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Hybrid Electric Drive for the SAE Mini Baja Car

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									  Hybrid-Electric Drive for the SAE Mini-Baja Car

                                      Design Document
                                       Project Number: May05-13




                   Client: Iowa State University, Society of Automotive Engineers


                   Faculty Advisor: Dr. Venkataramana Ajjarapu


                   Team Members:
                       Daniel Robinson (Team Captain)                               ME
                       Jeremy Boon                                                  ME
                       Godwin Itteera                                               EE
                       Douglas Milewsky                                             CprE
                       Nicholas Olson                                               EE
                       Rajdeep Wadhwa                                               EE

DISCLAIMER: This document was developed as a part of the requirements of an electrical and computer
engineering course at Iowa State University, Ames, Iowa. This document does not constitute a professional
engineering design or a professional land surveying document. Although the information is intended to be accurate,
the associated students, faculty, and Iowa State University make no claims, promises, or guarantees about the
accuracy, completeness, quality, or adequacy of the information. The user of this document shall ensure that any
such use does not violate any laws with regard to professional licensing and certification requirements. This use
includes any work resulting from this student-prepared document that is required to be under the responsible charge
of a licensed engineer or surveyor. This document is copyrighted by the students who produced this document and
the associated faculty advisors. No part may be reproduced without the written permission of the senior design
course coordinator.

                                         Date: November 12, 2004
Table of Contents                                  Page Number

     List of Figures                                   ii
     List of Tables                                    iii
     List of Definitions                               iv


Introductory Material
     Executive Summary                                 01
     Acknowledgement                                   02
     Problem Statement                                 02
     Operating Environment                             03
     Intended Users and Intended Uses                  03
     Assumptions and Limitations                       03
     Expected End Product and Other Deliverables       04


Proposed Approach and Statement of Work
     Proposed Approach                                 04
     Detailed Design                                   07


Estimated Resources and Schedules
     Estimated Resource Requirement                    11
     Schedules                                         15


Closure Material
     Project Team Information                          17
     Closing Summery                                   18
     References                                        18




                                         -i-
List of Figures                                                Page Number

    Figure 1: Diagram of series set-up hybrid-electric drive       iv

    Figure 2: Diagram of detailed electric drive                   6

    Figure 3: Diagram of DC-DC converter                           6

    Figure 4: Original Gantt chart of schedule                     15

    Figure 5: Gantt chart of schedule                              16




                                           - ii -
List of Tables                                Page Number

Table 1: Original Group Schedule              12

Table 2: Group Schedule                       12

Table 3: Original Other Resources             13

Table 4: Other Resources                      13

Table 5: Original Financial Costs             13

Table 6: Financial Costs                      14




                                    - iii -
List of Definitions
Series Set-up- Configuration of a hybrid-electric car where the components are in a series
arrangement. A gas engine produces initial energy for the system which is converted to
electrical power through a generator. The electrical current is managed by a controller to drive
motors to power the wheels through a transmission.




              Figure 1: A diagram of the series setup of the electric motor and components




                                                 - iv -
Introductory Material
This is a brief summary of what this Design Document will cover.

Executive Summary

The collegiate Society of Automotive Engineers (SAE) Mini-Baja team at Iowa State University
(ISU) is seeking to develop innovative design components into their competition racecar. The
ISU SAE Mini-Baja team participates in an annual design competition against other collegiate
teams. Points are awarded based on design, cost, presentation, and performance. ISU SAE feels
that a design including a hybrid-electric drive would gain their team a competitive advantage.

The May05-13 senior design team is tasked to develop and produce the design and methods for
implementing such a drive into future ISU SAE Mini-Baja racecars. This is a two-phase project
split into two year-long segments. The first year represents the May05-13 team which will
design the concept, simulate possible solutions through computer software, and create working
drawings. Phase two will be composed of an entirely separate team who will build, test, and
retrofit the hybrid-electric drive into the ISU SAE racecar.

