Street LegalElectric Car Street Legal Electric Car by qcr20525

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									 Street Legal Electric Car

                   Brendan Krissansen
                       Carl Budd
                    Christophe L i
                    Ch i t h Lenoir
                    Warwick Coombe


          Supervisor: Johan Potgieter
          Co-supervisor: Chris Chitty
143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                    Introduction and Motivation
Electric vehicles are an alternative to combustion engine vehicles. They have
  h           i           d            ll          i        ll f i dl b h
cheaper running costs and are generally more environmentally friendly but there
are problems, making them a less viable alternative:
•   Heavy compared with combustion engine vehicles (battery weight)
•   Low range
•   Inefficient (energy to weight ratio)
•   Long charge time
•   Expensive to buy

•   NOT APPEALING




        MASSEY
      ENGINEERING        143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                    Introduction and Motivation
                          p           y        g                     p
We wish to tackle these problems by creating a market where these problems are not
limiting for the particular application. and a new design and technology to solve other
problems. Design solutions:
l   M k vehicle as light as possible
    Make hi l         li ht        ibl
l   Create the vehicle relatively inexpensively
l   Modify existing technologies
l   MAKE IT LOOK COOL




                     +                                                   =
        MASSEY
      ENGINEERING           143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                           Literature Review
Information sources used over the past 7 weeks
l   Who killed the electric car? (DVD)
l   Top gear Tesla review, Honda FCX Clarity review (TV episode)
l   FSAE rules (Racing documentation)
l           l d           ifi i       l i
    New Zealand car certification regulations
l   LiFeBATT sales presentation
l            g
    Green Stage lectures and forum
l   ATMEL patent application

Research on current electric cars:
l  EV1
l  Tesla Roadster
l  Honda FCX Clarity
l  Electric Saker GT
l  Converted MRS
l  Many more
        MASSEY
      ENGINEERING           143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                                       j
                                     Objectives
Our EV is defined by three major constraints to help give direction and focus to the
project. Prioritised in descending order:
•   Must be road legal
•   Must be certifiable for Formula Society of Automobile Engineers racing
•   Must be cool

Target Market:
•  U b li i
   Urban living
•  Total drive time less than 80 km per day
•  People concerned with the environment
•  People interested in reducing transport costs
•  1.5-1.95 m tall
•  50 120 kg weight
   50-120




       MASSEY
     ENGINEERING          143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                                     j
                                   Objectives

Personal objectives agreed on b th t
P      l bj ti           d                to b        titi      d t
                              by the team t be a competitive product:
•  Single seat
•  Battery powered
•  Electric motor driven
•  Detachable roof
•  >100 kph max speed
•  >80 km single charge range
•  M d t l
   Moderate luggage space
•  <700 kg vehicle weight
•   6
   <6 hr charge time (standard wall socket)




       MASSEY
     ENGINEERING        143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                          j           g
                       Project Planning

Because this is a large project, it is not expected to be a complete product by
the end of the year. However, we have set more realistic goals.
l    All design complete
l    Have a rolling chassis
l    Have all working electronic components

Project split into four parts:
Brendan Krissansen – Chassis design and testing
                                  g           g
Carl Budd - Motor and motor controller
Christophe Lenoir – Batteries and battery management
Warwick Coombe - Suspension, brakes, and drivetrains

Other parts to be completed by the whole group
    MASSEY
  ENGINEERING         143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                                           g
                              Resource Management
Raw materials
Aluminium tubing, chromoly tubing, aluminium plate, wiring and electronic components, glass fibres and
resin.

Parts (most likely second hand from Pick a Part)
Wheels, tyres               springs             fittings            fittings             fittings seat
Wheels tyres, shocks and springs, steering and fittings, gauges and fittings, pedals and fittings, seat, 5 point
harness, wheel bearing and fittings and brakes.
Parts prices subject to later design requirements

Special parts
Hub motors ,motor controller, batteries, battery management system, battery charger.
Motors and motor controllers planned to acquire from F&P for no cost and batteries hopefully cheap from
LiFe BATT

Human resources:
l                                         Potgieter,
   Wednesday morning meeting with Johan Potgieter 9am - 11am
l  Friday morning group meeting, 10am – 11am
l  5-8 extra hours per student per week
l                 p                p g
   Fabrication help from workshop engineers
l  Holiday time used for project
          MASSEY
        ENGINEERING                 143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                                                   Chassis
The car chassis is to be made from a solid frame in accordance to FSAE regulations. The frame will be entirely
made from aluminium and chromoly tubing with structural plates for attachments. The frame will be designed in
solidworks and tested in COSMOSWorks and COSMOSMotion. The frame will be totally dimension driven in
solidworks so that it can easily changed and retested.
The chassis must comply with regulations from both road and race rules and therefore needs:
l     Side impact
l     Front roll hoop
l     Main roll hoop
l              p
      Front impact attenuator
There is a slight possibility that we could even put batteries in the tubing to save space and give good weight
distribution!




          MASSEY
        ENGINEERING                143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                                Motors
l   Fisher and Paykel Smart Drive brushless DC motors
l   36 coils wired in a multiphase DC configuration
l   High      i           ll    di     di
    Hi h starting torque allows direct-drive
l   Mounted in pairs , one pair driving each wheel
l   Standard rotor rated at 1200RPM max
l   Integrated Hall-effect sensors
l   Efficient
l   Reliable
l   Mass-produced




        MASSEY
      ENGINEERING       143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                    Motor Controller
l   PWM control
l   Use standard controller for testing
l   Develop                  ll f fi l  d
    D l custom controller for final product
l   Incorporate regenerative braking
l   Input from driver controls
l   Feedback from motors, batteries
l   Electronic differential control




        MASSEY
      ENGINEERING      143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
                                        Batteries
Common batteries used in Electric Vehicles are:
l   Lead Acid – Very low energy to weight ratio.
l   Nickel Cadmium – Expensive to produce, but can handle high abuse.
l   Nickel Metal Hydrate – Lighter than the previous, but a high self discharge rate.
l   Lithium Manganese– Provides a good balance of Safety/Cost/Weight. Low
    powe .
    power.
l   Lithium Polymer – Cheaper to produce than Li-ion, more robust.
l   Li-ion Phosphate – High capacity,
    durability, but still quite expensive to
    produce. Can handle upwards of 2000
                        cycles
    charge/discharge cycles.




        MASSEY
      ENGINEERING         143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
       y     g       y              g g
 Battery Management Systems and Charging

A battery management system (BMS) is a device that manages the
  battery by monitoring its Voltage, Current, State of Charge, and
                                  ill l k f      h b
  temperature. A BMS system will look after the battery by b
  preventing it to function outside of its operating area.



Th charging unit will have to fit into the car, and provide a
The h i         it ill h   t      i t th          d     id
  reasonably quick charge from a standard wall socket, without
                batteries
  affecting the batteries.



      MASSEY
    ENGINEERING     143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009
               p      ,
            Suspension, brakes and drivetrain
l   We would like to implement a direct-wheel-drive system for our EV
l   The F&P motors chosen are very versatile and allow for a number of potential
    solutions:
        Motor-in-wheel (hub-drive)
        Shaft Drive
l   Our choice: shaft-drive
l       p           p       ,
    Independent suspension, double wish-bone
l   Disc brakes, possibly a motorbike setup




        MASSEY
      ENGINEERING         143.485 Engineering Project   Project Proposal Poster   Albany Campus, April 2009

								
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