Calibration - Lafayette College



GLV Maintenance ManualECE 492 - Spring 2019Latest Revision: 5/10/2019Prepared by: Maxwell McFarlaneAbstractThis document is intended to satisfy GPR001 of the LFEV-2019 Statement of Work as a maintenance manual for the GLV system as it is implemented in the DYNO integration phase of the formula electric vehicle project.Table of Contents TOC \h \u \z Executive Summary PAGEREF _Toc6502463 \h 3Charging the GLV Battery PAGEREF _Toc6502464 \h 3Calibration PAGEREF _Toc6502465 \h 3Principal of Operation PAGEREF _Toc6502466 \h 4Safety Loop 1 PAGEREF _Toc6502467 \h 4Safety Loop 2 PAGEREF _Toc6502468 \h 4Car Operation – Starting GLV PAGEREF _Toc6502469 \h 4Car Operation – Operator Cutting Power PAGEREF _Toc6502470 \h 5Car Operation - Resetting the Safety Loop PAGEREF _Toc6502471 \h 5GLV Break Out Board (BOB) PCB Operation PAGEREF _Toc6502472 \h 5Block Diagrams PAGEREF _Toc6502473 \h 6GLV Systems Block Diagram PAGEREF _Toc6502474 \h 6 PAGEREF _Toc6502475 \h 6GLV BOB Block Diagram PAGEREF _Toc6502476 \h 7 PAGEREF _Toc6502477 \h 7Safety Loop Diagram PAGEREF _Toc6502478 \h 0Schematics/Layouts PAGEREF _Toc6502479 \h 1GLV BOB rev.4.2 Schematic (L19_GLV_07) PAGEREF _Toc6502480 \h 1GLV BOB rev.4.2 PCB Layout (L19_GLV_07) PAGEREF _Toc6502481 \h 2Mechanical Drawings PAGEREF _Toc6502482 \h 3L19_GLV_01 (8U Rack Panel) PAGEREF _Toc6502483 \h 3L19_GLV_02 (Top Panel) PAGEREF _Toc6502484 \h 4L19_GLV_03 (SCADA_Screen_MountBrackets) PAGEREF _Toc6502485 \h 6L19_GLV_04 (Cockpit Panel) PAGEREF _Toc6502486 \h 7L19_GLV_05 (Right Side Panel) PAGEREF _Toc6502487 \h 8L19_GLV_06 (Left Side Panel) PAGEREF _Toc6502488 \h 9Interconnectivity Diagram PAGEREF _Toc6502489 \h 10Bill of Materials PAGEREF _Toc6502490 \h 11GLV BOB BOM (L19_GLV_07) PAGEREF _Toc6502491 \h 11GLV Enclosure BOM ( L19_GLV_01, L19_GLV_02, L19_GLV_03) PAGEREF _Toc6502492 \h 14GLV COCKPIT & SIDE PANELS BOM (L19_GLV_04, L19_GLV_05, L19_GLV_06) PAGEREF _Toc6502493 \h 17Quality Assurance Testing Results PAGEREF _Toc6502494 \h 18Errata PAGEREF _Toc6502495 \h 26L19_GLV_07 PAGEREF _Toc6502496 \h 26L19_GLV_02 PAGEREF _Toc6502497 \h 26Appendix A: PAGEREF _Toc6502498 \h 27Acknowledgments PAGEREF _Toc6502499 \h 32Disclaimer PAGEREF _Toc6502500 \h 32Executive SummaryBecause the GLV system is implemented without software, maintenance of the system generally involves ensuring the wiring is correct throughout the system (see Interconnectivity Diagram). It is also important to ensure that the chips on the GLV PCB are functioning properly (see Quality Assurance Testing Results). The mechanical components of the GLV system do not require regular maintenance. Charging the GLV BatteryThe GLV Battery must be charged for proper operation of the GLV system. The GLV battery can be charged using a PST-G100-24F8 charger. This charger charges the 24V battery at 1.5A, and it includes a plug and forget algorithm which allows it to be plugged in without the possibility of overcharging the battery. The charger has lights which indicate when the battery has finished charging.CalibrationThe chips on the GLV PCB are calibrated using specific resistors and capacitors. Resistors are clearly labeled in the PCB Schematic.Two 2.2K? resistors (R7 and R8) used for current limiting into the opto-isolator. There is a 120? terminating resistor (R6) between the positive and negative CAN lines. Two 20k? pull-up resistors (R4 and R5) are used as pull-up resistors for I2C. Current limiting resistors are sized at 1k? (R9 and R10). All caps on the board are .1uF decoupling