Executive Summary - TheCAT - Web Services Overviewweb.cecs.pdx.edu/~far/Past Capstone Projects/Y2015... · Web viewDepending on the state of the potentiometer, the microcontroller

CycloPowerFinal Report – Spring 2015

Team Members

Nicholas BreningerCasey Freeman

Greg LaughlinTerry Rigdon

Alysia StricklandJustin Woodard

Faculty Advisor

Faryar Etesami

Executive SummaryCycloPower has experimented with current technology and investigated the

feasibility of a selective resistance, multi-person, electrical bicycle. This report outlines

the final product design and evaluation of the mechanical and electrical systems

required to build such a product. Research on previous and current electrically

regenerative bicycle systems and multi-person mechanical bicycle designs provided

baseline information to structure the product design specifications and select

components.

Although construction and testing of a full-scale prototype was beyond the scope

of this project, CycloPower’s electrical subsystem team designed and constructed a

small-scale system to demonstrate selective resistance feasibility, while the mechanical

subsystem team designed and conducted failure analysis of the full-scale modular

bicycle design. The extensive research and recommendations detailed throughout this

report may be used to construct a modular multi-person, selective resistance, electrical

bicycle or enhance current multi-person mechanical bicycle designs.

Page i of iii

Table of Contents

Page ii

Executive Summary.......................................................................................................... i

Table of Contents............................................................................................................. ii

Introduction......................................................................................................................1

Main Design Requirements..............................................................................................2

Alternate Design...............................................................................................................3

Final Design.....................................................................................................................4

Mechanical Design.......................................................................................................4

Module......................................................................................................................4

Chassis.....................................................................................................................5

Electrical Design...........................................................................................................6

Block Diagram...........................................................................................................7

Resistance Control....................................................................................................8

Electrical System......................................................................................................9

Final Product Evaluation.............................................................................................11

Structural Analysis of Mechanical Components......................................................11

Safety and Ergonomics...........................................................................................14

Maintenance & Cost................................................................................................15

Conclusion.....................................................................................................................17

Appendix I: Product Design Criteria...............................................................................18

Appendix II: Research (Sources)...................................................................................20

Appendix III: Alternate Designsrduino Code..................................................................21

Page iii

Appendix IV:Arduino Code Electrical Component Specifications...................................38

Appendix V: Electrical Components SpecificationsModule-generator Design Matrix.....43

Appendix VI: Modular-generator Design MatrixAssembly Drawings............................447

Appendix VII: Assembly DrawingsFEA........................................................................468

Appendix VIII: FEA …………………………………………………………………………....50

Page iv

IntroductionMulti-person bicycle tours have been growing in popularity over the last few

years. Most of these bicycles resemble a trolley car rolling down the street with space

for eight to sixteen people pedaling and one person, generally a tour guide, driving.

Some bikes are 100% human-powered by means of a single gear connecting each

pedaler, while others are operated in areas with rough terrain and require electric

assistance in addition to the human power.

Customers have commented that using a single gear for all pedalers makes it

exceptionally difficult for one user, while the rest of the group reaps the benefits of that

user’s strength. Meanwhile, drivers have been concerned with the possibility of the

machine assist running out of energy with less experienced pedaler groups, leaving the

tour stranded until users can exert enough energy, or the machine assist is electrically

charged or fueled. To provide both the customer and the driver a more enjoyable

experience, CycloPower has researched and designed an electromechanical alternative

to address these concerns.

Still utilizing the mechanical energy generated by individuals pedaling, we have

removed the universal single gear system connecting all pedalers, and replaced it with

multiple modular pedaling systems. The modular system provides electrical power

which is mechanically generated by an individual pedaling, while a standard bicycle tire

drives an electric generator at a twenty-six-to-one gear ratio. Each operator is able to

select his or her own resistance by means of a tablet device that interfaces directly with

the generator. The power produced by each operator is then directed to either an

electric motor driving the bike or a backup battery system that is capable of energizing

the electric motor in the event that the operators cannot produce enough power.

