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Production Electronics for a Light Weight Electric CarTeam 11Team leader: Mitch Wozniak Team members : Majed Alarawi, Xueyin Shi (Charlotte), Yiqing Zhou (Jack)
Industry Sponsor: Blair Jackson Orison Corporation
Advisors: Scott Schneider, Rebecca BlustIndustry Sponsor: Blair Jackson
Orison Corporation
Advisors: Scott Schneider
Rebecca Blust
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Outline for Presentation
Introduction System Layout and Components
Status of ComponentsRecommendation
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IntroductionHistory
BackgroundPurpose
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History
The Blair Jackson Orison Corporation, (“Orison”) was started by Blair Jackson
The company resides in Troy, OH Orison has developed a prototype of
electric single person vehicle
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Background
The Orison light weight vehicle is a 4-wheeled single rider electrical vehicle still in the development stage.
“Big Picture” The client wants to eventually begin manufacturing of this vehicle.
The mechanical design of the car was designed by Blair Jackson. The electrical systems were also developed by Blair Jackson. Blair Jackson wants improvements made to the electrical system.
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Purpose / Function
The purpose of this project is to provide a simple functional electrical system to be combined into the electrical vehicle created by Orison.
The function of the electrical system is the heart of the vehicle. It supplies power to all the working components.
The components will improve the use of the vehicle such as lights, speed control, simplicity, and braking.
Team 11 is improving the electrical systems so that manufacturing can be easier and the electrical systems will be improved.
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Project SpecificationsRequirements
Deliverables
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Functional Requirements Power Distribution PCB must connect directly to the UNO. It
controls voltages to different areas of the vehicle, organizes the wiring of the UNO, and has a transistor circuit to control voltage to the motor controllers.
New Hall Sensors control the throttle. They must be durable and water/dirt repellent.
The digital display is required to be able to display speed, battery life, and direction of the motors.
System of lighting around the vehicle is required to make it easy to drive at night and noticeable to others.
New motor controllers must allow for regenerative braking.
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Requirements Continued…
Power distribution PCB must control voltages and be able to send the voltage to the correct components.
Power distribution PCB must fit on the UNO. Power distribution PCB must have an easy to use and water proof plug
for wires. Hall Sensor must be water and dirt proof and must communicate with
UNO. Display must be visible in all weather and must show speed, battery
life, and direction. Lights must be be able to seen during day and night and have a visual
range of 50 feet at night. Motor controllers must provide voltage back to the batteries during
breaking.
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Deliverables There are five deliverables that will be accomplished
during the project1. Design of a power distribution circuit2. Research and selection of rotary hall sensors 3. Research and selection of a new digital display for vehicle speed, battery information and vehicle direction4. Selection and testing of new lighting system for headlights and running lights5. Research and test new four-quadrant motor controllers
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System OverviewPower Distribution Circuit
Hall SensorsDisplay
LightsMotor Controllers
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System Layout
1
2
4
3
5
Legend:Red – PositiveBlack – GroundBlue – I^2cPurple – Multiple Signal
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Power Distribution Circuit Section Layout
UNO Criteria for the Power Distribution Circuit Test Results from Multisim (Voltage & Amps) Breadboard Test Results Layout of Circuit in Multisim Layout of Circuit in Ultiboard 3D Visuals of Circuit board Components chosen for Circuit LDO Criteria LDO Matrix LDO Description Explanation of Transistor Circuit Replacement Status of Power Distribution Circuit
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Arduino Uno
The Arduino Uno is a microcontroller board based on ATmega328 It has 14 digital input/output pins Operating Voltage 5V Input Voltage (recommended) 7-12V Input Voltage (limits) 6-20V Digital I/O Pins 14 (of which 6 provide PWM output) Analog Input Pins 6 DC Current per I/O Pin 40 mA DC Current for 3.3V Pin 50 mA
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Power Distribution Circuit
Power Distribution CircuitCriteria Provide different voltages to components around the vehicle 3.3 volts for display, 9 volts for UNO, and 36 volts in series for
the lights Connectivity to UNO to minimize the complexity of wires Easy cable connection for communication sent from UNO to
front of the Vehicle Pin layout that coheres with the pin layout on the UNO Addition of transistors circuit that steps up voltage from UNO
to motor controllers to consolidate circuits
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Testing of the Circuit (Voltage)
Power Distribution Circuit
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Test of the Circuit (Amps)Power Distribution Circuit
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Breadboard Test
Overall Breadboard 9 Volt Regulator Test3.3 Volt Regulator Test
Power Distribution Circuit
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Lighting System Voltage
Layout of Power Distribution Circuit Power Distribution Circuit
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Layout of Circuit on to the PCB / Engineer Design
All of the traces (red and green lines) had to be sized correctly for the amount of current that was going to pass through. (0.75 mm for large voltage and current and 0.5 mm for all other traces)
The traces must be a certain distance apart to prevent jumping. (.25 mm)
Pin foot print needed to match exactly with the UNO.
