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Super Scooter 6000 v2.0 - Cost-effective Electric Scooter with Regenerative Braking

The Super Scooter 6000 v2.0 is a feature-rich and cost-effective electric scooter that utilizes regenerative braking to maximize energy efficiency. It offers accurate speed control, speed indication, battery life display, and low maintenance. Designed for users aged 14 and above, this scooter is suitable for the global market.

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Super Scooter 6000 v2.0 - Cost-effective Electric Scooter with Regenerative Braking

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  1. Team #4EE-318-595 Final Presentation12-6-04 Super Scooter 6000 v2.0 Team - 4

  2. Super Scooter 6000 v2.0Project Abstract • Currently, only one scooter exists in the marketplace that captures the otherwise wasted braking energy and stores it for later use in the batteries. This project aims at designing a cost effective, yet feature rich alternative that will fit in this empty market. • Cost, reliability, safety and efficiency are the key aspects of this project. Team - 4

  3. Super Scooter 6000 v2.0Project Description • Basis for the Super Scooter 6000 • 24V DC battery operated drive will provide accurate speed control of the PM DC motor • DC drive will take care of the regenerative breaking functions. • Control of the speed will be via a 5k ohm standard throttle • Speed will be fed back via a hall switch mounted on the wheel that will provide a frequency which is proportional to the speed of the wheel. • Speed evaluation to ensure that the scooter is up to speed before allowing the motor to produce torque. • Scooter will not be limited to 18mph. • A battery monitor will show the level of the batteries • An external battery charger will be included to replenish the batteries. Team - 4

  4. Super Scooter 6000 v2.0Features • Electric Propulsion with Regenerative Braking • Permanent Magnet DC Electric Motor • (2) 12V Sealed Lead Acid Deep Cycle Batteries • PWM Speed Control • Speed Indication • Battery life Display • Easy to operate/Low maintenance Team - 4

  5. Super Scooter 6000 v2.0Target Market • The product is being developed for use throughout the world. The AC charging circuit will allow 85-264V AC @ 47-63 Hz. • Age Group: 14+ yrs Team - 4

  6. Super Scooter 6000 v2.0Team • Grant Schoengarth • Joe Nickels • Nick Turdo • David DeHaai • Jesse Bissing • BSEE • BSEE • BSEE • BSEE • BSEE Team - 4

  7. Super Scooter 6000 v2.0Team Experience/Expertise • Grant Schoengarth • Joe Nickels • Nick Turdo • David DeHaai • Jesse Bissing • Expertise: Project Management, Design Experience: Johnson Controls / Plexus • Expertise: Power Systems Experience: Intern @ Kewaunee Nuclear • Expertise: PLCs, Drives/Motors, HMI products Experience: Professional Control Corp. • Expertise: Control Systems Theory Experience: Intern @ Pemco Paper Systems • Expertise: Systems Integration/Management Experience: Design Engineer, Electrical Contractor Team - 4

  8. Super Scooter 6000 v2.0Team Roles • Project Integrator & PCB Layout Mgr • Archive Web Mgr • Report Mgr • Presentation Mgr • Assembly & Proto Mgr • Grant Schoengarth • Joe Nickels • Nick Turdo • David DeHaai • Jesse Bissing Team - 4

  9. Super Scooter 6000 v2.0Team Experience/Expertise • 650 Man Hours Minimum • Broken Scooter • Bucyrus • $300 • Power generation and supply knowledge • Johnson Controls • Batteries • Parts ordering • Tools and Basic Electrical Materials Team - 4

  10. Super Scooter 6000 v2.0Block Diagram Team - 4

  11. Market Estimated Total Market Size $5,000,000.00 Estimated Annual Volume 25000 Minimum List Price $400.00 Maximum Product Mat Cost $180.00 Maximum Produce Mfg Cost $40.00 Power MinMax Min Oper Voltage Range Source 1 18V 28V Min Oper Voltage Range Source 2 110V 125V Max Total Power 70W Safety Power Signal Current Limit Max 70 A Power Signal Max Trip Time .08 s Power Signal Ground Fault Max 300 mA Super Scooter 6000 v2.0Project Level Standard Requirements Team - 4

  12. Mechanical Max Product Volume 39,600 cm3 Max Shipping Container Volume 56600 cm3 Max Number of PCB 2 Max Total PCB Area 600 cm3 Max Shock Force 10 Gs Environmental MinMax Min Oper Temperature Range 0 50 C Min Oper Humidity Range 5 95 %Rh Min Oper Altitude Range -300 3000 Max Storage Duration 2 years Life Cycle Estimated Max Production Lifetime 5 years Super Scooter 6000 v2.0Project Level Standard Requirements Team - 4

