies dynamics & saves some space.
12

13. Ω
G1
𝛕 -Ω
α
G2
-𝛕
-α
G1 & G2 Assumptions Realistic?
Same material & geometry Achievable w/in a tolerance
Flywheels spin equal & opposite
Precess opposite depends on H/W & S/W
Apply same torque
13

14. Φ
B
B
G1 G2 G
A
A
φ ̈(k9 +k4)−σψ ̇k7 +α ̇ΩIG33 +ψ ̇φΩIG33 =k7gφ
α ̈k5 +Ω(ψ ̇α−φ ̇)IG33 = 𝛕
The dynamics are linearized placed into state-space form, and
controlled w/ modern theory.
14

15. Game-changing Issues
Steering angle
These topics make loss of precession (α) occur
road incline rapidly, leading to the vehicle tipping over.
moving loads
Tire & suspension dynamics
15

16. WHEN I JOINED LIT
16

17. Lit made concepts and test
beds of the idea
The control system and stability
algorithm wasn’t figured out
17

18. I created the simulation & control algorithm
18

19. We installed the CMG in the full scale
vehicle, tuned it, and demonstrated it
19

20. The prototype sparked interest with the press
20

21. REORGANIZATION
Some internal restructure led to my leading the
engineering development. I took a new
approach to project.
21

22. VC Funding
NEED
A competent
team
A working
P.O.C.
P.O.C. = “Proof of Concept”
No documents
Internal
Knowledge of ROAD BLOCKS!
H/W gone
Vehicle CMG Landing Gear
Non- Existent
Algorithm
Rust-prone Driver not safe non-automated development
limitations Multi-person Falls over any
operation time
unrepeatable
Looks ugly Chassis isn’t rigid Hardware failure
latency issues
Driver not safe
22

23. SOLUTION?
23

24. A working TechCrunch
P.O.C. Disrupt 2012 VC Funding
24

25. C-1 OVERHAUL
25

26. The Process
Evaluate
Def Requirements
Functions Spec
H/W & S/W Spec
Purchase
Build
Validate
26

27. Summer 2012 Gantt
Interns Leave TCD
June July August September
Evaluation
The reorganization & evaluation occurred early
June ’12. The summer interns leave late August,
and the Tech Crunch Disrupt deadline is early
September.
27

28. Evaluate
Skill Set
Team
Bandwidth
Cost
Functional Specs
& Req’s
Tasks
Spec Feasibility
HW & SW
Time
Existing Platform
Capabilities
Tools & HW
28

29. Evaluate
Skill Set •Mech. design
Team •Electrical system design
Bandwidth •LabVIEW software design
Functional Specs
& Req’s
Tasks
Spec
HW & SW
Existing Platform •Access to 3-Axis CNC, lathe, press/ brake,
Capabilities laser cutter, etc.
Tools & HW •In-house: Mill, Arc & Mig, general shop tools
•Full-scale prototype
29

30. Evaluate
Team
Functional Specs
& Req’s
Tasks
Spec
HW & SW
Capabilities
Evaluated the team and our capabilities, then began
looking at all the tasks we could accomplish.
30

31. Tasks
C-1 Upgrade
Vehicle CMG Landing Gear
Control Gyro Energy LG
Windshield Custom Seat Storage
System Assembly Assembly
Body & Trim Head & Tail Sensors
Lights
The focus of this presentation & my primary scope
31

32. Tasks
C-1 Upgrade
Vehicle CMG Landing Gear
Control Gyro Energy LG
Windshield Custom Seat Storage
System Assembly Assembly
Head & Tail
Body & Trim Sensors
Lights
I oversaw subcontractors, interns, industrial designers
32

33. Functional Specs
Tasks & Req’s
Software: state machine, critical alarm sequence
Hardware: Off the shelf products, industry standard only, no redundancy
Power: 72 / 48 / 24 / 12 / 5 VDC
Control: stability initiated in normal operating sequence
Safety: landing gears are mechanically fail-safe, landing gear deployed if 𝜙 or
α are out of bound in the control and alarm states
Payload: Vehicle weight <700Lbs, Driver weight < 200lbs
Drive conditions: flat ground, <5MPH wind, dry weather, drive speed limit
of <10 MPH
TCDisrupt: Drive on stage balancing. Drive back & forth. Deploy landing
gear.
33