caps.There is a 15A circuit breaker between the GLV battery and the GLV system and a 10A circuit breaker between the GLV system power and other subsystems (These circuit breakers were analyzed and designed to satisfy EV6.1. The GLV battery circuit breaker was sized by the peak total current draw from the GLV system (around 15A). The subsystem circuit breaker was sized by the total current draw of the GLV system without including the safety loop peak current draw (around 7A). Refer to the Appendix: GLV Power Analysis for more information. Current and Power SensingThe ina226 chip on the GLV BOB is used for measuring current and power in the GLV system. There are several steps in order to calibrate this sensor. There is a calibration register that needs to be set. Its value is found using the following equations:CAL=0.00512CurrentLSB*RshuntCurrentLSB= Maximum Expected Current215The CAL value from equation (1) is the value programmed to the calibration register in the ina226 chip. A 0.01? resistor (R3) is used as a shunt resistor. When testing on board, this resistance was found to be 0.02?, so when calibrating the ina226 chip, specify a shunt resistance of 0.02?. Maximum Expected Current in equation (2) is measured in amperes. After calculating these, the current and power are found from the following equations:Current= ShuntVoltage*CAL2048Power= Current*BusVoltage20000The ShuntVoltage is measured by the chip and found in the shunt voltage register. The BusVoltage is also measured by the chip and should be the same voltage provided by the GLV system.Temperature SensingThe AD5593R chip is used for temperature sensing. Its temperature coefficient is found to be 20 ppm/°C. The following equation is used to calibrate the AD5593R temperature data.Temperature °C=25+ADC Code-0.5Vref* 4095(2.654 * (2.5/Vref))ADC Code is the 12-bit value read by the sensor and Vref is 2.5V according to the GLV BOB setup. All calibration was designed to satisfy D004.Principal of OperationThe GLV system provides 24V DC, in accordance with Article EV1.2 of the FSAE 2019 competition rules, to power all low voltage electrical systems as well as the four AIRs on the two TSV battery packs. The GLV system includes a safety loop which was designed in accordance with the Formula Hybrid Rules. The safety loop was I/O integrated in the dyno room on two rack mount panels. The safety loop is implemented on a PCB which interfaces with the safety loop I/O and provides GLV battery data to VSCADA.The safety loop is designed in order to satisfy the shutdown circuit specified in EV7.1 of the FSAE 2019 competition rules.Safety Loop 1The safety loop is composed of two loops. Safety loop 1 runs through the a circuit breaker, the GLV master switch, then the right E-stop, then the left E-stop before providing power to the car subsystems. It then passes through the Insulation Monitoring Device (IMD), and Accumulator Management System (AMS) relays (this is designed to satisfy EV7.2 - EV7.9 of the FSAE 2019 competition rules). When power is provided to the car subsystems, the GLV LED on the cockpit panel will turn on.Safety Loop 2Safety loop 2 is only powered when a jumper is placed between itself and the end of Safety loop 1 (this is designed to satisfy EV2.11.3 of the FSAE 2019 competition rules). This loop then passes back through the IMD to the Brake Over-Travel switch (this is designed to satisfy EVT7.3 of the FSAE 2019 competition rules). Once the Brake Over-travel switch closes, the SCADA relay receives power. This relay, when closed by