As of November 12, 2004, the May05-13 team has successfully completed a preliminary design
of the hybrid-electric drive for the ISU SAE racecar. The design involves using a Briggs and
Stratton motor, provided by SAE, to power a DC Generator which will generate electrical power.
This power is then input into a DC to DC Converter also known as a Buck Chopper which will
regulate the power that is sent to a DC motor which will then turn the wheels. The power sent to
the DC motor from the Buck Chopper will be controlled by the driver using a pedal. The pedal
will be connected to a potentiometer which will adjust the duty ratio of the Buck Chopper based
on the input from the pedal. Adjustment of the duty ratio of the Buck Chopper will result in
changes in the power provided to the DC motor resulting in the DC motor turning at a
differential speed.

Another aspect that the team is deeply involved in is finding a way to simulate the drive on
computers. The parts needed to fulfill the electric drive design are very expensive and cannot be
risked in any testing procedure. Due to this fact the team, after extensive research, came upon
the computer software known as SimPower, which can work with Matlab and Simulink to
simulate the electric drive design the team has developed. The team with the help of the faculty
advisor Dr. Ajjarapu has ordered SimPower through Iowa State University and is awaiting its
arrival. SimPower will allow the team to do extensive tests on the preliminary design and make
any necessary adjustments, without risking any equipment.

The team has also done extensive research to find exact specifications on the various pieces of
equipment found in the design of the electric drive that are available out in the market. The team
has contacted the New Generation Motors Corporation about a specific DC Generator
(MSF240140 Axial Flux, BLDC Motor) and specific DC motor (MSF215125 Axial Flux, BLDC
Motor). Zahn Incorporated sells an appropriate buck chopper that can be purchased. Using all
of these specifications, the materials necessary for design and building of the electric drive
without including labor will approximately be $22,300.


                                              -1-
Though the team has made a lot of progress there is much more to be accomplished. After the
arrival of the simulation software, SimPower, the team must proceed to simulate the developed
design under the many conditions that the racecar must handle, and then adjust the preliminary
design according to the results obtained and repeat the process until a satisfactory design is
found. Next the results should be used to find exact specifications on all of the components of
the electric drive system.

The last step is to use all of the data that is collected to develop a final design report for the
electric drive system. This report would include diagrams and schematics that will explain what
devices will be used for the electric drive system. Also, included would be instructions for the
SAE members on how to construct the system. Simulation and test results will be collected from
the many computer simulations that will be run, after the design has been finalized. This data
will be presented to the SAE members, providing evidence of the electric drive systems
capabilities. SAE members will know exactly what to expect from system once it is built.


Acknowledgement
The ISU SAE Mini-Baja team will cover all costs outside of costs associated with the EE/CprE
491/492 class requirements (poster, report binding and printing etc.). Other costs will be covered
by sponsorships obtained by the Mini-Baja team specifically aimed at the electric drive system.

Ethan Slattery will be providing assistance in the form of technical advice, and assistance in
accessing any SAE products or workshop facilities.


Problem Statement
The Iowa State University Society of Automotive Engineers (ISU SAE) Mini-Baja team requests
the design of a hybrid-electric drive for their Baja racecar. Design and implementation of project
will occur over a two-year period. Phase I, the design stage, is planned for the 2004-2005
academic year. Phase II, the implementation and testing stage, is planned for the 2005-2006
academic year. The senior design group will work as an independent entity from ISU SAE. Yet
it is intended that close ties remain between the groups. The senior design group will have full
access to ISU SAE shop facilities, previous designs, and working drawings. Any information
provided by SAE remains property of ISU SAE.

The hybrid-electric drive system is to be powered by a 10 HP Briggs and Stratton engine. The
senior design team will design a system to drive one or two electric motors that will in turn drive
the car. The senior design team will also design controls for the system as well as a power
generation system to be run by the Briggs and Stratton engine as previously stated. The senior
design team will need to conform to all rules set forth by the SAE Mini-Baja Collegiate Design
Series.




                                               -2-
Operating Environment
The hybrid-electric drive will be integrated into the design of a Baja race car. The car will be
subjected to many extreme conditions including dust, dirt, mud, water, potentially high
temperatures (>200°F), grease/oil (lubricant), high torque, shock loading, high stress loading,
and potential collision with solid object, i.e. rocks. All components must be designed to
withstand impact and shock loading from rough terrain. Critical components such as gear
housing and electronics must be sealed from contaminants. Adequate cooling must be supplied
to the electric motor yet the motor must also be protected from dust and water. Mechanical
components must be designed for high cycle life. Electrical equipment must be protected from
over currents and/or voltages that may result in electrical shock. Safety of the driver is critical.
All components must integrate with the car so that no hazard, i.e. electrical shock, fire,
mechanical failure threaten the safety of the driver or bystanders.


