Transcript Mike Travis - Lauren Shapiro - Duncan Lowder - JJ Houlton - Nathaniel Roberts - Chris Gudmundson.

Mike Travis - Lauren Shapiro - Duncan Lowder - JJ Houlton - Nathaniel Roberts - Chris Gudmundson

Milestone 1:
 Forward driving
 Sensors: Light, turn signal, odometer, speed,
cadence, LCD Display
 Throttle and braking
 1st prototype PCB ordered

Milestone 2:
 Forward Driving + Regenerative Braking
 Integrated buttons for LCD Display control
 2nd PCB




Regenerative Braking
Forward Driving
Sensors
LCD Display

DTS:





Motor mounted
Throttle and brake mounted
H bridge, 2 buck converters, optoisolator built
Batteries ordered
Interface:
 Lights built
 Cadence mounted
 LCD displays text
Parts Procured
Parts Needed
Description
36V 1000W Electric Motor
72 Tooth Sprocket for 8mm(T8F) Chain
8mm (T8F) Master Link
8mm (T8F) Chain Sold By The Foot
Twist Throttle Cable with 36 Volt LED Meter
Brake Lever with Switch (Right Side)
MOSFET N-CH 100V 65A TO-220
IC DRIVER FET FULL BRIDGE 20DIP
OPTOCOUPLER SCHMITT-TRIG 6-DIP
IC BUCK 12V 3A TO220-5
CAP ALUM 470UF 25V 20% RADIAL
DIODE SCHOTTKY 3A 60V DO-201AD
CAP ALUM 100UF 63V 20% RADIAL
INDUCTOR PWR DRUM CORE 330UH
IC REG LDO 1.5A 3.3V TO220-3
RECTIFIER FST REC 100V 1A DO-41
CAP ALUM 0.22UF 50V 20% RADIAL
IC DRIVER GATE IGBT/MOSFET 8DIP
Voltage output meter
N11MD 11' Natural CNL Tie 100
HSS20 Hose Clamp
HSS28 hose Clamps
Shrink tubing 1/8"
Shrink tubing 1/16" Black
Steel Bar
HSS104 Hase Clamp
Plumbing
Shrink Tubing 3/8"
LiFePO4 Battery 12 Cells EBike Battery Pack
Battery wall charger
Back Wheel
Bike Trainer
mount fabircation
throttle
brake lever
PCB
Power Sensor
Quantity
Total
Price/Item Subtotal Tax+ S&H
1
$84.99
$84.99
1
$10.00
$10.00
1
$1.50
$1.50
4
$3.50
$14.00
1
$10.00
$10.00
1
$9.00
$9.00
10
$1.53
$15.29
2
$5.71
$11.42
10
$1.07
$10.68
2
$2.83
$5.66
2
$0.41
$0.82
3
$0.44
$1.32
6
$0.39
$2.34
2
$2.97
$5.94
2
$1.51
$3.02
4
$0.58
$2.32
4
$0.19
$0.76
2
$0.73
$1.46
2
$4.95
$9.90
1
$7.99
$7.99
2
$0.99
$1.98
2
$1.09
$2.18
1
$2.29
$2.29
1
$1.89
$1.89
1
$6.99
$6.99
4
$2.39
$9.56
1
$0.99
$0.99
1
$3.99
$3.99
1
$290.00 $290.00
1
$26.91
$26.91
1
$35.98
$35.98
1
$0.00
$0.00
1
$50.00
$50.00
1
$10.00
$10.00
1
$9.00
$9.00
2
$33.00
$66.00
1
$10.00
$10.00
$736.17
Total
$13.17
$98.16
$10.00
$1.50
$14.00
$10.00
$18.90
$27.90
$15.29
$11.42
$10.68
$5.66
$0.82
$1.32
$2.34
$5.94
$3.02
$2.32
$0.76
$9.25
$10.71
$0.81
$10.71
$7.99
$1.98
$2.18
$2.29
$1.34
$3.23
$6.99
$9.56
$1.44
$2.43
$0.33
$4.32
$83.00 $373.00
$46.94
$73.85
$7.99
$43.97
$0.00
$50.00
$10.00
$9.00
$66.00
$10.00
$183.17 $919.34
Description
MSP430
LED-Red
LED-White
LED-Yellow
Digital Temperature Sensor(TMP102) Breakout
Photoresistor: 10mm OD-400
LCD Assembly Driver
LCD Character Display
DC/DC Boost Converter
Reed Switch
Horn
PCB
3-way switch (blinker)
Buttons
Quantity
Total
Avaliable UROP Funds
$1,000.00
Total DTS
$919.34
Total Interface
$195.14
Total Spent
$1,114.48
Remaining Funds
($114.48)
EEF Request
$500.00
Team Contribution($50 each)
$300.00
Total Potential Outside Funding
$800.00
Unit Price
Subtotal
Tax + S&H
Total
$0.00
$0.00
$0.00
1
$7.95
$7.95
$7.95
1
$7.95
$7.95
$7.95
2
$7.95
$15.90
$15.90
1
$5.95
$5.95
$4.43
$10.38
1
$3.95
$3.95
$3.95
1
$21.60
$21.60
$21.60
1
$14.95
$14.95
$4.60
$19.55
1
$0.00
$0.00
$0.00
2
$6.50
$13.00
$0.86
$13.86
1
$20.00
$20.00
$20.00
2
$33.00
$66.00
$66.00
1
$3.00
$3.00
$3.00
1
$5.00
$5.00
$5.00
$185.25
$9.89
$195.14