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Main Design Requirements The CycloPower design will achieve a maximum speed of 10 miles/hour and

cover distances exceeding five miles without battery regeneration, or more specifically,

without pedaling. The final design allows the safe transportation of 1500 pounds of

cargo, equating to approximately six users and an operator. The completed prototype

will be in operation amongst the everyday traffic day and night, which requires the

implementation of a headlight capable of projecting a minimum of 500 feet and two

taillights. The individual generators that are powered by each user will be equipped with

a change/fix voltage dividing controller mechanism, allowing the power generated to be

directed where it can be used most efficiently: either the battery for power storage, the

motor for its direct use in moving the vehicle forward. The voltage divider will also be

used to disperse generated wattage and power an interactive display logging individual

power generation data, which allows users to have an understanding of how much they

are contributing to the function of the vehicle. This will allow customization of where

users desire to send individual produced power via a calibrated spinning knob. The

different knob settings will reflect the different power destination options. An electric

motor capable of pushing one ton of weight to a maximum of 10 miles/hour must be

implemented and paired with the necessary steering and braking components capable

of operation under the specific load. The prototype must satisfy the Federal low speed

vehicle standards, as well as the Federal passenger vehicle standards outlined in

Appendix II: Research (Sources).

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Alternate Design

Mechanical

For the module there were other designs considered on what type of

generator system to be incorporated. An alternative design would be a direct-

drive generator as seen in Appendix III. This design would be ideal for the least

amount of components, however the cost of the controlling unit as well as the

feasibility of its programming proved unachievable for the scale of the Capstone

team. The direct-drive generator runs at a 1:1 ratio; at a higher ratio the

generator would create more power and be more efficient.

Electrical

The feasibility test of the individual resistance control setting required a

test stand to be made for the power generating system. An alternative design for

the test stand is a flipped bike with seat. This design would allow the user to sit

more comfortably as if they were riding a recumbent bike, but resources limited

this design. An example of the alternate design is in Appendix III.would be the

Final DesignTo ensure a full detail design of the multi-person bicycle system, CycloPower

focused on mechanical and electrical design aspects. The basic mechanical design of

the bicycle system starts with the assumption of needing each pedaler to drive a one

inch diameter generator shaft, while the bicycle system needs to be driven by an electric

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motor operating at 3000 rpm, and a location for the backup batteries has to be secured.

The electrical design focuses on which electrical components would be required to

create individual selective resistance, and direct the power produced by the generators

to either the electric motor or the backup battery system.

Mechanical DesignThe team responsible for the mechanical design of the bicycle system focused

on four key features: 1) individual modules to be placed along the chassis frame, 2) the

chassis, 3) placement of electrical components, and 4) safety and luxury accessories.

The structures, such as the module and chassis, were then analyzed for displacement

and stress under maximum loading.

Module

For the module design, the goal was to create a stand-alone unit which

could be replicated and installed in various quantities based on the end user’s

application. A lightweight and portable design offer ease of disconnect and

removal of the module for preventative maintenance, or in the event of individual

module failure. The design would also allow for a large variety of different seating

configurations and orientations, because the electrical and mechanical

components of each module are independent from adjacent modules.

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Each operator is able to adjust his or her seat height for comfort and

proficiency. As the operator pedals, the bicycle chain attached to the crankset

rotates a standard 26-inch bicycle rim connected to an electrical generator by a

V-belt for maximum efficiency. The operator can adjust his/her pedaling

resistance by means of a tablet on their tabletop integrated with relays controlling

the generator.

Figure 1: Module Design

Chassis

Independent front suspension was selected for increased handling to

accommodate the basic rack and pinion steering system. At the vehicle’s low

speed requirements, steering becomes compromised without the use of a

hydraulic or electrical assist. A double wishbone configuration was chosen,

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paired with a coil spring for ease of kinematic tuning, wheel movement

optimization, lightweight characteristics, market availability, as well as its high

reliability and low maintenance. The double wishbone also offers pedalers a

smooth ride by adapting to road imperfections such as potholes or bumps, as

compared to other available suspension. The final design chosen is modeled

below in Figure 2.

Figure 2: Double wishbone front suspension

Leaf springs were chosen for the rear suspension to assist the motor-

driven straight axle in distributing the load of the battery, motor, and gearbox

system over a three-foot section of the chassis rather than a single point with coil

springs. The main motivation for this decision was that leaf springs are readily

available and cost effective, as well as requiring minimum machining for

mounting.

