2007 R.E.V.2007 R.E.V.Racing Electric VehicleRacing Electric Vehicle

Senior Design ProjectSenior Design Project

OverviewOverview

PurposePurpose Improve community awareness of electric Improve community awareness of electric

vehiclesvehicles Raise publicity for school and design projectsRaise publicity for school and design projects To show potential plan for future Electric SAE To show potential plan for future Electric SAE

CompetitionCompetition Compete in SCCA Autocross and SAE Formula Compete in SCCA Autocross and SAE Formula

Hybrid RaceHybrid Race

Design ConstraintsDesign Constraints Meet safety guidelines from a combination of Meet safety guidelines from a combination of

SCCA, SAE Formula Hybrid specificationsSCCA, SAE Formula Hybrid specifications Weight and VolumeWeight and Volume

ObjectivesObjectives

0-60 mph in under 5 0-60 mph in under 5 seconds seconds

Weight under 650 lbsWeight under 650 lbs Battery life of 15 minutes Battery life of 15 minutes

for continuous drawfor continuous draw Wireless download data Wireless download data

capabilitycapability Prove an electrical Prove an electrical

system is comparable to system is comparable to an internal combustion an internal combustion systemsystem

AE ~ Aerospace Engineer, CE ~ Computer Engineer, EE ~ Electrical Engineer, ME ~ Mechanical Engineer

The TeamThe Team

Matt Reedy (EE/CE), Electrical LeadMatt Reedy (EE/CE), Electrical Lead Kristi Harrell (EE)Kristi Harrell (EE) Audrey Moyers (CE)Audrey Moyers (CE) Valerie Bastien (EE)Valerie Bastien (EE) Jason McSwain (CE)Jason McSwain (CE)

Elizabeth Diaz (ME), Team LeadElizabeth Diaz (ME), Team Lead Jason Miner (ME), Mechanical LeadJason Miner (ME), Mechanical Lead Jared Doescher (ME)Jared Doescher (ME) Kathy Murray (AE/ME)Kathy Murray (AE/ME) AJ Nick (ME)AJ Nick (ME) Josh Wales (ME)Josh Wales (ME) Dave Wickers (ME)Dave Wickers (ME) Oliver Zimmerman (ME)Oliver Zimmerman (ME)

Drive System/Electrical TeamDrive System/Electrical Team

Matthew ReedyElectrical Lead

Kristina HarrellPower Systems Lead

Audrey MoyersProgrammable Logic

Controller Lead

Valerie BastienSensors Lead

Jason McSwainCommunications Lead

ScheduleSchedule

Winter B

reak

Wireless Interface

•512 Ram•1462 m Range•Small C – freeware with limited assembler

PLC

EZPLC-D-96E:Voltage- 24V 96 I/O MaxCPU Processor 32 Bit, 40 MHz Memory Available: 64 K Words Total Registers 8192 16Bit

Motor

Advanced DC MotorFB1-4001Weight: 143.0 lbsInput Voltage: 96-144VCurrent Max:700 amps28 HP -Continuous Rating85 HP –Peak Rating

System DiagramSystem Diagram

Batteries 144V

Motor

Programmable Logic Controller

Motor Controller

E shutoff Voltage/Current Divider

Batteries 24V

E shutoff digital inputs and reset

Monitor Wireless Interface

User interface

T

T

T

E

E

L S

Key

T

L

E

S

Thermocouple

Encoder

Light Sensors

Speed Inputs

Serial/Ethernet

Wireless

Batteries

Lithium Ion BatteriesA123 SystemsPart Number: ANR26650M1Nominal capacity and voltage: 2.3 Ah, 3.3 VMax continuous discharge: 70 AOperating temperature range: -30˚C to +60˚CWeight: 0.154 lbs (70g)

Motor Controller

Zilla Controller-Z1K-LVWeight: 15.5 lbsMax. Motor Amps: 1000 ANom. Battery Voltage: 72 – 156 VPeak Power: 320,000 Watts

User Interface

EZ Monitor5.7” ScreenDisplays vital system information from PLC

User InterfaceUser InterfaceLeft side of main batteryDisplays the average voltage level of the batteries located on the left side. Changes color when any cell temperature is too high.

Right side of main batteryDisplays the average voltage level of the batteries located on the right side. Changes color when any cell temperature is too high.

Auxiliary batteryDisplays the voltage level of the auxiliary battery. Changes color when any cell temperature is too high.

TachometerAnalog display of the speed.

OdometerDigital display of distance traveled.

TimerTimer starts when “gas” pedal is initially pressed.

RPMDisplays revolutions per minute.

VoltageDisplays system main voltage.

CurrentDisplays system current.

Main Screen

User InterfaceUser InterfaceIndividual CellsDisplays the voltage level of the cell. Changes color when its temperature is too high.

Cell TemperatureDigital display of temperature.

Cell VoltageDigital display of voltage.

System CurrentShows the system current.

Average TemperatureDisplays the average temperature of the cells.

Average VoltageDisplays the average voltage of the cells.

PowerDisplays the average percentage of voltage remaining in the cells.

Auxiliary batteryDisplays the voltage level of the auxiliary battery. Changes color when any cell temperature is too high.

Battery Screen

BudgetBudget

Part Description Total Price

DC Motor 28HP continuous series wound DC motor $1,450

Controller 72-156VDC series wound controller, 1000A max. w/ HardBall $2,950

Throttle Control Swinging arm throttle input, 5k ohms $75

Speed Sensor Advanced DC Motor Speed Sensor $43

Fuse Up to 600A systems $109

Fuse Up to 800A systems $84

PLC 12 Slot EZPLC Base (96I/O Max) $289

PLC I/O 4 Thermocouple Input Module $556

PLC I/O 4 DC In, 4 DC Out Relay Module $39

PLC I/O 8 Analog Input (voltage) Module $99

PLC I/O 8 Analog Input (current) Module $99

PLC I/O 8 DC High Speed Input Module $48

PLC I/O 8 DC Output (source) Module $38

PLC I/O High Speed Counter Module $99

Touch Screen Display 5.7 viewable Touch Screen LCD display (outdoors) $2,500

Contactor Kilovac 600A continuous 12V contactor $931

Wire 00 gauge (Black) 33 feet $99

Wireless Device Connects 2 serial ports $322

Wireless Device Connest to the user interface $190

Li-ion Batteries (2 sets) Depends on Differential Ratio. 44S10P with 2 sets $18,000

Charger 110 or 220 system charger $3,099

$31,118.50

Electrical Components for Racing Electric Vehicle:

WebsiteWebsite

http://my.fit.edu/rev/http://my.fit.edu/rev/

Competition InformationCompetition Information SCCA AutocrossSCCA Autocross

• www.scca.orgwww.scca.org• www.floridaregionscca.com/solo.htmwww.floridaregionscca.com/solo.htm

SAE Formula HybridSAE Formula Hybrid• www.formula-hybrid.orgwww.formula-hybrid.org