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KGCOE MSD P15261
Revision 5
KGCOE MSD P15263
Offboard Electric Vehicle Charger
Joseph Droleskey, Tucker Graydon, Brian Hebbard, Christopher Liess
Index
Customer Project Readiness Package (PRP) 3
Customer Requirements 7
Engineering Requirements 8
Benchmarking 10
Risk Management 12
Morphological Table 15
Functional Decomposition 15
Team Schedule 16
System Layout and Design 18
AC-DC Rectification Subsystem 21
DC-DC Control Subsystem 23
Current Control Subsystem 25
Control and Logic System 26
CAN Communication Subsystem 27
Microcontroller 29
Prototype CAD Design 32
Estimated Bill of Materials 33
References 34
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Multidisciplinary Senior Design
Project Readiness Package
Project Title: / Electric Superbike Off-board ChargerProject Number:
(MSD will assign this) / P15261
Primary Customer:
(provide name, phone number, and email) / EVT, Josh Jones, Wheeler Law, Derek Gutheil
Sponsor(s):
(provide name, phone number, email, and amount of support) / MSD Senior Design department
Preferred Start Term: / Spring 2015
Faculty Champion:
(provide name and email) / Prof. George Slack,
Other Support:
Project Guide:
(MSD will assign this) / Slack
EVT, Josh Jones, Derek Gutheil / January 2015
Prepared By / Date
Project Information
Overview:
The RIT Electric Vehicle Team is a student run organization dedicated to promoting the viability of electric vehicles through real world demonstrations of electric drivetrains in action. The team aims to educate people on the principles of electric vehicle design by engaging students in challenging and rewarding projects that cover a wide variety of academic disciplines. The team’s main project is to design, build, and race a high performance electric motorcycle for competition in the 2015 eMotoRacing all-electric race series. The current bike is based off of the frame from a 2005 Kawasaki Ninja ZX6RR, and utilizes two Zero Z-Force 75-7 motors paired with two Sevcon Size6 controllers. In house engineering includes the design and fabrication of a battery management system, battery containment modules, structural framing for the mounting of the powertrain, as well as advanced data collection and analysis software. Based on this, the team is currently in need of a high powered charger that can charge the bike's battery pack in a reasonable amount of time.
Project Goals:
The R.I.T. Electric Vehicle Team proposes a portable off-board charger for an electric super bike. In order to compete in the E-Moto Racing series, the team requires an efficient and reliable method of charging the bike's 12 Kwh battery pack. Unlike traditional battery chargers, the superbikes charger must conform to the J-1772 electric vehicle charging standard.
References:
[1]
[2]
[3]
[4]
Customer Requirements (CR):
This list of customer requirements of anticipated activities.
CR # / Imp. / Customer Need / DescriptionCR1 / 1 / Battery connection / Able to safely connect and discount battery.
CR2 / 1 / Power on / off / Able to safely power on and power off charger
CR3 / 4 / LCD Display / Able to know the charging rates, state of charge, charging time, etc.
CR4 / 3 / Adjustable / Able to select voltage and current
CR5 / 1 / J-1772 standard / Able to implement given standard(s)
CR6 / 3 / Communication with the Superbike / Able to communicate with the Superbike's BMS via CAN
CR7 / 1 / Wall connection / Able to charge via J-1772 or 120V Wall connection
CR8 / 3 / Documentation / Every facet of the project must be well documented with instructions where necessary
CR9
CR10
Engineering Requirements (ER):
- Power Requirements
- The charger must be capable of charging a battery from full discharge to full charge in no more than 4 hours while using the J-1772 standard charging station
- The charger must also be capable of operating through standard 120V 15A 60Hz wall outlets. While in this low power mode, the charger must be capable of charging the battery in no more than 12 hours
- The charging system must automatically detect and switch between the low and high power modes
- Control Requirements
- The charger must be able to output voltage and current to within 20% of the nominal values in either mode. These outputs must also be regulated to within 1% of their set values
- The charger must be able to vary voltage and current through both software and a user interface
- Communication Requirements
- Needs to conform to the J-1772 communication protocol for use in high power mode
- During all modes of operation, the charger must be capable of communicating over CAN
Constraints:
Safety is of the upmost importance. It will be a factor in every aspect of the design. The batteries on the Superbike that will be charged have a large capacity, and as such, will not be readily available for testing. The Electric Vehicle Team has access to them and can provide them upon request. Most EVT members can be made available with a reasonable notice for assistance. EVT members will also be a regular part of the design process ensuring that their goals are met.