Intended Users
The design team’s electric drive is intended for the Mini-Baja team. The main user of this drive
will be the individual who is driving the vehicle at the time. The design team will give an
overview of this design to the whole Baja team. This is so each individual who directly works
on the vehicle will know how the drive works and functions in case there is a problem. In this
case, the Baja team should understand the available trouble shooting methods.


Intended Use
The use of this drive is intended for the Mini-Baja car and will be designed specifically for this
vehicle. By using the drive, the Mini-Baja team hopes to improve the performance of some
aspects of the car. The car is used in a nationwide test to see how well each vehicle is designed
and performs. The drive will be powered by the already existing Briggs and Stratton motor. It
will then deliver power to the wheels through some control.


Assumptions
Simplifications to aid design include:
    Constant electrical output from generator
    Constant power from gasoline engine running at a peak 3800 rpm
    Addition of hybrid-electric components does not affect center of gravity
    All power for electronics will be available from Baja car battery


Limitations
Rules, restrictions, and constraints related to the design include:
    Design must adhere to all rules defined by SAE Mini-Baja Collegiate Design Series
    No initial stored energy to power wheels.
    Weight considerations (Max weight limited by SAE rules)
    Size constraints from SAE


                                               -3-
      Power available from 10hp Briggs and Stratton engine
      Wet and dry conditions
      Design to meet original performance of original car


Expected End Product and Other Deliverables
 The next couple of sections describe the expectations of the senior design team.

Expected End Product (Delivery date: 5/5/2005):
The expected end product is a design for a system to drive the Mini-Baja car with electric motor.
In the end the design team would like to have a completed final design report for an electric drive
system that would drive the Mini-Baja car. This report would include diagrams and schematics
that will explain what devices will be used for the electric drive system. Also, included would be
instructions for SAE on how to construct the system. Simulation and test results will be included
with this report so SAE will know exactly what to expect from system once it is built.


Other Deliverables:

Simulation Results (Delivery date: 5/5/2005):
The simulation results will contain the data that will be collected from the many computer
simulations that will be run, after the design has been finalized. This data will be presented to
the SAE members, providing evidence of the electric drive systems capabilities.


Proposed Approach
Below is a list of the approach this design team will be taking to solve our problem.

   1. Design Objective
     The objectives the design team must abide to throughout the design include:
       The Baja car must attain a maximum speed of at least 30 miles/hr
       Wheels must be solely powered by electric motor
       Must be able to withstand outside weather
       Must comply with SAE rules

   2. Functional Requirements
     List of functional requirements.
          Vehicle must be drivable
          Driver will not be harmed
          Speed must be controllable by driver
          Wheels must only be powered by electric motor




                                               -4-
3. Constraints considerations
  Physical limits and requirements.
      Size: due to the min-Baja being a small vehicle
      Weight: rules outlined by SAE
      Power: 10HP engine to work max

4. Technology
  Technology utilized for design include:
      Motor (DC)
          The design team will be making use of a 144 V Dc motor because it was the
          lightest and most efficient motor in the design team’s price range.
          Advantages:
                  The motor weighs 22.2 kg and is relatively cheaper ($6000) than the other
                  motors that are available in the market. The motor is brushless, which
                  means it will have a longer lifespan than a motor with brushes.
          Disadvantages:
                  This motor was not the lightest or the most efficient motor on the market.
      Generators (DC,AC)
          The design team chose to use a DC generator so the speed of the system would be
          easier to control through the use of a buck chopper.
          Advantages:
                  The output is DC voltage, which is what the buck chopper uses.
          Disadvantages (AC):
                  Since the output is AC voltage it would need be converted to DC in order
                  for the electric motor to use it.
      Control systems
          The decision was made to use a potentiometer to control the output voltage of the
          buck chopper, which in turn controls the speed of the electric motor.
          Advantages:
                  The potentiometer is easier and cheaper than using a microcontroller.
          Disadvantages:
                  This is a less accurate but acceptable way to control the speed.
      Batteries
          Due to SAE rules the initial thought of storing any excess energy from the
          generator was ruled out.
          Advantages:
                  The design team could use the excess energy to power other electrical
                  components.
          Disadvantages:
                  It would be against the rules.
      Rectifiers
          This option was also ruled out because the design will not be using an AC
          generator (alternator). Therefore, there were no AC voltages to be converted to
          DC voltage.
          Advantages:


                                            -5-
                  It would be an easy way to convert AC voltage to DC.
          Disadvantages:
                  This would be an extra part of the design to test, simulate and buy.
      Buck-choppers
          The design team decided to use this item because it was an efficient was to
          control the voltages to the DC motor.
          Advantages:
                  It is easy to control the output voltages. The price is reasonable.
          Disadvantages:
                  This option may only decrease voltage and cannot increase it.

5. Technical approach
  Technical considerations for design team include:
    Simulations
          Simulations would be on a computer. It is an easy way to approximate the total
          design without ever buying or building one thing. For this project SimPower is
          being considered.
          Advantages:
                   Ensure compatibility of components with each other.
                   Ensure total design will operate near specifications.
          Disadvantages:
                   Must approximate values of components.
                   Real world might have factors not in simulation.
    Computer models
          These models help to visualize the actual components and how they fit together in
          real life. Currently these are not being considered do to the resources required
          and the lack of benefit they will provide since the Baja team says they can build
          the vehicle around the new power system.
          Advantages:
                   Ensure design will fit together properly in vehicle.
          Disadvantages:
                   Time and resources needed to produce these models.
    Mechanical blueprints
          These are a good way to organize the design of the vehicle. They also help to
          keep record for future work.
          Advantages:
                   Clear diagram of functionality.
                   Allows easier future work on vehicle.
          Disadvantages:
                   Requires time to produce blueprints.
    Electrical schematics
          These are a good way to organize the design of the electrical system. They also
          help to keep record for future work.
          Advantages:
                   Clear diagram of functionality.
                   Allows easier future work on electrical system.


                                         -6-
                 Disadvantages:
                       Requires time to produce schematics.

   6. Testing requirements
     List of two items considered on the testing level include:
        Simulation of controller and motor response by means of SimPower software
        Quarter-scale mock-up

   7. Recommendations for continuation or modification
     At this point the design team recommends that the project be continued because the design
   and later implementation is feasible.



Detailed Design
                                                                   Driver


                                                                  Gas pedal


            Throttle
            lever                                              Potentiometer
                                                               (controls duty ratio
                                                               of chopper)


                                         Overload               Buck chopper
        10 Hp engine     DC                                                                   DC motor
                                         circuit – for          (DC-DC
        provided         generator                                                                         Wheels
                                         safety                 converter)



                                                               Voltage and/or
                                                               current meters                            Speedometer



                                                                                      Output for
                                                                                      testing/
                                                                                      operation



              Figure 2: The diagram above displays a detailed look at the electric drive design

The basis for this design was the series setup shown in Figure 1. The design was modified to
meet the specific requirements of the team. For simplicity, the generator was changed from an
AC source to a DC generator. This takes out the need for the rectifier unit. The controls box
from Figure 1 is basically the buck chopper block along with controls for that buck chopper. The
test points are also shown in Figure 2 whereas Figure 1 does not include them. The last change
is that there will also not be any transmission as Figure 1 shows. The also simplifies the total
design. Overall, this is the basic series setup with a few changes for this project’s specifications
and to simplify the design.




                                                         -7-
This diagram shows the flow of power from the 10Hp Engine to the wheels and how this power
is controlled by the user. Basically, the mechanical energy from the engine is turned into
electrical power which is sent to the DC motor. Before it gets to the motor, it goes through a
converter that lowers the voltage proportionally to the driver’s gas pedal. This electric energy
that makes it to the DC motor is then turned back into mechanical energy and drives the wheels.
The only other part of the diagram includes a few testing points to ensure proper operation


Component Specification

Engine:

The mechanical motor that is being used is the Briggs and Stratton 10 horsepower motor. This
motor is a must as far as SAE rules are concerned. This motor is the main driving force for the
system and has a maximum speed of 3800 rpm. As seen in the diagram above the motor will be
connected to a generator to create the output voltage required to run the electric drive. This
motor is provided by the Baja team and no cost will be applied to the design team for its use.