Electrical DesignThe electrical portion of the design team focused their efforts on constructing a

test system comprised of a DC motor and battery, which are both powered by a bicycle-

driven generator. An Arduino UNO controls the test system. The system implemented

selective resistance by acquired power output needed from the generator. Through the

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use of a small-scale test stand, the team performed an analysis on how the system

operated, most importantly how the power went to the backup battery system and the

motor. Eleven different resistance settings were observed and analyzed in order to

control how the system was being powered. Each component used in the system is

fully explained in detail in the following subheadings with the complete specifications

laid out in Appendix V: Electrical Component Specifications.

Block Diagram

The power-generating system with individual selective resistance can be

seen in the block diagram in Figure 3. The generator sends power to a PWM

switching device, which is controlled by an Arduino UNO and potentiometer.

Depending on the state of the potentiometer, the microcontroller diverts power to

either the charge controller or voltage regulator. The PWM switching system is

implemented using relays to direct power. Power sent to the battery is first

passed through a charge controller. Depending on the actual battery voltage,

power transmission through the charger is regulated. The PWM switching system

also sends power to the BLDC motor. The voltage regulator limits the power sent

to the motor, keeping it from burning up.

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Figure 3: Block Diagram

Resistance Control

The resistance control system is put in place to give the user or pedaler

the ability to change the resistance or difficulty of pedaling by the turn of a knob

(potentiometer). Each module has a knob placed arm's length away in front of the

pedaler. The resistance of the pedaling happens by the generated power being

split into two directions: one to a voltage regulator to motor (Heavy load) and the

second to a charge controller to 12V battery (Light load). Both of these

connections have a relay between them. The relays are used as “ON” and “OFF”

switches. The Arduino is programmed to turn “ON” and “OFF” the relays based

on where the knob is positioned, which is an application of PWM. The Arduino is

programmed to have 11 resistance settings as seen in Table 1. The programing

code can be found in Appendix III: Alternate Designs.

Table 1: Distribution of voltage per setting

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The range of the knob is divided into these 11 settings. The duty cycle for

optimal efficiency is 100 milliseconds. At Setting 1 the Arduino is programmed to

turn “ON” the relay going to the battery for 90 milliseconds and “OFF” for 10

milliseconds sending 90% of the voltage generated to the battery to charge. Also

at setting 1, the program is to turn “ON” the relay going to the motor for 10

milliseconds and “OFF” for 90 milliseconds sending 10% of the voltage

generated to the motor. At this setting it will be at a light resistance. This same

effect happens for all the settings with the given percentage seen in Table 1.

Electrical System

Generator

The rear bicycle wheel is directly connected to a friction wheel attached to

the shaft of the generator. This generator uses the power produced by the bike to

go into the beginning of the system as shown in Figure 3. This power is split

using Pulse Width Modulation so the generated power is always going

somewhere where it is needed, whether that is to charge the battery, to directly

power the motor, or somewhere in between.

Arduino (PWM Switching)

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The Arduino Uno is a microcontroller board based on the ATmega328,

which is a 8-bit microcontroller. It has 14 digital input/output pins (of which 6 can

be used as Pulse Width Modulation [PWM] outputs), 6 analog inputs, a 16-MHz

ceramic resonator, a USB connection, a power jack, an ICSP header, and a reset

button. A picture of the Arduino Uno can be found in Appendix V. The Arduino

Uno can be programmed with the Arduino software having a similar language to

C++. The Arduino was chosen simply because of ease of use and meeting

specification needs.

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Speed Relay Shield (PWM Switching)

The Relay Shield provides a solution for controlling high-current devices

that cannot be controlled by the Arduino’s Digital I/O pins due to their current and

voltage limits. The Relay Shield features four high quality relays, only two are

used in this system, and provides NO/NC interfaces, four dynamic LED indicators

to show the on/off state of each relay, and the standardized shield from factors to

provide a smooth connection to the Arduino board or other Arduino compatible

boards. This shield attaches to the Arduino that controls them. The relays are

between the generator and the charge controller or voltage regulator. This Shield

was chosen based off the low cost and it meets the right specifications.