the SCADA, will then route power to the Master Reset (This relay can be programmed to be normally-open or normally-closed depending on the jumper in J4). Once the Master Reset receives power the Fault Led will turn off (this is designed to satisfy EV9.4). Once the Master Reset is pressed, both of the Safety System OK(SSOK) Lamps should turn on as well as the Safe light in the cockpit (this is designed to satisfy EV9.3). Only once the Cockpit BRB is closed and the Cockpit Reset Button has been pressed will the Tractive System Voltage (TSV) Master Switch receive power. When the TSV Master Switch (TSVMS) is closed, the AIRS will receive power. The AIRS+ Led in the cockpit and the Tractive System Active Light (TSAL) fwill then illuminate (this is designed to satisfy EV9.1).Car Operation – Starting GLVThe GLV system requires an operator on the outside of the car to turn the master switches and press Master Reset before the car can start. The driver is required to press the cockpit reset after the Master Reset is pressed to start the car. This will energize the AIRs if there are no safety loop faults in the GLV powered subsystems. Car Operation – Operator Cutting PowerThe GLV safety loop allows an operator on the outside of the car to turn off the GLV system entirely or turn off power to the AIRs using the exterior E-stops and master switches. The Driver only has access to the driver E-stop so that the driver can turn off the AIRs if needed, but the driver cannot cut power to the entire GLV system or power down subsystems.There are several relays in the GLV which can trip the safety loop. The SCADA relay and the AMS relays are all controlled by on-board processors which will trip the loop if certain thresholds are passed (this was designed to satisfy EV2.11.2). The IMD will also open the safety loop if there is an insulation fault between high voltage and ground.Car Operation - Resetting the Safety LoopIf an external device trips the safety loop, it must be reset using both the Master reset button and the Cockpit reset button. However, in the case that the driver decides to disable power from the AIRS using the Cockpit E-stop, then the driver can reset power to the AIRS by just pressing the Cockpit reset.GLV Break Out Board (BOB) PCB OperationThe BOB encompasses most of the routing for the safety loop, and it provides data to the Raspberry Pi (VSCADA) through CAN, and I2C. CAN is routed to VSCADA through the GLV PCB so that TSV, Cooling, and TSI can relay information to VSCADA. On board chips communicate through I2C to relay the voltage and current of the GLV battery as well as the temperature of the PCB to VSCADA. Each of these values will be displayed on the VSCADA screen. The Raspberry Pi receives power from a 24V to 5V DC/DC converter. There is a relay on the BOB which allows VSCADA to trip the safety loop. There are additional relays allowing the GLV system to trip the safety loop. All items are produced according to GPR005 in the 2019 Statement of Work.Block DiagramsGLV Systems Block DiagramFigure SEQ Figure \* ARABIC 1 GLV Higher-level System Block DiagramGLV BOB Block DiagramFigure SEQ Figure \* ARABIC 2 GLV Break out Board Block DiagramSafety Loop DiagramFigure SEQ Figure \* ARABIC 3 GLV Safety Loop Block DiagramSchematics/LayoutsGLV BOB rev.4.2 Schematic (L19_GLV_07)Figure SEQ Figure \* ARABIC 4 GLV BoB rev.4.2 PCB SchematicGLV BOB rev.4.2 PCB Layout (L19_GLV_07)Figure SEQ Figure \* ARABIC 5 GLV BOB rev4.2 PCB LayoutMechanical DrawingsL19_GLV_01 (8U Rack Panel)Figure SEQ Figure \* ARABIC 