Generator:

The second stage in the system is the MSF240140 Axial flux, BLDC generator. This generator
is basically like another motor except that it is attached backwards to the Briggs and Stratton.
This generator will supply a continuous output power of 6800 to 7500 Watts, which is 42.5 VDC
to 60 VDC, to the buck chopper. This generator will be obtained from New Generation Motor
Corp. and costs approximately $10000.

Throttle lever:

The throttle lever is just as it sounds, it is a lever used by the driver to increase the throttle (rpm)
of the Briggs and Stratton engine. For the system the design team will be designing the throttle
lever will be in the fully opened so the Briggs and Stratton engine produces at peak performance.

DC motor:

The electric motor is the force that is directly driving the wheels. As the diagram shows the
setup for the electric motor does not involve a transmission. This is because this motor functions
as an “electric transmission”. This means a multi-speed gear box is not needed and the motor
can be directly connected to the wheels with a fixed ratio. The DC motor gets a DC voltage
input from the buck chopper, then based on how much voltage is provided turns at a certain rpm.
The rpm for this DC motor is a nominal speed of 2200 rpm. Along with the rpm is the important
torque, which goes up to a maximum of 49 Nm. The DC motor will be obtained from New
Generation Motor Corp. and costs roughly $8000.




                                                 -8-
Gas pedal:

The gas pedal is a must due to SAE rules and is the drivers control for the speed of the vehicle.
The pedal will be attached to a potentiometer, which in turn controls the buck choppers output.

Voltage/current meter:

This will be used for trouble shooting purposes. In case something goes wrong with the
performance of the system, the Baja team would put the voltage/current meter in the specified
locations to test the voltage/current levels. This meter can be purchased from multiple places but
must be a high voltage/current device as the voltages can get up in the range of 150 volts. For
such a device the cost would be in the range of $300 to $400.

Speedometer:

A standard speedometer, based on wheel speed, will be used to compare for testing. This test
will basically compare the speed the car is traveling at to the voltage supplied to the motor. This
can then be used to compare actual results to the estimated results. A speedometer runs about
$100.

DC-DC converter:

A DC-DC converter accepts a DC input voltage and produces a DC output voltage which is
typically at a different voltage level than the input. The design team made use of a buck chopper
which is a step down DC-DC converter. The Buck chopper allows the design team to control the
voltage being provided to the dc motor and thus by altering the duty ratio of the buck chopper the
speed of the motor can be controlled. The buck chopper would have an input voltage of about 48
Vdc and an output voltage range of 0 to 48 Vdc. The step down dc-dc converter which is
planned on being used in this system would cost between $2500 and $3500. The design team
still has to decide as to what control interface that will be used for the system. A wiring diagram
of the top choice for converters right now is:




                                               -9-
         Figure 3: A diagram of a dc-dc buck chopper from http://www.zahninc.com/0010.html



Estimated Resources and Schedules
   The project would proceed while keeping the following requirements in mind:

Personnel effort requirements:
   As shown in Table 1, group members Daniel Robinson and Jeremy Boon will work an
   estimated 87 and 85 hours respectively. These hours are about half as much as the other
   members because they will only be working with the project for one semester instead of a
   full year. Group members Godwin Itteera, Doug Milewsky, Nicholas Olson, and Rajdeep
   Wadhwa will work an estimated 162, 169, 164 and 166 hours for the academic year.

Other resource requirements:
   The team will have access to the SAE shop (free of charge) if needed. The team will be
   making use of Simpower for simulating the hybrid drive.

