Transcript Electric Motorcycle Design Project

Electric Motorcycle Design Project
SR. Design Project
Fall 2008-Spring 2009
Justin Cole
Chad Dickman
Todd Sanderson
Kris Williams
Outline
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The project
Components
Where we stand
Budget
Sample Calculations
Data Tables
Graphs
Timeline
What’s Next?
Conclusion
The project
• Convert gasoline
motorcycle to electric
– Emissions
– Energy crisis
– Ideal for short
commutes.
• Create publicity for the
school.
– Outreach
– Open house
Components
• Batteries
– 4-12VDC sealed lead
acid
– Designed for electric
vehicles.
– electricmotorsport.com
• Charger
– Soneil 48 V 5 amp
– thunderstruck-ev.com
Components (continued)
• Motor
– Briggs and Stratton Etek-R
• 8 hp continuous
• 15 hp peak
• Controller
– Sevcon Milipack
– Regenerative
– 48VDC
• Wiring, fuses, throttle
• electricmotorsport.com
Where we stand
• Motor kit & Batteries
Purchased and received
– electricmotorsport.com
• Purchased motorcycle
– Lemon and Barrett’s
• Still need parts
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Chain
Sprockets
Charger
Miscellaneous
Budget
48 volt System Budget Breakdown
Item
Price
Supplier
Bike
$250.00
Lemon and Barrett’s
$1,075.00
Kit(which includes the following):
electricmotorsport.com
motor
controller
throttle
contactor
fuses
wiring
Charger
$175.00
thunderstruck-ev.com
4 Batteries @ $70
$280.00
electricmotorsport.com
Chain
$100.00
electricmotorsport.com
Gears
$200.00
electricmotorsport.com
General Costs
$300.00
subtotal
$2,380.00
Taxes
$142.80
Total
$2,522.80
Table of budget breakdown
Sample Calculations
Aerodynamic Drag Force (Fd):
Cd=
Coefficient of drag of the vehicle
A=
Frontal area of the vehicle in square feet
V=
The vehicle’s speed in mph
 C  A  V2
 d

Fd  
3 91
Rolling Resistance (Fr):
Cr=
Rolling resistance factor
W=
Vehicle weight in lbs
Fr   Cr W
Force due to Acceleration (Fa):
Ci=
Unit conversion factor
W=
Vehicle weight in lbs
a=
Acceleration in mph/second
Fa  Ci W a
Force due to Climbing Hills (Fh):
W=
Vehicle weight in lbs
Φ=
Angle of incline
Fh  W sin( )
Sample Calculation (continued)
Total Force on the Vehicle (FT):
All four forces added together
FT  Fd  Fr  Fa  Fh
Torque needed from the Motor (T):
hp=
Horsepower
RPM= Revolutions per minute
T 
The Horsepower needed (hp):
FT=
Total Force in lbs
V=
Speed expressed in mph
hp 
FT V
5252 hp
RPM
Conversion from hp to Watts (W):
W 
hp  1000
1.34
3 75
Current needed to Power in Amps(A):
V=
Volts from the battery
W=
Power need to run in Watts
A 
W
V
Sample Calculations (continued)
Time in hours the Vehicle can run (Time):
Ah=
Amp-hours from the battery
A=
Current
Time  
Ah
A
Total Distance in Miles Vehicle can Drive (D):
mph= Speed in mph
Time= Time in hours vehicle can run
D 
mph
Time
Battery Charging Time (Tc):
Ah=
Amp-hours from the battery
Amp= Amps from the battery charger
Tc  
Ah
Amp
Data Tables
Speed
Force
mph
Aerodynamic
Rolling
Resistance
Wind
Resistance
Acceleration
Resistance
Hill Climb
Total
5
0.128
7.320
0
69.365
14.63
91.446
10
0.512
7.320
0
69.365
14.63
91.830
15
1.151
7.320
0
69.365
14.63
92.469
20
2.046
7.320
0
69.365
14.63
93.364
25
3.197
7.320
0
69.365
14.63
94.515
30
4.604
7.320
0
69.365
14.63
95.922
35
6.266
7.320
0
69.365
14.63
97.584
40
8.184
7.320
0
69.365
14.63
99.502
Table of various resistive forces with a constant acceleration of 3 mph/sec and a 3%
grade.