Parts with high current and voltage create more heat. These were designed to be in open areas of the PCB for heat dispersion.
Power Distribution Circuit
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3D viewFront ViewSide ViewRear View
Top View
Power Distribution Circuit
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Electrical Components
On / off switchBoard to wire ConnectorLow drop out voltage regulator (3.3v & 9v)Power resistance (510 Ω & 220 Ω both 5 Watt rated)Capacitors (0.1μF or bigger) Fuse (250 mA)Circuit Breaker (4 amps)Pins
Power Distribution Circuit
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Criteria for the Low Drop Out Voltage Regulator
1. Complexity: components are simple to use2. Functionality: step up or step down voltage3. Ripple / Noise: fluctuation in voltages 4. Size: component shape size 5. Efficiency: Ability to transform voltage without losses6. Total Cost: the price of purchasing
Power Distribution Circuit
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LDO Matrix
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0123456789
10
LDOSWITCHING
LDOSWITCHING
CriteriaRaw Score out of
10 Linear LDO Switching LDO
Complexity 10 10 6
Functionality 8 7 6
Ripple/Noise 10 10 6
Size 9 9 7
Efficiency 7 4 7
Cost 5 5 3
Totals 49 45 36
Power Distribution Circuit
LDO
Credible for battery design(enable battery to be used up to the limit)
Low noise(no switching needed) Small size and simple Most frequently used in technology (phone-digital
camera-laptop) Less heat loss(no transformer) Complexity(amplifier-pass element)
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Power Distribution Circuit
Replacing the Transistors from the UNO to the Motor Controllers with a circuit on the PCB
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Multisim Circuit
3D VisualPower Distribution Circuit
Status of Power Distribution Circuit The circuit has been designed and tested successfully. All components were ordered and received. Final design in Ultiboard is ready for client approval and is
ready to be sent out to a PCB manufacturer.
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Part 2 - Hall Sensors
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Criteria Matrix Test results Information Status
Criteria
1. Resolution- The more resolution we have the more accurate the hall sensor
2. Interface- The interface should be suitable to work with the UNO
3. Temperature Range- The temperature range should be large to withstand all conditions
4. Supply Voltage - It should match what the UNO can provide5. Price- The team’s budget is limited, the price should be
reasonable
Hall Sensors
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Hall Sensors
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CriteriaRaw Score(out of 10)
AS5048A Rotary Sensor
ADS1208
ADS1201
Resolution 8 6 6 8Interface 8 8 3 3Temperature Range
10 10 55
Supply voltage 6 5 3 3Price 8 7 7 7Total 40 36 24 26
Matrix
Hall Sensor
The DRV5053-Q1 device is a chopper-stabilized Hall IC that offers a magnetic sensing solution with superior sensitivity stability over temperature and integrated protection features.
The 0 to 2V analog output responds linearly to the applied magnetic flux density, and distinguishes the polarity of magnetic field direction .