Financial requirements:
   As shown in Table 3, the estimated total cost of the project, including student labor is
   $8746.50




                                              - 10 -
Personnel effort requirements
The project is divided into 8 different tasks:

Task 1 – Project Plan
   Plan Project                            9/6/2004-9/17/2004       12 days
   Revise Project                          9/20/2004-10/5/2004      11 days

Task 2 – Paper Work
   Weekly Reports Every Week
   Unbound Design Report                   10/18/2004- 11/9/2004    18 days
   Status Report                           10/18/2004-11/9/2004     18 days
   Revised Design Report                   11/15/2004 -12/15/2004   22 days

Task 3 – Component selection
   Research                                9/6/2004-10/4/2004       20 days
   Set specification                       9/27/2004-10/8/2004      10 days
   Select Components                       10/25/2004-2/18/2005     65 days

Task 4 – Map power and efficiency thru drive
   Block diagram                 9/27/2004-10/8/2004                10 days
   Mathematical Diagram          10/4/2004-10/15/2004               10 days

Task 5 – Circuit diagram
   Research                                9/6/2004-10/4/2004       20 days
   Define system                           9/27/2004-10/8/2004      10 days
   Design                                  10/25/2004-3/04/2005     85 days
   Error check and Compatibility           1/24/2005-3/04/2005      35 days

Task 6 – Control System
   Research                                9/6/2004-10/4/2004       20 days
   Design Control system                   9/27/2004-10/22/2004     20 days

Task 7 – Simulation
   Develop model                           10/18/2004-11/5/2004     15 days
   Test specifications                     1/24/2005-3/4/2005       35 days

Task 8 – Design poster
   Design poster                           11/15/2004-12/15/2004    18 days




                                                 - 11 -
Table 1: Original Group Schedule. Breakdown of hours by team-member by task

     Group       Task Task Task Task Task Task Task Task Task
                                                              Total
     member       1    2    3    4    5    6    7    8    9
     Godwin
     Itteera      10      20     40      0     40      20     0       5       20    155
     Doug
    Milewsky      10      20     20      0      0       0    104      5        0    159
      Nick
      Olson       11      20      0      0     100      0     0       5       20    156
     Jeremy
      Boon         9      20      0     25      0       0     0       5       25    84
     Daniel
    Robinson      20      20      0     20      0       0     0       5       20    85
    Rajdeep
    Wadhwa        14      11      0      0     40       0     68      5       20    158

    Total Hrs     66     111     60     45     180     20    172     30       105   797

Table 2: Group Schedule. Breakdown of hours by team-member by task
     Group       Task Task Task Task Task Task Task Task
                                                         Total
     member       1    2    3    4    5    6    7    8
     Godwin
     Itteera      10      28     25      0     40      34     20      5       162
     Doug
    Milewsky      10      20     36      0      0      33     65      5       169
      Nick
      Olson       11      20     24      0     42      32     30      5       164
     Jeremy
      Boon         9      20     26     25      0       0     0       5       85
     Daniel
    Robinson      20      20     22     20      0       0     0       5       87
    Rajdeep
    Wadhwa        14      13     22      0      0      35     77      5       166

    Total Hrs     74     121    155     45     82      134   192     30       833


As shown in Figure 2, there are several tasks designated throughout the year. This chart shows
which activities overlap and which activities must be completed before the start of another
activity. It is a visual representation of the necessary order of work.



                                              - 12 -
Other resource requirements
    Upon completion of the design phase, the design team will be required to do some
    simulation/testing of the electric drive. Some simulation would also be required during the
    design phase itself. The power lab, as indicated in Table 2, which is a part of the electrical
    engineering department, has 3 hp motors that could be used for simulation and testing
    purposes. The Baja team is also willing to let the senior design team use their shop facilities.


Table 3: Original Other Resources. This table shows other resources that will be utilized
                 Item                 Team hours               Other hours                  Cost
                Poster                    12                        0                       $50
               Power lab                  40                        0                        0
               Baja Shop                  35                        0                        0
                Totals                    87                        0                       $50

Table 4: Other Resources. This table shows other resources that will be utilized
                 Item                 Team hours               Other hours                  Cost
                Poster                    12                        0                       $50
               Power lab                 130                        0                        0
               Baja Shop                  35                        0                        0
                Totals                   177                        0                       $50


Financial Requirements
    The financial budget has been presented in Table 3. The SAE Mini Baja team is funding a
    major part of the project. The costs for the poster will be taken care of by the student design
    team. The design team’s advisor, Dr. Ajjarapu will be providing some reference materials.
    If any other reference material is required, the group members would pay for it and could
    keep it.