  13. Super Scooter 6000 v2.0Project Level Performance Requirements • Motor: 400W • Drive Type: Belt • Battery 24V • Life of Battery: 300 Charges • Charger: 110V-60Hz • Charging Time: 6-8 hrs • Distance per Charge: 12-16 miles • Rated Top Speed: 16 MPH • Climbing Capacity: 10 degree of incline • Max Capacity: 220 lbs • Net Weight: 45 lbs • Gross Weight: 45 lbs Team - 4

  14. Super Scooter 6000 v2.0Safety Concerns • Super Scooter Safety Concerns • All circuitry will be completely enclosed • Scooter will be limited to 18 mph • All high amperage wiring will be fused Team - 4

  15. Super Scooter 6000 v2.0Maintenance • The scooter should be inspected every 2-3 weeks • Inspections should include • Clear all moving parts of debris • Check belt for signs of deterioration • The scooter’s batteries will be able to be replaced • Battery Replacement and Disposal • Take battery to any battery recycling store to be recycled • Replace with 2 PS-12120 Power-Sonic • Before installation of new battery check terminals for corrosion/debris • Ensure terminals are securely attached Team - 4

  16. Super Scooter Disposal Remove battery from scooter. The battery must be properly recycled at any battery recycling facility The rest of the super scooter can be disposed of at a standard disposal facility Super Scooter 6000 v2.0Disposal Team - 4

  17. Block Level Summary • Money Allocated • Man-hour Allocation • Dave - $35 88.8 hours • Jesse - $294 153 hours • Grant - $115 95.3 hours • Joe - $40 164.8 hours • Nick - $150 135.4 hours Team - 4

  18. Speed Feedback/Eval BlockNick Turdo

  19. Speed Feedback/Eval Block Team - 4

  20. Speed Feedback/Eval Block Interface +5 Volt Supply Magnetic Hall Switch Square Waveform 0 – 15 V DC Output Frequency-to-Voltage Conversion Team - 4

  21. Speed Feedback/Eval BlockPurpose/Overall Function • Purpose • Provide speed feedback to the user • Ensure that the scooter is not allowed to exceed its speed limit (18 mph) • Ensure that the scooter is initially kicked up to 3 mph before allowing the motor drive to enable. • Scale the input frequency to a useful signal • How?? • This block will comprise of a hall switch mounted on the wheel and a circuit that will evaluate the signal and convert it to an analog signal. • As the magnet rotates on the wheel, it will produce certain frequency, this frequency will be converter via a frequency to voltage converter circuit. Team - 4

  22. Speed Feedback/Eval BlockStandard Requirements • Humidity Range 0%RH to 70%RH • Block Cost $20 • Parts Count 15 • Block Size 48cm2 • Block Mass 95.5 grams • Max Power Consumption 1W • Operating Temperature Range -20C to 70C • Storage Temperature Range -60C to 95C • Operating Humidity 5-90% • Reliability (MTBF) 3 Years • Allocations • Cost 5% • Parts 2% • Unique Parts 2% • Power Cons. 1% • Mass 1% • Area PCB 5% Team - 4

  23. Speed Feedback/Eval BlockPerformance Requirements • Electrical Interfaces • Digital Signals • Supply voltage (VCC): 10 - 28V • Input low voltage (VIL): 0.5 V • Input high voltage (VIH): 2.0 V • Input leakage current (IIL): .10 µA • Analog Signals • Output voltage (VCCO): 0.0 to 15.0 V • User Interfaces • None • Operation Modes • Normal Team - 4

  24. Speed Feedback/Eval Block Detailed Design What Hall Switch Was Chosen and Why? - Hamlin 59140 Series This Hall Switch was chosen mainly because of its compact size, simplicity, and robustness • Compact Size • 3.2 cm2 • Simplicity • No Standby power required • Operates through non ferrous materials such as wood, plastic, or aluminum • Robustness • Hermetically sealed • Max 100 G of shock Team - 4

  25. Speed Feedback/Eval Block Detailed Design What is the Output Voltage Range ?? • Our Frequency to Voltage Converter circuit will give us a linear voltage which is a function of frequency based on the equation: • Vo = Vcc * fin * C1 * R1 • This equation will allow us to calculate component values based on the desired output voltage at max frequency…..for our case we wish to have 10V at 18mph. Team - 4

  26. Speed Feedback/Eval Block Detailed Design • Given the wheel diameter of 5.5” (.1397 m) we make the following calculations: • Circumference = 2*pi*R = 2*pi*.06985 = .4388 m • Max speed of scooter: 18 mph = 8.046 m/s • 8.046/.4388 = 18.33 rev/s • Having one magnet on the wheel with give us a max frequency of 18.33 Hz, thus our frequency range into the speed evaluation block will be 0-18.33 Hz which corresponds to 0 – 18 mph. Team - 4