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Information
Hall Sensors
Tested with LabVIEW Hooked into the Breadboard
Power Distribution Circuit to prove that they work together
Tested with Multi-meter LabVIEW writes information to
excel file
Test Results
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Hall Sensor
Cleaned up test values Chart for linear equation for
the hall sensor These equations can be used
in RobotC to convert the pulse width signal to distance
Test Results
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Status
Component has been researched and ordered Experiment connecting to the UNO has been completed and
failed Alternative methods to test the Hall Sensors were done in
LabView and Multi-meter We proved that they can work and found out what type of
signal is being used Having the knowledge of the signal type and how it works will
help in setting up the Hall Sensors with the UNO
Hall Sensors
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Part 3 - Display
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Criteria Matrix Information Status
Criteria for the Display
1. Size - The bigger the size, the easier that the customer can see the information
2. Information on the Board -The board should show multiple information at the same time
3. Supply Voltage -The voltage should be at 5V4. Price - The team’s budget is limited, the price should be
reasonable
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Display Matrix
CriteriaRaw Score(out of 10
NHD-0420DZW-AB5
NHD-2.23-12832UMB3
Size 8 8 6Information on the board 10 10 6Supply voltage 8 8 8Price 10 8 10Total 36 34 30
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Display NHD-0420DZW-AB5
4 lines x 20 character Blue LED display
3V or 5v power
4.75mm character height
Size: 98mm x 60mm
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Information
Status of Display
Other parts of the project were needed before the display could be integrated so we concentrated on those parts.
The other crucial parts should be finished before the display is worked on.
The project was not as far along as we thought so we researched the display, and did not purchase it.
The display was not ordered.
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Part 4 – Lighting System
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Head Lights Criteria Matrix Information
Running Lights Matrix Information
Status
Criteria for Lighting System
1. Voltage - The voltage needs to be 12V which is suitable to the circuit.2. Color of Lens and Lights - The color of rear light should be yellow. The
color of the head light should be white.3. Number of LEDs - Determines the brightness of the light. 4. Material- The material should be steel. 5. Price- The team’s budget is limited, so the price should be reasonable.
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Head Light
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CriteriaRaw Score(out of 10)
Black Motorcycle Headlight 5" LED Head Lamp
Double Dual Lamp Street
7" LED Motorcycle Halogen Headlight
Voltage 8 8 8 8Color of lens and lights
8 3 83
Number of the LED 10 10 0 6Material 6 6 3 3Price 8 7 2 4Total 40 34 21 24
Matrix
Head Light
Color: BlackLens Color: Clear
Number of LED: 30Cable Length: 7 1/2" (19cm)
Voltage: DC 12VWattage: 3w/5w
Material:Steel & Glass Lens3 wires connection
system.
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Information
Running Lights
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CriteriaRaw Score(out of 10)
1x Rectangle Reflector Amber Yellow LED Rear turn signal light Car Clear Lens
Motorcycle Custom LED Reflector Tail Trunk Rear Fog Light Shadow Clear Lens ND
Smoke For Suzuki 05-06 GSXR1000 LED Intergrated Tail Light Turn Signals Brake
Voltage 8 8 8 8Color of lens and lights
8 8 33
Number of the LED 10 9 9 10Material 6 3 3 3Price 8 8 8 4Total 40 36 31 28
Matrix
Running Lights
Type of Lights : 24 high power LED light clip inside each light Size (length x Width x Depth): ~89mm x 39mm × 9.5 mm It works at 12 V There are three wires: black, blue and red
Black line→ cathode / ground / negative wire Blue line→ small light (for 50% light) positive wire Red line→ turn signal or brake light (for 100% light) positive wire
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Information
Lighting System
The lighting system was also dependent on the team finishing other components of the project.
The parts were ordered and received. The parts are ready for installation once the
Power Distribution Circuit is finalized. Lights have been tested with the breadboard
Power Distribution Circuit.
Head lightRunning Lights
Status
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Motor Controllers
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Information Status
Kelly KBS-X Brushless Motor Controller
KBS36051X Four quadrant motor control Less expensive Already programmed Client recommended
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Status of Motor Controllers The Motor Controllers were purchased and have been experimented
with. Research was done to determine the best way to wire the motor
controllers to the motors and the UNO. We have been working with the motor controller to get them to turn
the motor but have been unsuccessful. We have tried different ways of wiring and changing parameters in
the program both of which have come with no results.
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Criteria for Wiring System
1. Number of Wires – Cables are capable of running 1 to 48 wires for this application. For this application we needed 20.
2. Protective Coating – A PVC coating is needed to protect the wires from outside contaminates.
3. Shielding – Important for 2 reasons. It prevents EMI and ESD interference of the signal and it prevents the wires from easily being pinched.
