Electric Snowmobile Team

Table of Contents

Team members

Starting point

Definition of problem

Solutions

System Overview

Key Components

Monitoring system

Charging System

Generator System

Design schedule

Budget

Thanks

Questions

Project Team

Students Members Faculty Advisor Lindsey ChironRoger Gauthier

Dr.Kraft

Parker McDonnell Michael Swanson

Patrick Hingston

Bryce Kelley

Starting Point

Building off Electric Snowmobile Built last year Comprised of 20KW electric motor

Motor mounted on solid aluminum frame

96V Battery Bank (eight 12V Lead Acid Batteries)

Batteries stored under seat compartment

Pulse Width Modulation Circuit controls transistor ON/OFF

IGBT (Insulated Gate Bipolar Transistor) controls armature current

Zero to max RPM motor control using PWM

Direct drive transmission requires no clutch

20KW electric motor 96v Battery Bank PWM CircuitZero To Max RPM

Definition of Problem

Current Issues

Lack of real time system monitoring

No user heads up display

Nonexistent charging system

No emergency backup power

Lack of safety features (GPS location, IGBT temperature monitoring, Battery State of Charge)

Lack of Headlights

Drive shaft held together with cotter pin

Weak drive shaft

Loud engine whine

Proposed Solutions

System To Be Implemented Sensors measuring system vitals

Monitoring System using CompactRIO

Integrated GPS unit

Smart Battery Charger

Emergency Generator system

User heads up display

HID headlights

Noise reduction materials

Hardened steel drive shaft/tightened drive chain

Compact RIO

Touch Panel

DC Motor

GPS Unit

Sensors 120V GeneratorCharging Circuit

Charging System

Compact RIO

Battery Bank

Generator

Touch Panel

DC Motor

PWM Circuit

Sensors

Diagram Legend

High Power

Output Signal

BidirectionalSignal

System Overview

CompactRIODevice Description

Donated by National Instruments

Small, rugged embedded control and data acquisition

Embedded real-time processor built into chassis (400MHz Freescale)

Powered by National Instruments Labview (Graphical programming language)

Hot-swappable industrial I/O modules with built in signal conditioning for direct connection to a variety of sensors and actuators

Extremely rugged, -40 to 70 °C (-40 to 158 °F) operating temperature

Up to 2,300Vrms isolation

50g Shock Rating

Dual 9 to 35 VDC supply input low power consumption (7 to 10W typical)

(7.07 X 3.47 X3.47 in.) and weighs 3.47 lb

HMI connection for interface with

touch panel module

UNIT PRICE$2500

Touch Panel Device Description

Donated by National Instruments

5.3’’ touch panel display

Max power Consumption of 20W

18-32 VDC power input

-20 to 70 °C (-4 to 158 °F) temperature operation

320 X 240 Pixels (256 Colors)

416 MHz Intel XScale processor running Windows CE

Ethernet connection for communication with

CompactRIO

UNIT PRICE$809

Generator

Device Description 2100 Watts of AC Power

125-cc, 4 Stroke air cooled engine (no need to mix oil/gas)

62dB at 7 meters (23 feet)

1.5 gallon fuel tank

2.5 hour runtime at full load

Pull start

22 x 20 x 11 inches

62 pounds

Economy mode reduces noise and fuel

consumption

UNIT PRICE$498

Beginnings of Charging System

Device Description

Step down transformer 120v to 14.5v (RMS) Full Wave rectifier Large capacitor reduces AC ripple Voltage comparator provides charging status ON/OFF switch LED lights show status of batteries Fuse protect batteries from over current Provides constant DC voltage to batteries

ESTIMATED PRICE+$300

20KW DC Motor

PWM Signal

Pulse Accumulator

Magnetic Pickup or Optical Encoder Pulses

Battery Monitor System Output

Analog PortEthernet Connection

NI Touch panel Module

Temperature Reading

Analog Port

Instantaneous Current and Voltage

NI Compact Rio

IGBT Thermistor

96v Battery Bank

Garmin GPS 18

GPS Position, heading, velocity serial data

Monitoring System

2KW Generator

Parts List

NI Compact Rio ($2500) NI touch panel ($809) Honeywell Magnetic Pickup Sensor ($10) Garmin 18 ($60) Thermocouple ($5) Headlights($10) Capacitors (Cheap) Resistors (Cheap) Relays ($50) Transistors (Cheap)

System MonitoringThe CompactRIO will be used to monitor a variety of the snowmobiles vitalsUsing analog I/O DAQ modules

Measurements

Motor current (Current) Motor RPM (frequency) PWM signal (Voltage vs time) Duty Cycle of PWM signal Distance Traveled Battery Level (Voltage) Global Position (Serial data) Generator Power output (voltage) Outside Temperature (thermocouple voltage) IGBT temperature level (thermistor voltage)

ESTIMATED TOTAL$150

Battery Monitoring

State of Charge

12 Volt battery

Volts per Cell

100% 12.7 2.12

90% 12.5 2.08

80% 12.42 2.07

70% 12.32 2.05

60% 12.20 2.03

50% 12.06 2.01

40% 11.9 1.98

30% 11.75 1.96

20% 11.58 1.93

10% 11.31 1.89

0 10.5 1.75

To determine the state of charge per battery we will be measuring the voltage across each batteries terminal

The voltage measured can be used to determine the percentage of charge present according to the figure

The NI CompactRIO analog I/O port willBe used to measure this voltage, determine the percent charge and display this information in a bar chart for the user to see

RPM and Other measurements

To measure the RPM of the DC motor a magnetic toothed gear will be mounted on the drive shaft. A Honeywell magnetic pickup sensor will generate a pulse each time the magnet passes by

These pulses will be sent back to the counter module of the CompactRIO

The frequency of these pulses will be determined and effectively RPM can be found using the relationship RPM = Fp

The other measurements to be taken will be comprised of voltages that can be easily measured with the analog DAQ module on the CompactRIO

CompactRIO

DC Motor

Sensor Voltages

Transformer

Battery Bank

Ripple Remover

FW Rectifier

Fuse

120V Outlet

Diagram Legend

High Voltage

Low VoltageHigh Current

Relay Circuitry

ChargingSystem

Charging System

The charging system will be used to recharge the snowmobiles batteries quickly and safely

Parts List

High powered relays ($50 a piece) Transformer ($30) Diodes (Cheap) Capacitors (Cheap) Resistors (Cheap) Green, Yellow, Red LEDs (Cheap) Operational Amplifiers (Cheap) Power Cables ($10) High Powered Switches ($10)

ESTIMATED TOTAL$300

Battery Bank

120V Generator Diagram Legend

High Voltage

High Current

GeneratorSystem

CompactRIO

Signal Voltage

Control Signal

DC Motor

Charging Circuit

Generator system

The generator system will be used toProvide emergency power to the batteries in the event of discharged batteries

Parts List

Honeywell 2100 Watt Generator ($498) Power Cables ($10) Welded shelf frame (Donated) Gasoline hopper ($20) High powered Relay ($50)

ESTIMATED TOTAL$580

With a few tweaks the generatorShould be able to directly interface with the input of the charging system

Design Schedule

Fall Semester

Design Schedule

Spring Semester

Item Price

NICompactRIO Donated ($2500)

Touch Panel Donated ($809)

Circuit components $150

LabVIEW Donated

Generator $580

Shelf for Generator Donated

Charging System $300

Total $1,030

Project Budget

Thank You

Dr. Gordon Kraft & Dr. Barbara Kraft

Lesley Yu of National Instruments

Stephen Doran, Luke Varitek, Bryce Kelley

Questions?