Power System Components
 36V Lithium Iron Phosphate (LiFePO4) Battery Pack
▪ Preassembled and compact for easy install onto bike
 SEPIC Step-Up Charge Controller
▪ DC-DC Boost is no longer needed to supply motor
 DC-DC Switching Buck Converter
▪ 12V needed for h-bridge power mosfets
 Step-Down Voltage Regulators
▪ Provides power to microchips and sensors
 Opto-Isolators
▪ Protects motor controller

Advantages of LiFePO4 Battery Pack
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12 Cells in Series
Nominal Voltage: 36V
Voltage Limits: 24V – 43.8V
Fast Charge Rate: 1 – 2C
Long Cycle Life: 2000 cycles
Dimensions: 108x194x268mm
Weight: 6kg
Much longer discharge period for
extended riding time
▪ 20V range rather than 10V range

Ideal Power Output
 Voltage vs. Capacity Graphs
▪ 0.2c Charge Curve (Right)
▪ 2c Discharge Curve (Left)

Advantages of the LTC3862 Battery Charger


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Maintains Constant Voltage needed for LiFePO4
Two Phase, Constant Freq, Current Mode Boost
SEPIC Controller drives N-channel power MOSFETs
Programmable Freq: 75kHz to 500kHz
Input Voltage: 4 to 36V
Output: Up to 48V
Under-Voltage Protection
Voltage Step-Up
No DC-DC Boost Needed

Why not use LT3652 Chargers (right)
 More expensive
 Testing required to replace damaged chips
 Too many external components
▪ Higher failure rate
▪ Minimum 10 additional switches needed for logic control

LTC3862 (left) vs. LT3652 (right)
 The left graph provides a constant 36V and 2A
▪ Battery pack has maximum continuous charge of 2A
 The right graph shows 1 of the 4 parallel chips needed
▪ Only outputs 250mA per chip = 1A total

LM2576 Switching Buck Voltage Converter
 Drops the 36V supply to constant 12V
▪ Input Voltage Range: 4V to 40V
▪ Max Current Output: 3 A

AP1086 Step-Down Regulator
 Provides 3.3V and 5V rails
▪ Input Voltage Range: 4.7V to 12V
▪ Max Current Output: 1.5 A

Parallel Buck Converters
 LM2576/LM2576HV Series
 2 x 3A = 6Amp output current
 Vin = 36V
 Vout = 12V
Circuit
Input Voltage
Output Voltage
36V supply
12V supply
5V supply
3.3V supply
Motor
Bike Lights
H-Bridge
HIP4081
LiFePO4
36V
Battery
Buck
Voltage
Converter
36V->12V
LM2576
Opto-Isolators
5V Voltage
Regulator
12V -> 5V
AP1084
All Sensors
MicroController
MSP430
LCD
LCM2004D
Opto-Isolators
3.3V Voltage
Regulator
12V -> 3.3V
AP1084
MSP430
Throttle
Brake
Power
Meter
H-Bridge
Driver
ADC
Ahi PWM
Optoisolator
Ahi
Power
FET
Alo PWM
Optoisolator
Alo
Power
FET
Bhi PWM
Optoisolator
Bhi
Power
FET
Blo
Power
FET
Digital In
ADC
Blo PWM
Optoisolator
ADC
Digital Signal
(3.3V or 0 V)
PWM
Analog Input
Ahi
Bhi
Battery
Manager
Motor
Alo
Forward Current Flow
Blo
Regenerative Current
Flow

Forward Motion
 Throttle position measured though ADC
 PWM duty cycle is adjusted accordingly

Regenerative Braking
 Forward motion is disabled
 PWM signal is modified for braking


Controller measures
change in voltage
from throttle
Brake disables throttle
and enables
Regeneration mode
Throttle at 65%
Throttle at 35%


Input test waveforms/ test
parameters
7500V input/output Voltage
Isolation

HIP4081A
 Generates Vgs to turn on Hi-side FET’s
▪ Charge Pump
▪ Bootstrap
 Logic Buffer
 Introduces Dead Time
▪ Prevents current shoot thru

70N10F4
 100V, 65A N-Channel MOSFET
Pedals: Single-speed freewheel
Motor: 1000W 36VDC fixed gear
72 and 11 tooth sprockets
6.5:1 gear ratio
Theoretical 39 mph top speed
No Load
With Load
Voltage
Current
Speed
Torque
Speed
Output Power
Current
Efficiency
Series
Model
[V]
[A]
[rpm]
[Nm]
[rpm]
[W]
[A]
[%]
MY1020
1000W-36V
36
1.2-2.5
3700
3.2
3000
1000
≤35.6
η≥78
Power [W]
MY1020 Characteristics
2000
100.00%
1800
90.00%
1600
80.00%
1400
70.00%
1200
60.00%
1000
50.00%
800
40.00%
600
30.00%
400
20.00%
200
10.00%
Power(In)
Power(Out)
Efficiency
0
0
500
1000
1500
2000
RPM
2500
3000
0.00%
3500