Voltage Regulator

The step-down voltage regulator chosen is shown in Appendix V. The

device has a maximum input voltage of up to 30 Volts. The regulator decreases

the high voltage coming from the generator to a level that the 12-Volt brushless

DC motor can accept. A potentiometer on the device was tweaked to adjust the

highly variable generator voltage.

Motor

The motor chosen is a quarter-horsepower, brushless DC (BLDC) motor

which operates in an optimal range of 12-14 Volts. The specifications of the

motor are listed in Appendix V. The motor was chosen because of its low cost,

and nominal voltage, which matched with our 12-Volt battery.

Charge Controller

The charge controller chosen has a rating between 12-24 volts, and can

take up to 10 amps of charging current. The battery can only take 12-14 volts at

once so the charge controller is put in so that it gets an optimal amount to

charge. This one was also chosen because of it’s ability to protect itself from

overcharging which is a potential problem due to the amount of voltage going into

it (from operating the test stand, even at steady, slower pedaling speed it’s

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possible to reach 25-30 volts without taking into account what the arduino is

doing to the system).

Battery

The battery chosen is a deep cycle 12-Volt marine battery. It is used as a

backup power supply and can directly power the motor. In the event that the bike

is stopped, users can still send power into the battery.

Final Product Evaluation

Structural Analysis of Mechanical Components

The frame was designed primarily with rectangular and square A36 mild

steel tubing, selected for its low cost and easy weldability. A yield strength of

36,000 psi was judged to be sufficient for this application. Where possible, simple

90 and 45 degree angles were used to simplify fabrication and reduce production

costs.

The first design test was a torsional FEA model, where the frame was

fixed by the rear leaf spring mounting points, and one of the front lower control

arm tabs. This was done to allow the frame to twist, rather than bow upwards

uniformly like a cantilever beam. A 1000lb upward force was applied to the

coilover spring mounting point, to simulate the force of running over an obstacle

with one front tire. Several iterations of frame layout and tubing thicknesses were

tested, with the goal of minimizing total displacement and providing the highest

overall torsional rigidity. The design that provided the minimum displacement was

a cross-braced layout, with 0.250” wall thickness frame rails and braces. The

peak von Mises stress was actually located on the front control arm tab, due to

the fixture method that is available in the student version of SolidWorks FEA

software. However, the stress throughout the rest of the frame was relatively

minor, as shown in Figure 4.

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Figure 4: Von Mises Stress of Chassis Frame

After the torsional analysis was run, a simulation of the overall sagging of

the frame due to loading from the individual modules and passengers was done.

An assumption of 250lbs per module and rider was made, and 6 individual

downward forces were applied in line with the centerline of the modules. The four

rear leaf spring mounts were fixed to the frame, and both front upper coilover

spring mounts were also fixed to the frame. The maximum displacement was

0.0137”, which was assessed to be well within acceptable limits (see Figure 5).

Maximum stress was also acceptable, with a safety factor of approximately 6:1.

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Figure 5: Von Mises Stress of Frame with Module Loading

The final design of the frame came to a total weight of 729 lbs, less than

half of the total empty vehicle weight. Compared to the approximately 2000 lbs of

a similar sized mechanically powered vehicle, this represents a major decrease

in overall mass from just the frame design.

The frame of the module was designed with the purpose of mounting the

passenger’s seat, pedal hub, generator, bicycle rim/chain, and a small tabletop.

Welding two sections of ¼ “steel plate to the sides of the post, and securing the

module to the frame rails via two ½” bolts in double shear created a mounting

solution for the bottom of the main post. This makes for a robust, yet quick

installation mounting method. A36 steel was specified, for the same reasons as

the main vehicle frame.

The challenges presented designing individual modules were minimizing

stress concentrations and deflection under maximum loading. Finite Element

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Analysis (FEA) was used to analyze the module frame for total displacement and

von Mises stress. The frame was fixed at the four bottom attaching bolt holes,

and a 250lb downward force was applied to the end of the seat post. Several

iterations of various tubing sizes, gusset thicknesses, and geometry were

analyzed. The best result used 1” and 1.5” square 0.125” wall tubing, with a ¼”

thick gusset. Maximum displacement was 0.0785”, located at the end of the seat

post. Maximum von Mises stress was 20,980 psi, located on the weld radius of

the lower diagonal tubing member. This gives a safety factor of 1.72, assuming

36,000-psi yield strength. This optimization process resulted in a very stiff yet

lightweight frame, at approximately 19.6 lbs.

