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James Kast Andrew Kuharske Timothy Lenberg Daniel Taylor

James Kast Andrew Kuharske Timothy Lenberg Daniel Taylor. Introduction. Objective: To advance the development of an in house hybrid electric vehicle for use in testing Dr. Dean Edwards' experimental lead acid batteries. Background: Existing platform containing Dr. Edwards’ batteries

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James Kast Andrew Kuharske Timothy Lenberg Daniel Taylor

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  1. James Kast Andrew Kuharske Timothy Lenberg Daniel Taylor

  2. Introduction • Objective: • To advance the development of an in house hybrid electric vehicle for use in testing Dr. Dean Edwards' experimental lead acid batteries. • Background: • Existing platform containing Dr. Edwards’ batteries • Components from HUMV • Specs • APU • PEU/Motor • Exhaust • Safety

  3. AccomplishmentsThis semester Axels installed First Battery Isolation Test Voltage Controlled Fuel Test

  4. Auxiliary Power Unit (APU)

  5. Throttle Control Control Method Options Mechanical Control Electrical Control

  6. Microcontroller APU Control Scheme Options • Linear Organization • RTOS Centered Controller Choice Familiarity Analog Inputs

  7. Sensing Task Check Sensors Check for Overvoltage Increment Coulomb Count Check Charge Parameters vtaskdelay

  8. I/O Task Check Buttons Decode Buttons Output LEDs Update LCD vtaskdelay

  9. APU Start Task Connect Kill Switch Start vtaskdelay(?) Altern. Voltage Step Up Voltage Regulate Voltage Connect

  10. APU Operation Task Assess State +/- Throttle Voltage vtaskdelay

  11. APU Shutoff Task Disconnect Decelerate Disconnect Kill Switch

  12. APU Questions?

  13. Sensor & Button Placement

  14. Sensor Placement 1

  15. Voltage Sensor • Specifications • 500Vdc rated • Digital/Analog output • Accuracy <= 1% • CYHVS500T Sensor • 500Vdc rated • 4V-5V analog output • Accuracy <= 1% • -10 C to +70 C • Cost ~ $80

  16. Current Sensor • Specifications • 300 Amp rated • Digital/Analog output • Accuracy <= 2% • LEM HTR 300 Sensor • 300 Amp rated • 4V analog output • Accuracy <= 2% • -10 C to +70 C • Cost ~ $180

  17. User Input • Required User inputs • Force APU on • Force APU off • Regen braking on/off • Reset Coulomb count • Specifications • Minimal distraction • Easy to reach • Quick to implement/build

  18. Steering Wheel • On Steering Wheel • Pros: • Easy to reach • Won’t have to glance over • Cons: • Difficult to install

  19. Ground • Ground Next to Driver • Pros: • Easy to place build • Can be easily moved • Cons: • Driver must look down

  20. Podium • Podium Next to Driver • Pros: • Easy to reach • Adaptable • Cons: • More materials required

  21. Seat • Side of Seat • Pros: • Buttons are easier to reach • Eyes can stay on road • Cons: • Unconventional setup mayconfuse people • Buttons not visible

  22. Decision • Build ground setup first • Quick build time gives us more time for testing • Build Podium • The ground button setup can be placed directly on the podium without much extra work

  23. Sensors and InputQuestions? • Work Cited • Current Sensor: http://www.lem.com/hq/en/component/option,com_catalog/task,displaymodel/id,70.22.46.000.0/ • Voltage Sensor: http://www.hallsensors.de/HallVoltage.htm • Button: http://www.grainger.com/Grainger/SCHNEIDER-ELECTRIC-Illuminated-Plastic-Operator-6HW87?Pid=search

  24. Exhaust Design • Basic Requirements/Restrictions • Design Sketches • Pros and Cons • Chosen Design • Safety - Heat Shielding • Questions

  25. Basic Requirements/Restrictions • Restriction-Clearance • Route Exhaust • Incorporate Muffler • Eliminate Safety Hazards

  26. Design Sketches Short Middle • Pros – Geometry, Length • Cons – Routing • Pros – Routing • Cons – Geometry, Length, Safety

  27. Design Sketches - Cont. Side Dual • Pros – Routing, Geometry • Cons – Length, Safety • Pros – Routing • Cons – Geometry, Length, Safety

  28. Design Sketches - Cont. Stack (top view) Stack (side View) • Pros – Routing • Cons – Geometry, Location

  29. Chosen Design - Side

  30. Heat Shielding Exhaust Wrap Exhaust Shielding

  31. Exhaust Questions?

  32. Fuse Setup • Radiator Mounting Issues

  33. Fuse Setup Before After

  34. Fuse Setup PEU Rectifier Fuse 360 V

  35. Radiator

  36. Fuse Setup and Radiator Questions?

  37. Cost Breakdown • Voltage Sensors x2 = $160 • Current Sensors x2 = $360 • Micro Controller = $100 • Exhaust = $350 • Gear Oil x3 quarts = $27 Total = $997 *Prices are an estimate only

  38. Project Timeline

  39. Potential Problems Existing Components Outsourcing Weather Time Constraint

  40. Final Questions?

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