Project Deliverables:
Minimum requirements:
●All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test results)
●working prototype
●technical paper
●poster
Additional required deliverables:
●List here, if applicable
Budget Information:
List major cost items anticipated, and any special purchasing requirements from the sponsor(s).
Intellectual Property:
There are no IP restrictions on this project
Customer Requirements
CR # / Imp. / Customer NeedCR1 / 1 / Battery Connection to charger meets safety standards
CR2 / 1 / Power on / off
CR3 / 4 / LCD Display
CR4 / 3 / Adjustable Outputs
CR5 / 1 / J-1772 standard
CR6 / 3 / Communication with the Superbike
CR7 / 1 / Wall Connection
CR8 / 3 / Documentation
CR9 / 1 / Overall Design must be User Safe
CR10 / 1 / Monitoring of battery charging
CR11 / 1 / Adhering to EVT safety protocols
CR # / Description
CR1 / Able to safely connect and disconnect battery
CR2 / Able to safely power on and power off charger
CR3 / Able to know the charging rates, state of charge, charging time, etc
CR4 / Able to select voltage, current
CR5 / Able to implement given standard(s)
CR6 / Able to communicate with Superbike's BMS via CAN
CR7 / Able to charge via J-1772 or 120V wall connection
CR8 / Every facet of project must be well documented with instruction where necessary
CR9 / The final implementation must be safe to use even for a person who has never been trained on it
CR10 / The charger must monitor the battery status over CAN communication to prevent damage to battery
CR11 / While working on the charger and with the batteries the team must adhere to all the safety protocols the Electric Vehicle Team has in place and a member of EVT must always be present.
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Engineering Requirements & Specifications (revision 4)
Some features have been omitted since they do not necessarily have engineering metrics to rate success. These features include the user interface being simple and user friendly, Certain safety implementations such as key switches and emergency stops. These are addressed in the respected subsystem documentation.
Specifications
Below are the current specifications for the charger: They currently based on the XALT 63 Ah High Power LIPO Cells in a pack of 25 connected in series. The list will be continuously updated as more data becomes available.
Parameter / Min / Expected / Max / Unit / CommentsUnderVoltage Lockout / 2.6 / V / Bat. Too low
Charge Current / 1 / 15 / 50 / A / Depends on Source
Charge Voltage / 25 / 50 / 110 / V / Pack Size dependent
Battery Termination Voltage / 4.1 / V
Accuracy / -1 / 0 / 1 / %
Battery Overvoltage Threshold / 0.1 / V
Battery Detection / 2.5 / 2.9 / 4 / V
Battery Detection Timer / 333 / ms
Start Charging Delay Timer / 1 / min
Charge Complete Timer / 5 / min
Safety Timer / 2910 / 35 / min / Based on Charge Param.
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Benchmarking
PARAMETERSRequired / EVT / Energica Ego
Charge Rate / <4hrs / Charge Rate / <4hrs / 3.5hrs
Cool Rate / 40deg C stability / Cool Rate / 40deg C stability / Not Specified
PWR Response / 1 sec / PWR Response / 1 sec / Not Specified
Capacity / 11.544 kWh / Capacity / 11.544 kWh / 11.7 kWh
Life / 1200 CYCLES / Life / 1200 CYCLES / 1200 CYCLES
V/I Reg. Accuracy / >99% / CFM / TBD / 90
Output Voltage / 50-60V+ / 110/220V
Cost / <$1000 / >$1000
Attached Below is a expanded graph of efficiency and voltage characteristics of other EV Chargers analyzed by EnergyStar for approval. These values will be used to compare the end product with what is on the market currently.
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MSD Risk Assessment
ID / Risk Item / Effect / Cause / Likelihood / Severity / Importance / Action to Minimize Risk / OwnerDescribe the risk briefly / What is the effect on any or all of the project deliverables if the cause actually happens? / What are the possible cause(s) of this risk? / L*S / What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring? / Who is responsible for following through on mitigation?