Data Table (continued)
Speed
Acceleration
Force Total
Power
Torque
Current
Time
min
Distance
RPM
mph
mph/sec
lbs
HP
W
ft*lbs
Amps
Hrs
2830.6
40
1
30.57
3.26
2433.40
6.05
50.70
0.69 41.42
27.62
2830.6
40
2
53.69
5.73
4273.93
10.63
89.04
0.39 23.58
15.72
2830.6
40
3
76.81
8.19
6114.46
15.20
127.38
0.27 16.49
10.99
2830.6
40
4
99.93
10.66 7954.99
19.78
165.73
0.21 12.67
8.45
2830.6
40
5
123.06
13.13 9795.52
24.35
204.07
0.17 10.29
6.86
Table of Distance and other parameters with varying accelerations
Miles
Data Tables (continued)
Speed
Grade of
Incline
Force Total
MPH
%
lbs
HP
W
ft*lbs
Amps
Miles
40
1
20.38
2.17
1622.59
4.03
33.80
41.42
40
2
25.26
2.69
2010.91
5.00
41.89
33.42
40
3
30.14
3.21
2399.00
5.96
49.98
28.01
40
4
35.01
3.73
2786.74
6.93
58.06
24.11
40
5
39.87
4.25
3174.01
7.89
66.13
21.17
40
6
44.73
4.77
3560.71
8.85
74.18
18.87
40
7
49.58
5.29
3946.72
9.81
82.22
17.03
Power
Torque Current Distance
Table of Distance and other parameters with varying inclines
Data Tables (continued)
Accelerating at 4 mph/sec
KWh used when
KW needed
Accelerating
Total KWh
accelerating at 4
Distance
Accelerating
for
Time in Hours
from the
mph/sec for a total
traveled
to 40 mph
accelerating (30 stop and
batteries
of 5 min worth of accelerating
at 4mph/sec
go's)
accelerating
0 to 5
5 to 10
10 to 15
15 to 20
20 to 25
25 to 30
30 to 35
1.00674668
35 to 40
Total KWh
Remaining
used
KWh
accelerating
0.41
0.59
0.599
1.801
3.014
0.01
0.01
0.01
0.01
0.02
0.03
0.05
0.10
0.16
4.246
5.505
6.798
8.134
0.01
0.01
0.01
0.01
0.04
0.06
0.07
0.08
0.21
0.26
0.31
0.36
9.518
0.01
0.10
0.42
Hours of
constant
speed
0.44
Distance
traveled in miles Distance traveled
after
accelerating
Accelerating at
(miles)
40 mph
17.56
1.88
Total
Distance
traveled in
miles
19.43
Table of distance with a period of acceleration followed by a period of constant
speed.
Graphs
Max distance when driving at constant speed
45
40
35
Speed (MPH)
30
25
20
15
10
5
0
0.000
20.000
40.000
60.000
Distance (Miles)
80.000
100.000
120.000
Graphs (continued)
Performance when climbing inclines
8
Grade of Incline (%)
7
6
5
4
3
2
1
0
0.00
5.00
10.00
15.00
20.00
25.00
Distance (Miles)
30.00
35.00
40.00
45.00
Previous Designs
• Very similar
– Motor
– Batteries
– Type of bike
• Verified project
calculations
• Made in home garage.
• Proves feasibility
• Total project costs less
than $3000
Picture of bike that uses the same motor and
type of batteries as this project.
Current Timeline
Electric Bike Conversion Gantt Chart Timeline
October
1
2
November
3
4
1
January
2
3
4
1
February
2
3
4
1
2
March
3
4
1
April
2
3
4
May
1 2 3 4
Research
Budget
Calculations
Design of
Bike Specs
Design of Bike Layout
Writing Sponsorship Proposal
Presenting to Companies
Purchasing the Bike
Buy Batteries
Build Batt. Trays
Buy Electric Motor Kit
Drive train Assembly
Motor Mount
Electric Assembly
Testing
Demo
1
What’s Next?
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Bike preparations
Layout of components
Bike Design
Assembly
Wiring
Testing
Demonstrations
Conclusions
• The design is feasible
• Some minor funding is still needed
• The project is coming along pretty well
according to the plan.
• The preliminary research and calculations are
complete.
• The bike is ready to begin laying out the
components.