34. Spec
Tasks HW & SW
High Level BOM
Item# QTY Primary Subsystem Description System Tag OTS?
System
1 2 CMG Mechanical Gyroscope Housing Assembly - N
2 1 CMG Mechanical Gyroscope Chassis Assembly - N
4 2 CMG Mechanical Flywheel F1 / F2 N
5 A/R CMG Mechanical Bearings - Y
6 2 CMG Mechanical Flywheel Motor FM1 / FM2 N
7 2 CMG Mechanical Servo Motor SV1 / SV2 Y
8 1 CMG Electrical Gyroscope+Inertial Sensor VEC1 Y
9 5 CMG Electrical DC/DC Converter - Y
10 A/R CMG Electrical Wiring, Terminal Blocks, Relays, & Misc. H/W - Y
11 1 CMG Electrical NI CompactRIO MCU1 Y
12 A/R CMG Electrical AI, DI, DO Modules - Y
13 A/R CMG Electrical Flywheel Motor Driver, Inductors, Capacitors FMC1 / FMC2 Y
14 1 CMG Electrical 72VDC LiFePo4 Battery Pack + BMS - Y
15 1 CMG Test Bed Stability Control Test Platform Assembly - N
16 1 CMG Test Bed Torque Output Test Platform Assembly - N
17 2 Landing Gear Mechanical Fail-Safe Landing Gear Assembly LG1 / LG2 N
18 2 Landing Gear Mechanical Pneumatic Cylinder, Hosing, & Fittings - Y
19 2 Landing Gear Electrical Solenoid valve - Y
20 A/R Vehicle Chassis Steel Subframe Assy - N
21 A/R Vehicle Body Bondo & Paint - N
22 1 Vehicle Interior Carbon Fiber Seat - N
23 A/R Vehicle Exterior Windshield, Trim, Headlights, Taillights - N
34

35. Spec
Tasks HW & SW
High Level BOM
Item# QTY Primary Subsystem Description System Tag OTS?
System
1 2 CMG Mechanical Gyroscope Housing Assembly - N
2 1 CMG Mechanical Gyroscope Chassis Assembly - N
4 2 CMG Mechanical Flywheel F1 / F2 N
5 A/R CMG Mechanical Bearings - Y
6 2 CMG Mechanical Flywheel Motor FM1 / FM2 N
7 2 CMG Mechanical Servo Motor SV1 / SV2 Y
8 1 CMG Electrical Gyroscope+Inertial Sensor VEC1 Y
9 5 CMG Electrical DC/DC Converter - Y
10 A/R CMG Electrical Wiring, Terminal Blocks, Relays, & Misc. H/W - Y
11 1 CMG Electrical NI CompactRIO MCU1 Y
12 A/R CMG Electrical AI, DI, DO Modules - Y
13 A/R CMG Electrical Flywheel Motor Driver, Inductors, Capacitors FMC1 / FMC2 Y
14 1 CMG Electrical 72VDC LiFePo4 Battery Pack + BMS - Y
15 1 CMG Test Bed Stability Control Test Platform Assembly - N
16 1 CMG Test Bed Torque Output Test Platform Assembly - N
17 2 Landing Gear Mechanical Fail-Safe Landing Gear Assembly LG1 / LG2 N
18 2 Landing Gear Mechanical Pneumatic Cylinder, Hosing, & Fittings - Y
19 2 Landing Gear Electrical Solenoid valve - Y
20 A/R Vehicle Chassis Steel Subframe Assy - N
21 A/R Vehicle Body Bondo & Paint - N
22 1 Vehicle Interior Carbon Fiber Seat - N
23 A/R Vehicle Exterior Windshield, Trim, Headlights, Taillights - N
The focus of this presentation & my primary scope
I oversaw subcontractors, interns, industrial designers
35

36. Spec
Tasks HW & SW
Software Development Tasks
Item# Primary System Subsystem Description
1 CMG Mechanical Servo Motor Initialization and Tracking
2 CMG Electrical Gyroscope+Inertial Sensor configuration
4 CMG Electrical NI CompactRIO Control algorithm, State-Machine, Data Acquisition
5 CMG Electrical AI, DI, DO Module configuration, FPGA programming, & Drivers
6 CMG Electrical Flywheel Motor Driver configuration & Main controller
7 CMG Test Bed Stability Control Test Platform: Algorithm dev. & validation
8 CMG Test Bed Torque Output Test Platform: SISO Analysis
9 Landing Gear Electrical Solenoid Valve / Relay Digital Output Configuration & Override
36

37. Tasks Spec
HW & SW CMG: I/O
24VDC
5VDC
on/off Switch
α, 𝛕 Ω
HI-DIO
RS232
DIO
MCU1 ALM LED SV1 FM1
RDY LED
-α, -𝛕
FM2 SV2
PWM
FMC1
-Ω
FMC2
Φ
VEC1
LG1
LG2
After deciding requirements, evaluating previous prototype and
current skill set, I came up with this architecture for the CMG.
37

