Rochester Institute of Technology
==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 17
AC-DC Rectification Subsystem 20
DC-DC Control Subsystem 22
Current Control Subsystem 24
Control and Logic System 25
CAN Communication Subsystem 26
Microcontroller 28
Prototype CAD Design 30
Estimated Bill of Materials 31
References 32
Multidisciplinary Senior Design
Project Readiness Package
|Project Title: |Electric Superbike Off-board Charger |
|Project Number: |P15261 |
|(MSD will assign this) | |
|Primary Customer: |EVT, Josh Jones, Wheeler Law, Derek Gutheil |
|(provide name, phone number, and | |
|email) | |
|Sponsor(s): |MSD Senior Design department |
|(provide name, phone number, email, | |
|and amount of support) | |
|Preferred Start Term: |Spring 2015 |
|Faculty Champion: |Prof. George Slack, gbseee@rit.edu |
|(provide name and email) | |
|Other Support: | |
|Project Guide: |Slack |
|(MSD will assign this) | |
| |January 2015 |
|EVT, Josh Jones, Derek Gutheil | |
|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 |Description |
|CR1 |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):
1. Power Requirements
a. 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
b. 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
c. The charging system must automatically detect and switch between the low and high power modes
2. Control Requirements
a. 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
b. The charger must be able to vary voltage and current through both software and a user interface
3. Communication Requirements
a. Needs to conform to the J-1772 communication protocol for use in high power mode
b. 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 Need |
|CR1 |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. |
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 |Comments |
|UnderVoltage 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. |
Benchmarking
|PARAMETERS | | | |
| |Required | |EVT |Energica Ego |
|Charge Rate | ................
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