Electrical Feasibility of Resistance Control Implementation

A test stand was made to check the feasibility of having a resistance

control feature. The test stand design consist of a bike that attaches to a rear

bike tire stand that is bolted to a platform for safety. A custom bracket was

machined to attach the generator to the tire stand allowing the rear tire to

connect to the friction wheel on the generator. The front tire rests on a stand that

connects to the fork of the frame. The resistance control box is located at the

head of the bike with the wires going down the frame to the back of the platform.

A box was made and bracketed to the rear platform for the rest of the systems

components (Arduino, charge controller, battery, voltage regulator, motor). The

test stand follows:

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Figure 6: Test stand, generation system, and resistance control system

With the full electrical system in place, the module was tested by multiple

users at PSU ME prototype day. Every user experienced the resistance in

pedaling by turning the resistance setting knob. From testing the full system with

multiple users it is apparent that this feature will be feasible to implement into the

module design.

Safety and Ergonomics

The completed prototype includes a removable vinyl roof protecting the

users from the occasional shower, as well as too much sun. A step bar is also

included on the chassis design offering safe access to the module seating

without unnecessary strain. The tires included on the final prototype are ensured

to have a small rolling coefficient; in other words, the force resisting the forward

movement is minimal. The modular seating is adjustable allowing the users

customization on seat height, avoiding possible injury stemmed from improper

use. The prototype comes equipped with an adjustable rear seat. Following

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standard requirements, an emergency brake is included. Equipped with front disc

brakes and rear drum brakes, the completed prototype offers exceptional

stopping ability with respect to the vehicle’s top speed.

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Maintenance & Cost

The individual modular design is unique with respect to maintenance.

Upon potential failure, a module can be extracted by removing two bolts, allowing

for convenient and quick repair. The bill of materials is listed below.