38. Spec
Tasks HW & SW CMG: Power Distribution
24VDC
5VDC
on/off Switch
α, 𝛕 Ω
HI-DIO
RS232
DIO
MCU1 ALM LED SV1 FM1
RDY LED
-α, -𝛕
FM2 SV2
24/5VDC
FMC1
48/12VDC -Ω
FMC2
72/24VDC
72/48VDC Φ
VEC1
LG1
72/48VDC
LG2
72VDC
LiFePo4 +
BMS
38

39. Evaluate
Team
Cost
Tasks
Feasibility
Time
Capabilities
Developed the scope of work. Next, I budgeted the cost for parts & services.
39

40. After deciding LabVIEW & cRIO for prototyping,
I applied for & won the Green Grant from NI (good for $25K grant towards software & support)
After NI support,
parts & services for CMG ~$60K
40

41. Evaluate
Team
Cost
Tasks
Feasibility
Time
Capabilities
Next, I determined the amount of man-time it would take to
complete the scope.
41

42. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Battery Pack + BMS
Switches, relays, LEDs, wiring, misc HW
Test Bed 1 Modification & CL Control
Test Bed
Test Bed 2: S,P, & LT
Test Bed 2: CL Control
Torque Bed
Torque Bed: S,P, & LT
Torque Bed: SW
Integration
CMG + C-1
Full Scale
CMG + LG
S = “Specification” CL Control
Validation
Full Scale
P = “Purchase”
LT = “Lead Time” LG
BMS = “Battery Management System”
CL = “Closed Loop”
CL Control+LG+ Drive
42

43. Evaluate
Team
Cost
Tasks
Feasibility
Time
Capabilities
Is it feasible?
43

44. Evaluate
Team
Cost
Tasks
Feasibility
Time
Capabilities
Yes. It will be intense, and we may need to cut
out a few low priority tasks, but the primary
goals will be accomplished.
44

45. WHAT REALLY HAPPENED
45

46. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Battery Pack + BMS
Switches, relays, LEDs, wiring, misc HW
Test Bed
This was the initial plan.
Plan
Torque Bed
Integration
Full Scale
S = “Specification”
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System”
CL = “Closed Loop”
46

47. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Battery Pack + BMS
Switches, relays, LEDs, wiring, misc HW
This was the reality. The causes: part lead-time, last-
Test Bed
minute functional requirement changes, and
compatibility issues. Reality
Torque Bed
Integration
Full Scale
S = “Specification”
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System”
CL = “Closed Loop”
47

48. Summer 2012 Gantt
Interns Leave TCD
CMG: S, P & LT June July August September
The initial plan to modify test bed 1 & 2 and created
a torque output validation system.
Test Bed 1 Modification & CL Control
Test Bed
Test Bed 2: S,P, & LT
Test Bed 2: CL Control Plan
Torque Bed
Torque Bed: S,P, & LT
Torque Bed: SW
Integration
Full Scale
S = “Specification”
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System”
CL = “Closed Loop”
48

49. Summer 2012 Gantt
Interns Leave TCD
CMG: S, P & LT June July August September
The test bed 1 & 2 development was pushed back.
The torque output validation system was partially
done, but S/W not complete by deadline.
Test Bed 1 Modification & CL Control
Test Bed
Test Bed 2: S,P, & LT
Reality
X
Test Bed 2: CL Control
Torque Bed
Torque Bed: S,P, & LT
Torque Bed: SW
Integration
Full Scale
S = “Specification”
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System”
CL = “Closed Loop”
49

50. Summer 2012 Gantt
Interns Leave TCD
CMG: S, P & LT June July August September
If all went well, we could demo a working prototype for
the interns before they returned to school.
Test Bed
Plan
Torque Bed
Integration
CMG + C-1
Full Scale
CMG + LG
S = “Specification” CL Control
Validation
Full Scale
P = “Purchase”
LT = “Lead Time” LG
BMS = “Battery Management System”
CL = “Closed Loop”
CL Control+LG+ Drive
50

51. Summer 2012 Gantt
Interns Leave TCD
CMG: S, P & LT June July August September
As I thought, the project development took up to the
last hour before the TCD demo.
Test Bed
Reality
Torque Bed
Integration
CMG + C-1
Full Scale
CMG + LG
S = “Specification” CL Control
Validation
Full Scale
P = “Purchase”
LT = “Lead Time” LG
BMS = “Battery Management System”
CL = “Closed Loop”
CL Control+LG+ Drive
51

52. How it happened
A few snapshots in the process
52

53. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Battery Pack + BMS
Switches, relays, LEDs, wiring, misc HW
Test Bed 1 Modification & CL Control
Test Bed
Test Bed 2: S,P, & LT
Test Bed 2: CL Control
X
Torque Bed
Torque Bed: S,P, & LT
Torque Bed: SW
Integration
CMG + C-1
Full Scale
Here’s the entire summer.
CMG + LG
S = “Specification” CL Control
Validation
Full Scale
P = “Purchase”
LT = “Lead Time” LG
BMS = “Battery Management System”
CL = “Closed Loop”
CL Control+LG+ Drive
53

54. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Switches, relays, LEDs, wiring, misc HW
Test Bed
Torque Bed
Early July, already specified what
we wanted and needed.
Integration
Full Scale
S = “Specification”
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System”
CL = “Closed Loop”
54

55. Functional / Software
Requirements
Hashed out requirements in teams over
whiteboard sessions. Lots of sticky notes too.
55

56. Hashed out the hardware layout. Hey there’s me in
the corner with some of the E-team
56

57. Of course I took work home during crunch time.
57

58. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Battery Pack + BMS
Switches, relays, LEDs, wiring, misc HW
Test Bed 1 Modification & CL Control
Test Bed
Test Bed 2: S,P, & LT
Test Bed 2: CL Control
Torque Bed
Torque Bed: S,P, & LT
Torque Bed: SW
Integration
Full Scale
Early August, a lot of H/W & S/W was developed
and the CMG was working on test bed 1.
S = “Specification”
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System”
CL = “Closed Loop”
58

59. Control Test Bed1
Again, the E-team (L). Test bed 1 working
with new servo and controller (R).
59

60. Torque Output Test Bed
Led the freshman & sophomore interns in designing
the torque bed and ball-park checking geometry
with properties of materials
Pancake force sensors
60

61. Torque Output Test Bed
Amplifiers
Pancake
Power Supply force sensors
Didn’t complete S/W.
61

62. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Battery Pack + BMS
Switches, relays, LEDs, wiring, misc HW
Test Bed 1 Modification & CL Control
Test Bed
Test Bed 2: S,P, & LT
Test Bed 2: CL Control
X
Torque Bed
Torque Bed: S,P, & LT
Torque Bed: SW
Integration
CMG + C-1
Full Scale
The interns left, I took over all aspects of the CMG
control H/W & S/W development. CMG + LG
S = “Specification”
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System”
CL = “Closed Loop”
62

63. Battery Pack
72VDC LiFePo4
Charger
Battery Tray
Battery Management
System
63

64. CMG: Rack CAD & Design
Home for the control system CAD & laser cut shelving for H/W
I measured the spacing and designed the control system so
that it contours with the seat and geometry of the vehicle.
64

65. CMG: Rack CAD & Design
Test fitting
65

66. CMG: Rack Wiring
4th floor, Controller & IO
FMC1
HI-DIO
RS232
DIO
FMC2 MCU1
3rd floor, Flywheel motor
controllers
LG1
LG2 24/5VDC
72/24VDC
72/48VDC 48/12VDC
72/48VDC
1st floor, Main power 2nd floor, IO & power
distribution distribution
66

67. CMG: Rack Wiring
Assembled & Tested
67

68. Control Test Bed 2
Test bed 2 is much more rigid
than the First
68

69. CMG: Rack Testing
The entire control system in closed loop control on test
bed 2, prior to vehicle integration.
69

70. CMG: Test bed to vehicle integration
70

71. Summer 2012 Gantt
Interns Leave TCD
June July August September
Functional Requirements
NI Grant, CRIO + Modules
CMG: S, P & LT
Power distribution
Sensors
Servo Motors + Gearhead
Battery Pack + BMS
Switches, relays, LEDs, wiring, misc HW
Test Bed 1 Modification & CL Control
Test Bed
Test Bed 2: S,P, & LT
Test Bed 2: CL Control
X
Torque Bed
Torque Bed: S,P, & LT
Torque Bed: SW
Integration
The final days before TCD deadline. The vehicle was CMG + C-1
Full Scale
drive-validated at the lab, then taken to the event CMG + LG
an hour before the event.
S = “Specification”
CL Control
Validation
Full Scale
P = “Purchase”
LT = “Lead Time”
BMS = “Battery Management System” LG
CL = “Closed Loop”
CL Control+LG+ Drive
71

72. 72

73. 73

74. The C-1 balanced and drove on stage before thousands of
viewers. We placed 2nd in the competition.
74

75. That’s Gavin Newsom!
75

76. More press coverage
post TechCrunch Disrupt
76

77. SUCCESS OR FAILURE?
Its a gray zone to some
Did we meet our needs? Kinda
Did Lit get funded? No
Did it balance & drive @TCD? Yes
It was an unforgettably great experience. I led and worked with talented
and smart people. I learned through the development process, and
adapted to the numerous setbacks and unpredictable occurrences.
To me, it was success.
77

78. Thank you.
Questions?
Disclaimer: Please do not ask about brands,
vendors, or numerical specs for any of the
disclosed information.
78