1 / J-1772 interface unobtainable / The charger will not be usable with J-1772 chargers unless an adapter is manufactured in house / IP restrictions/low demand or supply for the interface / 1 / 6 / 6 / Conduct proper research into the ability to purchase this interface / Team
2 / Over current / Damaged equipment, injured operator/bystander / Current regulation does not work / 1 / 9 / 9 / Researching and developing a safety mechanism that shuts down the charger and electrical system when failure is detected / Team
2 / Over current / Damaged equipment, injured operator/bystander / Software fails to detect current / 1 / 9 / 9 / Debugging code and perform testing / Team
3 / Battery management system fails to cut off the charge / Batteries overcharge/lifecycle decreases / Microcontroller fails to detect a full battery/communication disconnect / 3 / 7 / 21 / Thorough debugging of code/firmware will be implemented, a microcontroller that can effectively communicate with the BMS will be researched and purchased. Use test equipment to ensure that the battery cells will not exceed or meet 100% capacity / Team
4 / Input voltage detection / Batteries Damaged / Microcontroller/software fails to detect input voltage / 1 / 7 / 7 / Thorough debugging of code/firmware will be implemented, a microcontroller that can effectively communicate with the BMS will be researched and purchased / Team
5 / Damage to charger / Must replace damaged equipment/increased cost due to replacement / Improper use, overheating, system design, short circuit / 2 / 9 / 18 / Implementation of redundant safety systems and procedures. Adequate research and testing to validate design / Team
6 / Design Over-Budget / Not all components are obtainable / Lack of oversight, incorrect parts ordered, replacement to damaged parts / 2 / 7 / 14 / Keep a log of desired items/components, assign an estimate cost to each system, and minimize risk 5. / Team/Project Manager
7 / Design behind schedule / Project deliverables incomplete / Unforeseen design complications, Risk 5,
Lack of communication between team / 3 / 5 / 15 / Team must update/adhere to schedule on a regular basis and maintain communication of any possible complications or FMEA’s / Project Manager/Team
8 / System function fails test / Function must be corrected / Inadequate components within system, not designed to interface with other functions / 2 / 6 / 12 / Adequate research will minimize risks. Having multiple concepts per subsystem/function will provide a backup in case system is proven to fail. / Team
9 / System overheats / Damaged Equipment / Inadequate cooling / 2 / 6 / 12 / Add sufficient vents, fans, and heat sinks. / Team
9 / System overheats / Damaged Equipment / Software does not detect temperature / 1 / 6 / 6 / Debugging code and perform testing to determine sensor is recording accurate values / Team
10 / Battery Cell Detection / Damaged Batteries / Software does not detect correct number of cells / 1 / 6 / 6 / Debugging code and perform testing to determine code is recording accurate values / Team
11 / Output Voltage Detection / Damaged Batteries / Software does not detect correct output voltage / 1 / 6 / 6 / Debugging code and perform testing to determine code is recording accurate values / Team
Likelihood scale / Severity scale
1 - This cause is unlikely to happen / 1 - The impact on the project is very minor. We will still meet deliverables on time and within budget, but it will cause extra work
2 - This cause could conceivably happen / 4 - The impact on the project is noticeable. We will deliver reduced functionality, go over budget, or fail to meet some of our Engineering Specifications.
3 - This cause is very likely to happen / 9 - The impact on the project is severe. We will not be able to deliver, or what we deliver will not meet the customer's needs.
“Importance Score” (Likelihood x Severity) – use this to guide your preference for a risk management strategy
Prevent / Action will be taken to prevent the cause(s) from occurring in the first place.
Reduce / Action will be taken to reduce the likelihood of the cause and/or the severity of the effect on the project, should the cause occur
Transfer / Action will be taken to transfer the risk to something else. Insurance is an example of this. You purchase an insurance policy that contractually binds an insurance company to pay for your loss in the event of accident. This transfers the financial consequences of the accident to someone else. Your car is still a wreck, of course.
Accept / Low importance risks may not justify any action at all. If they happen, you simply accept the consequences.