Drive gear mounts to disk brake using a
custom fabricated top hat adaptor

UHMW-PE and/or Lexan will be used as
protection for:
 Drive Gear Chain
 Lights, LCD Display, Sensors
 PCBs

All cases will be weatherproofed and sealed
using silicone
Light Sensor
MSP430
Photo resistor
Comparator
Brake Sensor
Digital In
3-Way Switch
Digital In
Lights
Digital Out
Front Light
Digital Out
Brake Light
Digital Out
Turn Signals
Digital Out
LCD Display
Cadence, Velocity,
Distance
Reed Switch
(Cadence)
Digital In
Reed Switch
(Distance and
Velocity)
Digital In
Temp. Sensor
TMP102
Digital In
Power Meter
Current Sensor
Voltage Divider
ADC
ADC
Analog Signal
Digital Signal
(3.3V or 0V)

Low-Side Current Sensor
 Measures current powering motor

Voltage Sensor
 Voltage divide to limit voltage to ADC limits


Photo-resistor is used in a
voltage divider
When voltage increases past
reference point lights are turned
on
 Front light is constantly on
 Back light flashes, turns solid when
braking
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Sparkfun Digital Temperature Sensor
Breakout Board
I2C Interface
High Accuracy (accurate to 0.5° C)
TMP102
Digital output in binary
Negative temperature(ex. -25⁰C)
 Two’s complement format
Cadence
Reed
Switch
Record
Time
Between
Closures
Convert
to RPM
Average
Over
Several
Samples
Print to
LCD
Speedometer
Reed Switch
Record
Time
Between
Closures
Divide
Circumference of
Wheel by Time
Between Closures
Average
Over
Several
Samples
Print
to LCD
Distance Reed
Switch
Record
Number
of
Closures
Multiply Number
of Closures by
Circumference of
Wheel
Convert
Units
Print
to LCD

MSP430 F169
 Programmed using JTAG interface
 Debugging interface: MSP-FET430UIF
 Code Composer Studio v 5.1

LCM2004D
 Built in controller circuitry
 Using 4 bit MPU interface

LCD Display
 5 Volts
▪ Power for backlight, contrast, logic
 Driven by MSP430F169 μProcessor
 16 pin connection:
▪
▪
▪
▪
▪
▪
▪
4 bit parallel data (DB4-DB7) input Pins
RS (Register Select) Pin
EN (Enable) Pin
Common Ground Pin
Logic Hi, Lo
Backlight Hi, Lo
Contrast

Optical pulse sensor
 Shine light into skin, amount reflected varies
based on presence of blood


Clips on to finger or ear lobe
3 or 5 volts in, analog out

Low Quality Motor
 Probability of malfunction

Over heating
 Large currents could cause overheating of
components

Unforeseen events
Brown, Tom, Carissa Bocock, Robert Pomeroy, Sam
Siewert, and Jeries Shihadeh. Personal interview. 1 Feb.
2012.
 Danz, George E. "HIP4081, 80V High Frequency H-Bridge
Driver." HV Labs. Intersil, Feb. 2003. Web. 1 Feb. 2012.
<http://www.hvlabs.com/files/HIP4081application.pdf>.
H-Bridge Applications/Datasheet
 Hilgers, Harry H. "Motor/Generator Discussion." Personal
interview. 1 Feb. 2012.
 "LCM2004D-NSW-BBW." Modern Design. Longtech
Optics, 1 Dec. 2008. Web. 1 Feb. 2012.
<http://cdn.shopify.com/s/files/1/0038/9582/files/MD_Blue
20x4LCD_2004D.pdf?1260926418>. LCD Display
(1x20x4LCD) Datasheet

"Low Power Digital Temperature Sensor With SMBus™/Two-Wire
Serial Interface in SOT563." Texas Instruments. TI.com, Oct. 2008.
Web. 20 Feb. 2012.
<http://www.ti.com/lit/ds/symlink/tmp102.pdf>. Temperature
Sensor (TMP102) Datasheet
 "MSP430F15x, MSP430F16x, MSP430F161x MIXED SIGNAL
MICROCONTROLLER." Texas Instruments. Www.TI.com, Mar.
2011. Web. 1 Feb. 2012.
<http://www.ti.com/lit/ds/symlink/msp430f169.pdf>. Microcontroller (MSP430) Datasheet
 Torrens, Richard. "4QD Controllers Motor Speed Controllers."
4QD. 2012. Web. 1 Feb. 2012. <http://www.4qd.co.uk/>.
 "Types of Lithium-ion." Battery University. Cadex Electronics Inc,
2012. Web. 20 Feb. 2012.
<http://batteryuniversity.com/learn/article/types_of_lithium_ion>.
Lithium Ion Phosphate Battery Reference