Components

Quantit

y Price Ea. Total Price Vendor

Front Crossmember 1 $220.00 $220.00 www.welderseries.com

Upper Control Arms 1 $200.00 $200.00 www.speedwaymotors.com

Lower Control Arms 1 $300.00 $300.00 www.speedwaymotors.com

Coilover Shocks 2 $200.00 $400.00 www.speedwaymotors.com

Steering Rack 1 $150.00 $150.00 www.speedwaymotors.com

Spindles 2 $160.00 $320.00 www.speedwaymotors.com

Brake Rotors 2 $30.00 $60.00 www.speedwaymotors.com

Brake Calipers 2 $25.00 $50.00 O'Reillys Auto Parts

Caliper Brackets 2 $12.50 $25.00 www.speedwaymotors.com

Axle Housing 1 $295.00 $295.00 www.quickperformance.com

Differential 1 $300.00 $300.00 www.quickperformance.com

Leaf Springs 2 $75.00 $150.00 www.speedwaymotors.com

Tie Rods 4 $14.00 $56.00 www.speedwaymotors.com

Master Cylinder 1 $47.00 $47.00 www.summitracing.com

Batteries 4 $170.00 $680.00 www.summitracing.com

Front Wheels 2 $45.00 $90.00 www.summitracing.com

Rear Wheels 2 $45.00 $90.00 www.summitracing.com

Front Tires 2 $35.00 $70.00 www.summitracing.com

Rear Tires 2 $45.00 $90.00 www.summitracing.com

Axles 2 $125.00 $250.00 www.quickperformance.com

Pedal Sets 6 $50.00 $300.00 www.performancebike.com

Bike Rims 6 $35.00 $210.00 www.amazon.com

Page 18 of 52

Bike Chains 6 $15.00 $90.00 www.performancebike.com

Drive Belts 6 $20.00 $120.00 www.grainger.com

Bike Seats 6 $18.00 $108.00 www.amazon.com

Steering Wheel 1 $20.00 $20.00 www.summitracing.com

LED Headlights 2 $22.00 $44.00 www.amazon.com

Tail Lights 2 $12.50 $25.00 www.amazon.com

Touch Screens 6 $99.00 $594.00 www.amazon.com

Horn 1 $15.00 $15.00 AutoZone

Emergency Brake 1 $102.00 $102.00 www.amazon.com

Voltage Regulator 6 $13.00 $78.00 www.amazon.com

Charge Controller 2 $12.00 $24.00 www.amazon.com

Generators 6 $250.00 $1,500.00 www.amazon.com

Motor 1 $500.00 $500.00 www.amazon.com

Subtotal $7,573.00

Materials Feet $/Ft Price Source

2x4 0.250" wall A36

Tube 70 $16.00 $1,120.00 www.onlinemetals.com

2x2 0.250" wall A36

Tube 22 10.75 $236.50 www.onlinemetals.com

1.5x1.5 0.125" wall

A36 Tube 24 $4.75 $114.00 www.onlinemetals.com

1x1 0.125" wall A36

Tube 23 $3.00 $69.00 www.onlinemetals.com

1.5 OD 0.125" wall

A36 Tube 19 $5.37 $102.03 www.onlinemetals.com

1x1 0.125" wall

6061-T6 100 $2.25 $225.00 www.onlinemetals.com

Subtotal $1,866.53

Grand

Total $9,439.53

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Conclusion The completed prototype shows the design of the chassis, frame, suspension,

gearing and the electrical components needed to fulfill the goal of having a human

powered bike that has an individual selective pedaling resistance implemented as a key

feature. Through finite element analysis, the mechanical design includes structurally

sound components that maintain sufficient rigidity throughout operational loads and

stresses. From building, designing, and testing an electrical system it is feasible to have

a resistance control feature added to the module. Ensuring use of components readily

available, the prototype was designed to include parts that can be conveniently replaced

upon failure, minimizing operational downtime. Fulfilling the design requirements

pushing the forefront of existing multi-person bicycles, the completed design is a model

of a new innovative idea unique to the growing market, as well as renewable power

generation.

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Appendix I: Product Design CriteriaPerformance

● Greater than 70% efficient under optimum conditions

● Maximum speed of 10 miles per hour

● Exceed 5 miles of travel on batteries alone (no pedaling)

● Individual selective resistance to pedaling

● Optimum seat height and angle

● Chassis and body to support 1000 lbs (5 operators)

● Controllers to regulate and divide energy to motor or battery

● Visual display for individual power generation data

● Aesthetically pleasing

● Lifetime of 10 years

Environment

● Minimal suspension for city road use

● Covered pedaler and driver seating for shelter from weather

● Watertight electrical connections

● Corrosion resistant coating on environmentally exposed components

Ergonomics

● Pedalers and driver able to comfortably sit for 30 minute intervals

● Adjustable seating to maintain proper ergonomics while providing highest

efficiency

● Operator interaction with controllers to be efficient, yet not cause additional

stress by too rapid of an adjustment

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Safety

● Roadworthy to ODOT standards

● Headlight capable of projecting a minimum of 500 feet

● Two taillights

● Free of sharp edges and pinch points

Maintenance

● Weekly maintenance not to exceed 1 hour

○ Mud, grime, and debris removal

● Quarterly maintenance not to exceed 1 day

○ Lubrication and securing fasteners

● Annual maintenance not to exceed 1 week

○ Replacement of worn components

Materials

● Lightweight to maintain efficiency

● Commercially available components

Page 22 of 52

Appendix II: Research (Sources)Solar charge controllershttp://www.banggood.com/10A-MPPT-Solar-Panel-Battery-Regulator-Charge-Controller-CE-12V24V-p-940304.html?currency=USD&refreshTmp=1&utm_source=google&utm_medium=shopping&utm_content=libao&utm_campaign=Smart-US&gclid=CPby_cHP3cMCFYdgfgodFiAbA

Voltage regulator (5-9V output)http://www.ebay.com/itm/20A-SBEC-Switching-Voltage-Regulator-output-5-9V-adjustable-max-currect-25A-/261584031077?_trksid=p2141725.m3641.l6368