6 8U Rack Panel detailed mechanical drawingL19_GLV_02 (Top Panel)Figure SEQ Figure \* ARABIC 7 GLV DYNO assemblyFigure SEQ Figure \* ARABIC 8 GLV detailed mechanical drawingL19_GLV_03 (SCADA_Screen_MountBrackets)Figure SEQ Figure \* ARABIC 9 Scada Mounting Brackets detailed mechanical drawingL19_GLV_04 (Cockpit Panel)Figure SEQ Figure \* ARABIC 10 Cockpit Panel detailed mechanical drawingL19_GLV_05 (Right Side Panel)Figure SEQ Figure \* ARABIC 11 Right side panel detailed mechanical drawingL19_GLV_06 (Left Side Panel)Figure SEQ Figure \* ARABIC 12 Left side panel detailed mechanical drawingInterconnectivity DiagramFigure SEQ Figure \* ARABIC 13 Wiring diagram for the GLV systemBill of MaterialsGLV BOB BOM (L19_GLV_07)DescriptionSupplierSupplier P/NUnit CostQuantity POPO PriceCAP CER 0.1μF ±10% 50V X7R 0805Digikey478-1395-1-ND$0.106$0.60RES SMD 10K OHM 1% 1/8W 0805DigikeyRMCF0805JT10K0CT-ND$0.1012$1.20RES SMD 0.001 OHM 1% 1W 1206DigikeyCSNL1206FT1L00CT-ND$0.651$0.65RES SMD 120 OHM 5% 1/8W 0805DigikeyRMCF0805JT120RCT-ND$0.101$0.10RES SMD 1K OHM 5% 1/8W 0805Digikey311-1.0KARCT-ND$0.104$0.40RES 2.1K OHM 1% 1/8W 0805DigikeyRMCF0805FT2K10CT-ND$0.101$0.10RES SMD 200 OHM 1% 1/8W 0805DigikeyRMCF0805FT200RCT-ND$0.101$0.10LED YELLOW/GREEN CLEAR 0805 SMDDigikeyVAOL-S8GT4CT-ND$0.406$2.40TERM BLK 3POS SIDE ENTRY 5MM PCBDigikeyWM13971-ND$1.603$4.80MOSFET P-CH 50V 130MA SOT-23DigikeyBSS84CT-ND$0.241$0.24RELAY GEN PURPOSE SPDT 16A 24VDigikeyZ2618-ND$2.174$8.68DGTL ISO 2.5KV 2CH I2C 8SOICDigikey296-34872-1-ND$4.321$4.32IC REG LINEAR 5V 100MA 8SODigikey497-1182-1-ND$0.351$0.35CONN RCPT TYPEA 4POS R/ADigikeyED2989-ND$0.501$0.50OPTOISO 3.75KV 2CH DARLNG 8DIP (Opto-Isolator)DigikeyCLA186-ND$2.172$4.342 Position Rectangular Housing Connector Receptacle BlackDigikeyWM10385-ND$0.512$1.02CONN HEADER VERT 40POS 2.54MMDigikeyS1012EC-40-ND$0.513$1.53DC/DC CONVERTER 5V 20WDigikey102-2927-ND$33.851$33.85IC ADC I/O PORT (ADC/DAC & Temp I2C)DigikeyAD5593RBRUZ-ND$7.901$7.90IC MONITOR PWR/CURR BIDIR 10MSOP (Current Monitor)Digikey296-29034-1-ND$3.441$3.44DIODE SCHOTTKY 100V 3A DO214ACDigikeySK310A-LTPMSCT-ND$0.604$2.40Connector Header Through Hole 10 position 0.224" (5.70mm)DigikeyWM16846-ND$4.831$4.83Connector Header Through Hole 4 position 0.224" (5.70mm)DigikeyWM16837-ND$3.952$7.90Connector Header Through Hole 2 positionDigikeyWM16836-ND$3.412$6.82Connector Header Through Hole 6 position 0.224" (5.70mm)DigikeyWM16838-ND$4.282$8.5610 Position Rectangular Housing Connector Receptacle Black 0.224" (5.70mm)DigikeyWM10389-ND$1.361$1.364 Position Rectangular Housing Connector Receptacle Black 0.224" (5.70mm)DigikeyWM10386-ND$0.672$1.346 Position Rectangular Housing Connector Receptacle Black 0.224" (5.70mm)DigikeyWM10387-ND$0.962$1.92Socket Contact Tin 14-16 AWG CrimpDigikeyWM11981CT-ND$0.2534$8.50CONN D-SUB PLUG 9POS R/A SOLDERDigikey182-909ME-ND$1.781$1.78$121.93GLV Enclosure BOM ( L19_GLV_01, L19_GLV_02, L19_GLV_03)DescriptionSupplierSupplier P/NUnit CostTotal CostSINGLE BOARD COMPUTER 1.2GHZ 1GBDigi-Key1690-1000-ND$40.00$40.00RASPBERRY PI 10.1" LCD DISPLAYDigi-Key1597-1102-ND$95.63$135.63PiCAN 2 - CAN Interface for Raspberry Pi 2/3CopperHill technologiesPiCAN2-SMPS$59.95$195.58CONN RCPT 40POS 0.1 GOLD PCBDigi-KeySAM11925-ND$6.85$202.43Standoffs amd Spacers 1.125''Mouser534-4835$0.49$206.35Unthreaded Spacer 1/8" OD, 5/32" Long, for Number 2 Screw SizeMcMaster-Carr92510A415$0.77$212.51Passivated 18-8 Stainless Steel Pan Head Phillips Screw 2-56 Thread, 5/8" LongMcMaster-Carr91772A082$4.15$216.66USB Connectors USB Female