4. Gauge – It is the thickness of the wire which determines how much voltage and current can be sent through.
5. Twisted Pairs – Reduces crosstalk for balanced drive applications. 6. Price – Need the above requirements but at a price that is reasonable.
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Wiring System
CriteriaRaw Score out of 10 3M 3600x series Mcmaster-CARR 7741k17 General Cable XLPE/XL-CPE
# of Wires 8 8 7 8Protective Coating 6 6 6 6
Shielding 10 10 0 8
Gauge 10 10 7 9
Twisted Pairs 8 8 0 8
Price 5 2 3 2
Totals 47 44 23 41
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Matrix
Wiring System The wire system was researched and we found
the solution. 3M Round, Shielded/Jacketed, Disc. Wire Cable
3600x Series We did not purchase it because we were not to
that point in the project. You have to buy a set distance of wire, the
shortest being 100ft. The price was too much for the bench test. We used single wire for the bench test to make it
easier to test different configurations of wires.
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Information / Status
Project ManagementBudget
Gantt ChartRecommendation
Conclusion
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Budget
Given $1,000 budget by Blair Jackson Company credit card with rules about
each purchase Spent total of $550 dollars Totally cost to produce the Power
Distribution PCB $78.13 Total electrical system cost $285.17 Additional budget was spend on
components for testing
BudgetNumber of Parts
Price of Part
Shipping Price
Sales Tax / Process Fee
Total Price
Delivered(Y/N)
Total - Available
Part NameUNO 1 $34.99 $6.99 $3.04 $45.02yHall Sensors 2 $25.00 $0.00 $0.00 $50.00yMotor Controllers 2 $59.00 $31.00 $0.00 $149.00yTransistors 10 $0.25 $0.00 $5.00 $7.50yCircuit Breaker 4 amp 2 $9.25 $0.00 $0.00 $18.50yHall Effect Sensor 4 $1.04 $7.00 $0.00 $11.16yLDO Regulator 3.3v 10 $0.40 $6.99 $0.80 $11.83yHead Light 1 $24.99 $0.00 $0.00 $24.99yCircuit Breaker 25 amp 1 $21.73 $0.00 $0.00 $21.73yRegulator 9v 10 $0.25 $2.67 $5.00 $10.17y $850.00Running Lights 1 $14.98 $0.00 $0.00 $14.98yElectronic Parts 1 $8.91 $0.00 $0.00 $8.91yElectronic Parts 1 $13.45 $0.00 $0.00 $13.45yElectronic Parts 1 $25.26 $0.00 $0.00 $25.26yConn Recept 20 pos 2 $1.00 $0.00 $0.64 $2.64yConn Header 20 pos 2 $0.91 $0.00 $0.00 $1.82yConn term female 50 $0.10 $0.00 $0.00 $4.95y50 pcs 5mmX20mm glass tube 1 $17.97 $0.00 $0.00 $17.97y510 OHM resistor 1 $22.83 $0.00 $0.00 $22.83yeasy more 40 pin 1 $25.26 $0.00 $0.00 $25.26y220 ohm resistor 1 $13.45 $0.00 $0.00 $13.45y
Electronic Parts 1 $22.09 $0.00 $0.00 $22.09yTotal Left Over
$523.51 $326.39School of Engineering Innovation Center
Project Management
Gantt Chart
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Project Management
Recommendation
Power Distribution Circuit – Order circuit board from a PCB manufacturer and test it with the UNO.
Hall Sensors – Rewrite the RobotC and use the equation derived by LabView for UNO to understand the signal being sent by the Hall Sensors.
Display – Get all other components working before working on the display. Once the system is working take signals that are needed and run them to the display.
Head lights – Lighting system is ready to be plugged into the Power Distribution Circuit as soon as it is complete.
Motor Controllers – Get the Hall Sensors working with the UNO then try to hook the Motor Controllers to the UNO.
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Project Management
Questions??
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Status of the Project
Researched DesignedParts Ordered
Parts Received Assembled Testing Finished
Power Distribution PCB þ þ þ þ þ In Progress In Progress
Hall Sensors þ N/A þ þ In Progress In Progress In Progress
Display þ N/A In Progress In Progress In Progress In Progress In Progress
Lighting þ N/A þ þ In Progress In Progress In Progress
Motor Controllers þ N/A þ þ In Progress In Progress In Progress
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