Information http://www.instructables.com/id/Playing-with-Voltage-Regulators/

Adjustable buckhttp://www.ebay.com/itm/DC-DC-15A-Converter-Buck-Adjustable-4-32V-12V-to-1-2-32V-3-3V-5V-24V-Step-Down-/231104103029?_trksid=p2141725.m3641.l6368

Pedal Powered applicationshttp://pedal-power.com/http://www.lowtechmagazine.com/2011/05/pedal-powered-farms-and-factories.html

AmpFlow Motorhttp://www.ampflow.com/standard_motors.htmhttp://www.ampflow.com/G43-500_Chart.gif

Design Inspiration Imageshttp://www.ecofitnessbusiness.com/7-the-best-equipment-to-generate-electricity-with/http://pedal-power.com/products/the-pedal-gennyhttp://www.bikerumor.com/2014/01/13/an-electric-bike-desk-pedal-power-for-the-world/

ODOT Vehicle Informationhttp://www.oregon.gov/ODOT/DMV/pages/vehicle/low_speed.aspxhttp://www.oregon.gov/ODOT/DMV/docs/vcb/vcb811.pdfhttp://www.oregon.gov/ODOT/DMV/pages/vehicle/electric_hybrid.aspxhttp://www.oregon.gov/ODOT/DMV/pages/vehicle/assembled.aspx

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Appendix III: Alternate DesignsDirect-Drive Generator

Flipped bike with seat

Appendix IV: Arduino Codeint motor=7; //Relay between generator and motor controlled by pin 7

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int batt=6; //Relay between generator and battery controlled by pin 6

int resistance=3; //Analog reading from potentiometer set to pin A3

int rval=0;

int data=11;

int clock=3;

int latch=2;

int leds=0;

int relay1=LOW;

int relay2=LOW;

long trelay1=0;

long trelay2= 0;

long delay1=10;

long delay2=20;

long delay3=30;

long delay4=40;

long delay5=50;

long delay6=60;

long delay7=70;

long delay8=80;

long delay9=90;

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void setup() {

Serial.begin(9600);

pinMode(motor, OUTPUT);

pinMode(batt, OUTPUT);

pinMode(battMot, OUTPUT);

pinMode(data, OUTPUT);

pinMode(clock, OUTPUT);

pinMode(latch, OUTPUT);

}

void loop() {

rval=analogRead(resistance);

//Serial.println(rval);

int mrange= map(rval, 0 , 1023, 0, 10);

unsigned long m= millis();

int numLEDSLit=rval/180;

leds=0;

for(int i=0;i<numLEDSLit; i++) {

bitSet(leds,i);

Page 26 of 52

}

updateShiftRegister ();

switch (mrange) {

case 0:

digitalWrite(batt, HIGH);

digitalWrite(motor,LOW);

Serial.print("Battery 100%");

Serial.print("\t");

Serial.println("Motor 0%");

break;

case 1:


Serial.print("\t");


if ((relay1 == HIGH) && (m - trelay1>= delay9)) {

Page 27 of 52

relay1=LOW;

trelay1=m;

digitalWrite(batt,relay1);

}

else if ((relay1 == LOW) && (m-trelay1>= delay1)) {

trelay1=m;

relay1=HIGH;


}

if ((relay2 == HIGH) && (m-trelay2>= delay1)) {

trelay2=m;

relay2=LOW;

digitalWrite(motor,relay2);

}


trelay2=m;

relay2=HIGH;

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}

break;

case 2:


Serial.print("\t");



trelay1=m;

relay1=LOW;


}


trelay1=m;

relay1=HIGH;


Page 29 of 52

}


trelay2=m;

relay2=LOW;


}


trelay2=m;

relay2=HIGH;


}

break;

case 3:


Serial.print("\t");


Page 30 of 52


trelay1=m;

relay1=LOW;


}


trelay1=m;

relay1=HIGH;


}


trelay2=m;

relay2=LOW;

digitalWrite(motor,trelay2);

}


trelay2=m;

Page 31 of 52

relay2=HIGH;


}

break;

case 4:


Serial.print("\t");



trelay1=m;

relay1=LOW;


}


trelay1=m;

relay1=HIGH;


Page 32 of 52

}


trelay2=m;

relay2=LOW;


}


trelay2=m;

relay2=HIGH;