Table 5: Original Costs. The table shows all costs of the project by parts, material, and labor
                                 Item                     W/o labor       With labor
                             Parts and Materials
                                            Poster             $50           $50
                                    Motors ( two)             $418          $418
                        Briggs and Stratton engine           Donated       Donated
                                     Rectifier unit            $40           $40
                                        Alternator             $25           $25
                                             Subtotal         $533           $533

                              Labor at & 10.50/hr
                                   Godwin Itteera                          $1627.50
                                  Doug Milewsky                            $1669.50
                                       Nick Olson                          $1638.00
                                     Jeremy Boon                            $882.00


                                                    - 13 -
                                   Daniel Robinson                          $808.00
                                   RajdeepWadhwa                           $1659.00
                                           Subtotal                        $8284.00
                                              Totals          $533        $8817.00
Table 6: Costs. The table shows all costs of the project by parts, material, and labor
                                 Item                     W/o labor       With labor
                             Parts and Materials
                                            Poster              $50            $50
                                         Generator           $10000         $10000
                                            Motor             $8000          $8000
                        Briggs and Stratton engine           Donated        Donated
                           DC-DC Buck Chopper                 $3500          $3500
                               Testing Equipment               $500           $500
                                             Misc.             $250           $250
                                          Subtotal           $22300         $22300

                              Labor at & 10.50/hr
                                   Godwin Itteera                          $1701.00
                                  Doug Milewsky                            $1774.50
                                       Nick Olson                          $1722.00
                                     Jeremy Boon                            $892.50
                                 Daniel Robinson                            $913.50
                                 RajdeepWadhwa                             $1743.00
                                         Subtotal                          $8746.50
                                              Totals         $22300      $31046.50




                                                    - 14 -
                                            Schedules




Figure 4: Original Gantt Chart. The chart above shows the necessary order of operation graphically



                                              - 15 -
Figure 5: Gantt Chart. The chart above shows the necessary order of operation graphically




                                         - 16 -
Project Team Information

                                  Team members:
Acting client:
                                  Daniel Robinson (Team Captain)
Ethan Slattery                    Mechanical Engineering
Project Manager 2004-2005         151 University Village, Apt C
ISU SAE Mini-Baja                 Ames, IA 50010
1306 Iowa Cir                     Cell: (515) 460-1819
Ames, IA 50014                    drobins@iastate.edu
Cell: (641) 821-0202
ejslap@iastate.edu                Jeremy Boon
                                  Mechanical Engineering
                                  2820 Lincoln Way #2
                                  Ames, IA 50014
                                  Cell: (515) 291-3220
                                  jerboon@iastate.edu

                                  Godwin Itteera
Faculty advisor:                  Electrical Engineering
                                  4290 Birch Lange
Dr. Venkataramana Ajjarapu        Ames, IA 50013
Office: 1122 Coover               Home: (515) 572-3559
Ames, IA 50011                    gitteera@iastate.edu
Home: 2704 Valley View Rd
Ames, IA 50014                    Douglas Milewsky
Office: (515) 294-7687            Computer Engineering
Home: (515) 292-3887              3218 Lincoln Way
Fax: (515) 294-4263               Ames, IA 50014
vajjarap@iastate.edu              Home: (515) 268-1569
                                  dmilewsk@iastate.edu

                                  Nicholas Olson
                                  Electrical Engineering
                                  4138 Fredericksen Ct
                                  Ames, IA 50010
                                  Home: (515) 572-7880
                                  nolson1@iastate.edu

                                  Rajdeep Wadhwa
                                  Electrical Engineering
                                  4112 Lincoln Swing #216
                                  Ames, IA 50014
                                  Home: (515) 441-0284
                                  rajdeep@iastate.edu


                             - 17 -
Closing Summary
The challenge of this project is to determine a way to design an electric drive using a supplied 10
hp Briggs and Stratton motor. It must be determined how the drive will be tested and how it will
be setup.

Many different requirements and considerations will have to be looked at to make sure the
design is feasible, functional, within SAE rules, safe and has not infringed on any patents or
intellectual property.

The expected solution would be a full design of how the electric drive will be implemented into
the Baja car’s existing setup. This design should include a list of all the components needed and
documentation of where these components came from and why they are needed.


References
http://www.public.iastate.edu/~isusae/Baja/




                                              - 18 -

								
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