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Morphological Table
Functional Decomposition
Team Schedule
Week # / Dates / Team MembersBrian Hebbard / Chris Liess / Tucker Graydon / Joe Droleskey
1 / 8/24/2015 / Catch team up on project status and goals, develop weekly meeting time outside of MSD II / Begin building prototype, full-scale AC-DC voltage regulation system / Begin developing initial software and firmware framework / Begin building prototype, full-scale DC-DC voltage/current regulation system
2 / 8/31/2015 / Review progress of hardware, software and firmware development / Finish building prototype AC-DC voltage regualtion system, begin contstructing test setup / Continue developing software and firmware framework, confirm that the framework allows the PIC to boot / Finish building prototype AC-DC voltage/current regualtion system, begin contstructing test setup
3
Milestone Review #1 / 9/7/2015 / Prepare team for "Milestone Review" #1 / Test AC-DC voltage regulation system in an isolated (from other subsystems) test setup, compile and report on test results / Continue developing software and firmware, adding initial menus to the UI / Test DC-DC voltage/current regulation system in an isolated test setup, compile and report on test results
4 / 9/14/2015 / Ensure that Edge content is up to date, review results from software and hardware testing / Begin tracing PCB for Rev. 2 of the AC-DC voltage regulation system, with the test results driving any design changes / Continue developing software and firmware, adding warning messages and flags / Begin tracing PCB of Rev. 2 of the DC-DC voltage/current regulation system, with the test results driving any design changes
5 / 9/21/2015 / Purchase initial "project box" for Rev. 2, based on size of the PCB / Assist other team members in development/project box selection / Continue developing software and firmware, adding key functions (charge rate, etc) / Send final PCB design for Rev. 2 of the subsystems to the manufacturer, assist other team members in development/project box selection
6
Milestone Review #2 / 9/28/2015 / Prepare team for "Milestone Review" #2 / Conduct qualitative inspection of received PCB to ensure that no defects are present / Develop and ensure that methods of communicating over CAN are robust and functioning properly, load firmware Rev. 1 onto the PIC, test key software functionality, report on results of testing / Mount lock & key system to the project box
7 / 10/5/2015 / Review test/inspection results, address any anomolies/failures, ensure that Edge content is up to date / Time delegated for addressing any possible anomolies/setbacks encountered during previous weeks (PCB failures, new parts being required, etc)
Note: This 2 week block could be spread throughout the Semester, and is represented here only to illustrate that there is "breathing room" for the project development.
8 / 10/12/2015
9
Milestone Review #3 / 10/19/2015 / Prepare team for "Milestone Review" #3 / Assist in software/firmware development / Continue developing software and firmware, adding remaining features (per ER and CR) / Mount PCB, relays and other subsystems that aren't on the PCB to the project box
10 / 10/26/2015 / Develop a user's manual for the charger that can be easily understood / Consult with and assist Brian in developing software guidelines for a user's manual for the charger / Begin debugging any known non-functional key software/firmware features / Consult with and assist Brian in developing hardware guidelines for a user's manual for the charger
11 / 11/2/2015 / Develop final software and hardware test procedures / Assist in developing hardware and software test procedures, taking into consideration ER and CR / Finish debugging known non-functional key software/firmware features, begin debugging known UI issues / Conduct a read-over of the user's manual to ensure that the manual could be easily understood
12 / 11/9/2015 / Finalize software and hardware / Verify via "dry-runs" that developed software and hardware test procedures are robust, testing all key subsystems sufficiently / Begin finalizing software and firmware development / Verify via "dry-runs" that developed software and hardware test procedures are robust, testing all key subsystems sufficiently
13 / 11/16/2015 / Ensure that Edge content is up to date / Conduct software tests, cycling through various test procedures to ensure that all features work as intended / Address issues found via software and hardware testing / Conduct hardware tests, cycling through various test procedures to ensure that all features work as intended
14
Thanksgiving Break / 11/23/2015 / Time delegated for addressing any possible last-minute anomolies/setbacks encountered during previous weeks
15 / 11/30/2015 / Prepare for final presentation
16
Final Presentation / 12/7/2015 / Final Presentations
System Design
Subsystems Covered:
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- Power Switch & Key
- J1772 Inlet
- AC/DC Rectifier System
- Voltage Control System
- DC-DC Controller
- Current Limiter
- Output
- User Interface
- MicroController
- CAN Bus
- Emergency Systems
- Relays
- J1772 Shutoff
- Temperature Control
- Programing Interface
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