}

break;

case 5:


Serial.print("\t");



Page 33 of 52

trelay1=m;

relay1=LOW;


}


trelay1=m;

relay1=HIGH;


}


trelay2=m;

relay2=LOW;


}


trelay2=m;

relay2=HIGH;

Page 34 of 52


}

break;

case 6:


Serial.print("\t");



trelay1=m;

relay1=LOW;


}


trelay1=m;

relay1=HIGH;


}

Page 35 of 52


trelay2=m;

relay2=LOW;


}


trelay2=m;

relay2=HIGH;


}

break;

case 7:


Serial.print("\t");



trelay1=m;

Page 36 of 52

relay1=LOW;


}


trelay1=m;

relay1=HIGH;


}


trelay2=m;

relay2=LOW;


}


trelay2=m;

relay2=HIGH;


Page 37 of 52

}

break;

case 8:


Serial.print("\t");



trelay1=m;

relay1=LOW;


}


trelay1=m;

relay1=HIGH;


}

Page 38 of 52


trelay2=m;

relay2=LOW;


}


trelay2=m;

relay2=HIGH;


}

break;

case 9:


Serial.print("\t");



Page 39 of 52

trelay1=m;

relay1=LOW;


}


trelay1=m;

relay1=HIGH;

digitalWrite(batt, relay1);

}


trelay2=m;

relay2=LOW;


}


trelay2=m;

relay2=HIGH;

Page 40 of 52


}

break;

case 10:

digitalWrite(batt, LOW);

digitalWrite(motor,HIGH);


Serial.print("\t");


break;

}

}

void updateShiftRegister() {

digitalWrite(latch, LOW);

shiftOut (data, clock, LSBFIRST, leds);

digitalWrite(latch, HIGH);}

Appendix V: Electrical Component SpecificationsArduino

Page 41 of 52

Microcontroller ATmega328

Operating Voltage 5VInput Voltage (recommended)

7-12V

Input Voltage (limits) 6-20VDigital I/O Pins 14 (of which 6 provide PWM output)Analog Input Pins 6DC Current per I/O Pin 40 mADC Current for 3.3V Pin 50 mAFlash Memory 32 KB (ATmega328) of which 0.5 KB used by

bootloaderSRAM 2 KB (ATmega328)EEPROM 1 KB (ATmega328)Clock Speed 16 MHzLength 68.6 mmWidth 53.4 mmWeight 25 g

Figure 7: Arduino UNO

Page 42 of 52

Relay Shield

Figure 8: Speed Relay Shield

Generator

Motor Model No. MY6812

Nominal voltage: 24 VDC

Speed at 24 VDC: 3000 RPM

Current: 8 Amperes

Power: 135 Watts

Page 43 of 52

Figure 9: Unite Motor Model MY6812

Voltage Regulator

Module properties: non-isolated step-down module (BUCK)

Input Voltage: DC 5-40V

Output Voltage:DC 1.25-36V

Output Current: 12A

Figure 10: DROK DC Car Power Supply Voltage Regulator Buck Converter

Page 44 of 52

Motor

Power: 1/4 HP

Voltage: 12 DC

Speed/Amps:

2600 RPM, 2.2 amps no load

2300 RPM, 25 amps, 7 in.lbs. torque

Figure 11: 12V BLDC Motor

Charge Controller

Rated voltage: 12V or 24V

Rated charging current: 10A

Rated load current: 10A

Voltage of stop power supply: *10.8V or 21.6V

Voltage of resume power supply: *11.8V or 23.6V

Page 45 of 52

Voltage of stop charging: *14V or 28V

Figure 12: Docooler Charge Controller

Battery

Page 46 of 52

Figure 13: Energizer 12 VDC Battery

Page 47 of 52

Appendix VI: Module-generator Design Matrix

Page 48 of 52

Appendix VII: Assembly Drawings

Page 49 of 52

Page 50 of 52

Appendix VIII: FEA

Page 51 of 52

Page 52 of 52

Documents

Executive Summary - TheCAT - Web Services Overviewweb.cecs.pdx.edu/~far/Past Capstone Projects/Y2015... · Web viewDepending on the state of the potentiometer, the microcontroller