  27. Speed Feedback/Eval Block Detailed Design • Knowing that we have a 18.33 Hz max signal coming from our magnetic switch, we can calculate the components necessary to achieve 0 – 10V. Using the formula given to us based on using the LM2907 frequency-to-voltage converter as a tachometer, we can calculate our component values. • Vo = Vcc * fin * C1 * R1 • Knowing we want a 10V signal at 18.33 Hz we can calculate C1 and R1 • Starting with a standard value capacitor for C1 = .1 uF we calculate • R1 = 227 k • Also we need to calculate C2, to do so we use the equation for voltage ripple given as: • Vripple = Vcc/2 * C1/C2 * (1-(Vcc*fin*C1)/I2) • Plugging in the appropriate values gives a voltage ripple of .09V with a capacitor value C2 of 1 uF. • This should be quite adequate for our application Team - 4

  28. Speed Feedback/Eval Block Detailed Design • National Semiconductor LM2907 Frequency to Voltage Converter IC • Block Diagram • Why the LM2907 ?? • Output swings to ground for zero frequency input • Simple to configure and utilize for frequency to voltage conversion (tachometer) • Fully protected from damage due to swings above Vcc and below ground • Minimum external components for tachometer operation Team - 4

  29. Speed Feedback/Eval Block Detailed Design • Schematic Layout • Using the LM2907 as a tachometer Team - 4

  30. Speed Feedback/Eval Block Detailed Design BOM – Prototyping: Team - 4

  31. Speed Feedback/Eval Block Detailed Design BOM – Mass Production: Team - 4

  32. Speed Feedback/Eval Block Detailed Design EMC Requirements Team - 4

  33. Speed Feedback/Eval Block Manufacturing Aspects • Manufacturing Process • Utilize Surface-Mount Pick and Place Technology • Reflow Soldering • Manufacturing Testing • Visual Inspection • Test 1 out of 50 for functionality as part of quality Control Team - 4

  34. Speed Feedback/Eval Block Detailed Design Reliability Analysis Team - 4

  35. Speed Feedback/Eval Block Detailed Design Obsolescence Table • No obsolescence issues with these components. Team - 4

  36. Speed Feedback/Eval Block Detailed Design Obsolescence Table • No obsolescence issues with these components. Team - 4

  37. Speed Feedback/Eval Block Standard Verification Team - 4

  38. Speed Feedback/Eval Block Performance Verification Team - 4

  39. Speed Feedback/Eval Block Prototype Verification Team - 4

  40. Motor Drive BlockNick Turdo Team - 4

  41. Motor Drive Team - 4

  42. Motor Drive Block Interface +24V Supply Throttle Position Inhibit Signals 0 – 5 k ohm 24 V Switch DC Motor Drive 24 V PWM DC Motor Team - 4

  43. Motor DrivePurpose/Overall Function • Purpose • Provide the 24V PWM signal to allow speed control of the motor • How?? • This block will take in the speed set-point signal from a uni-polar potentiometer and output the appropriate signal to the motor. • As the position of the throttle is changed the drive will react accordingly to either increase the duty cycle of the output signal, thus providing more current….or reducing the duty cycle and returning excess current to the batteries. Team - 4

  44. Motor DriveStandard Requirements • Humidity Range 0%RH to 70%RH • Block Cost $150 • Parts Count 2 • Block Size 160cm2 • Block Mass 400 grams • Max Power Consumption 1.68 kW • Operating Temperature Range 0C to 50C • Storage Temperature Range -10C to 65C • Operating Humidity 10-75% • Reliability (MTBF) 3 Years • Allocations • Cost 20% • Parts 15% • Unique Parts 15% • Power Cons. 5% • Mass 10% • Area PCB 50% Team - 4

  45. Motor DrivePerformance Requirements • Electrical Interfaces • Digital Signals • Supply voltage Range (VCC): 16.5-28V • Frequency 18 kHz • On/Off Signals Input High Voltage VIH: 15V Input Low Voltage VIL: 10.5V • Output Signals Output High Voltage VOH: 23.5V Output Low Voltage VOL: 10.5V Max Output Current: 85A for 3 sec • User Interfaces • None • Operation Modes • On/Off Team - 4

  46. Motor Drive Detailed Design • Summary of the Pacesetter Plus DC Drive – Why this Drive ?? • High efficiency MOSFET design reduces motor and battery losses while providing silent operation • Four-Quadrant operation provides true regenerative operation for braking and speed control • Allows speed control of permanent magnet (PM) DC motor • Compact Design (5.75” x 3.8”) • Speed control by standard or custom 5k throttle potentiometer • Operated by 24 V DC Supply or Battery Team - 4

  47. Motor Drive Detailed Design EMC Requirements Team - 4

  48. Motor Drive Detailed Design Reliability Analysis Team - 4

  49. Motor Drive Standard Verification Team - 4

  50. Motor Drive Performance Verification Team - 4

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