GLV Systems Preliminary Design Report Electrical and Computer Engineering Class of 2015
Roadmap ● 2013 System Overview ● System Hierarchy ● Subsystem Reports ○ Power ○ Safety ○ VCI ○ TSI ● Budget ● Schedule Psdgraphics.com
2013 Safety Box ● Pros ○ Functioning safety loop ○ Materials ● Cons ○ Not chassis mountable ○ Large Source: CDR Presentation 2013
2013 VSCADA Box ● Pros ○ Working Relay system ○ Some Usable Parts ● Cons ○ Not chassis mountable ○ Large ○ Messy Wiring Source: CDR Presentation 2013
2013 Load Controller ● Pros ○ Many useful materials ● Cons ○ Not chassis mountable ○ Needs better high/low voltage isolation ○ TSAL board Source: CDR Presentation 2013
2013 GLV Power ● Pros ○ Acts as a good test stand ● Cons ○ Not a battery Source: CDR Presentation 2013
GLV
GLV Power
VCI / Safety
Driver Controls
TSI
GLV Power Subsystem ● Priority #1 - buying a battery ● Charging and power management ● Cabling, distributing power to different parts of the car
Power - Requirements Highlights (End Goal) ● power GLV and other non-tractive systems ● power for >3 hours ● battery protection ● grounding to chassis ● packaging and mounting Psdgraphics.com
Power - Test Plan Highlights ● Analysis + Inspection ○ System ground, electrical insulation, prohibited insulators, battery type, fusing ● Tests ○ System ground, tractive system power up, GLV failure, battery duration, charge from zero, data measurement
Power - potential battery 24V, 10Ah, NiMH, High Temp Protection, $185 All-battery.com
Power - potential smart charger 12V-24V, NiMH/NiCd, $20, includes temperature sensor All-battery.com
Power - potential battery 12V, 12Ah, Lead Acid, $49 (would need two) Digi-Key.com
Power - potential charger 12V, $99, indicator lights Digi-Key.com
Budget Comparison All-battery.com Digi-Key.com $185 + $20 = $205 $49 + $49 + $99 = $196
Power Management LTC4365 Overvoltage/Undervoltage Protection $2 LTC4365 Data Sheet LTC2945 Power Monitor $9 LVR055 PolySwitch $2 Max Currents: 1.2A - 7A options Board $30 Housing $150 Digi-Key.com
Safety Systems Description ● Keeps high level voltage system in a safe state ● Monitors status of the system and provides multiple shutdown options to both driver and surrounding personnel ● Interacts with each electrical subsystem ● Follows rules presented in SAE International Formula Hybrid Rules 2015
Shutdown State Analysis
Top Level Overview of the Safety Loop ref 2012 PDR: slide 12
Basic Components ● Safety Controller 1. Start and end to safety loop 2. Contains system status LEDs ● Safety Panel 1. User access to the safety loop 2. 4 ways to shut off the safety loop: one BRB for the cockpit and one on each side of the car, and the Brake Over-Travel switch
Basic Components Cont. ● BRBs (owned) 1. Push-Rotate (in our case) where pushing opens the shutdown circuit 2. Pushing any of the 3 BRBs separates tractive system for the accumulator ● Master Switch (owned) 1. GLVMS and TSMS are rotary type and direct acting with removable key 2. Disables power to all electrical circuits; all battery power flows through this switch
Safety - Budget ● Budget of $200 needed ● BRBs and Master Switches are already owned ● $150 dollars required for fuses, wires, sensors (according to 2013 BOM) ● Could potentially reuse these materials assuming they are up to spec
Safety - End Goal ● The safety loop will keep the driver and other team members safe on and off the track ● Maintain safe operating status of the system and shut down if there are any failures ● Meet the desired specifications and shutdown appropriate systems when necessary
Safety - Test Plan ● Can demonstrate proper function by triggering different shutdown protocol ● Follow Table 17 from the spec pertaining to shutdown priority
TSI ● Tractive System Interface ● Load Controller ○ Connect motor controller to battery pack ○ Keep TSV isolated from the rest of the vehicle
TSI - Requirements Analysis ● Galvanic isolation ● Electrical insulation and layout ● TSMP and GLV GMP ● TSAL ● IMD ● IMD indicator light ● MCS cabling ● Tractive System restart
TSI - 2013 Load Controller ● TSAL PCB ○ Opto-isolator resistor ○ IO Holes ○ Incorrect labeling ● TSMP ● GLV GMP ● IR LEDs ● VSCADA control ● IMD
TSI - What to Expect ● Car ready container ● Electrical insulating barriers ● TSAL circuit board ● MCS cabling ○ High voltage power-lock connectors ● IMD indicator light ● Interfaced with VSCADA ● Tractive system reset
TSI - Test Plan ● TSAL Test ● TSMP and IR Indicator Test ● IMD Safety Loop Test ● IMDT ○ As outlined in Formula EV rules ● VSCADA Interface Test
TSI - Budget
Vehicle Computer Interface (VCI) ● Collect and deliver data from sensors to VSCADA ● The collected data will be converted from the analog to digital and then formated by the VSCADA team ● Important to coordinate with VSCADA to determine the appropriate sensors ● In charge of purchasing the sensors ref Phidgets Inc.
Top Level Overview of the VCI Subsystem ref GLV Systems PDR page 5
Ready to Drive Sound ● When the car is set to ready to drive mode it must emit a sound ● Sound needs to be audible in front of the vehicle in noisy environments ● Modify the amplifier to meet requirements
VCI - Budget ● Speaker/Amplifier - $50 ● Sensors ○ Temperature (x4) - $25 ○ Current (x2) - $30 ○ Voltage (x2) - $60 ○ State of Charge - $6 ○ Rate of Charge - $15 ○ Rate of Discharge - $15 ● Container - $150 ● Total $330
VCI - End Goal ● Ready to Drive Sound feature is fully functionable and meets the requirements ● Sensors required by VSCADA are implemented ● Data is correctly converted from analog to digital ● Data is delivered to VSCADA
VCI - Test Plan ● RTD Sound Length Test ○ Should last for 1-3 seconds ● RTD Sound Tone Test ○ Tone of 2500-3500 Hz ○ Minimum loudness of 68 db at 2 ft from the car ● Required Sensor test ○ Compare sensors’ output to the specified requirement ○ VSCADA is receiving properly converted data
Budget ● Total ○ $1,399
Budget
Schedule ● User Manual ○ February 12th ● CDR Planned ○ March 5th ● Hardware Purchase ○ March 12th
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