AdaptorMouser706-17-200001$9.43$226.09PCF8523 Real Time Clock for Raspberry PiAdafruit3386$5.95$237.99CR1220 12mm Diameter - Lithium Coin Cell BatteryAdafruit380$0.95$239.8914U Steel Rack PanelMouser546-PBPS19014BK2$32.76$239.89Passivated 18-8 Stainless Steel Pan Head Phillips Screw8-32 Thread, 3/8" LongMcMaster-Carr91772A192$6.88$246.778 x Press Fit Nuts for sheet metal (2-56)McMaster-Carr95185A105$9.40$256.17Aluminum, 3/16" Hex Size, 1" Long, 2-56 Thread SizeMcMaster-Carr93505A217$3.60$259.77Steel Phillips Screws 2-56McMaster-Carr90272A079$3.28$263.05Passivated 18-8 Stainless Steel Pan Head Phillips Screw 8-32 Thread, 3/8" LongMcMaster-Carr91772A192$6.88$269.938-32 Thread Size, for 0.03" Minimum Panel ThicknessMcMaster-Carr95185A155$10.59$280.52Steel Pan Head Phillips Screws 4-40 Thread, 3/8" LongMcMaster-Carr90272A108$1.65$282.174-40 Thread Size, for 0.03" Minimum Panel ThicknessMcMaster-Carr95185A110$10.29$302.75Digital Display MultimeterAmazonB013PKYILS$14.99$317.74DT 2 WAY FLANGED RECEPTACLEDeutschDT04-2P-L012$4.48$331.18Deutsch dt 4 way flange receptacle connectorDeutschDT04-4P-L012$7.47$346.12AHD10-6-12P-LDigi-Key889-1062-ND$10.05$356.17DT04-8PATE-ConnectivityDT04-08PA-LE11$10.49$366.66Deutsch dt 12 way flange receptacle connectorDeutschDT04-12PA-L012$10.53$377.19USB Panel Mount ConnectorAmazonB07CZDXJGX$8.99$386.18USB/HDMI Panel Mount ConnectorAmazonB077T853NZ$11.90$398.08CIR BRKR THRM 10A 250VAC 32VDCDigikeyQ503-ND$2.23$400.31CIR BRKR THRM 15A 250VAC 32VDCDigikeyQ504-ND$2.04$402.35Splined Press-Fit Threaded Standoffs with Open EndMcMaster-Carr92985A110$12.78$415.13Male-Female Threaded Hex Standoff Aluminum, 1/4" Hex Size, 1" Long, 4-40 Thread SizeMcMaster-Carr93505A436$0.61$420.01Aluminum Unthreaded Spacer 3/16" OD, 1/8" Long, for Number 4 Screw SizeMcMaster-Carr92510A688$0.33$422.65Passivated 18-8 Stainless Steel Pan Head Phillips Screw 4-40 Thread, 1/4" LongMcMaster-Carr91772A106$3.39$426.04Male-Female Threaded Hex StandoffAluminum, 3/16" Hex Size, 1/2" Long, 4-40 Thread SizeMcMaster-Carr93505A103$0.04$426.39$426.39GLV COCKPIT & SIDE PANELS BOM (L19_GLV_04, L19_GLV_05, L19_GLV_06)DescriptionManufacturerManufacturer P/NSupplierSupplier P/NUnit CostTotal Cost22MMHW SeriesEmergency Stop Switches IDECHW1E-LV4F11QD-R-24VAllied70172680$55.52$166.56Push Button; Panel Mount; 2500 V (1 min.); 10 A; NC; Shrouded; High? Low;Altech Corp.2ALF3LB-024Allied 70156696$22.19$210.94Car Rotating Battery/Electrical Master Switch DealExtreme 22003$7.83$226.60Rectangular LED Lights Amber/SSOKSuper Bright LED'sMDB-A12Super Bright LED'sMDB-A12$6.49$246.07Tractive System Energized LightEncellSTB-A35 AmazonB01K9X1ZCE$30.00$276.07Panel Mount Indicator (Green)Dialight6823235142F Digi-Key350-4053-ND$8.94$320.77Panel Mount Indicator (Red)Dialight682-3132-141F Digi-Key350-4050-ND$8.94$347.59$347.59Quality Assurance Testing ResultsSAFETY LOOP QATest#DescriptionTest MethodExpected ResultsPASS/FAIL1.0Energize Subsystems-24V Power Supplied to GLV Subsystems.Supplied 24V of power to the GLV system using an external power supply. The 10A circuit breaker, GLVMS, BRBRS, BRBLS, and 10A circuit breaker were closed. The 24V output was measured on J10 (6 pins of GLV power and Can Bus line) on the GLV enclosure.24V was measured on J10.The GLV LED turned on.PASS2.0Energize AIRS- Power supplied to Accumulator AIRs.Supplied 24V of power to the GLV system using an external power supply. The GLVMS, BRBLS, BRBRS, TSVMS, circuit breakers, and driver BRB were closed. The exterior master switch and driver reset were pressed.The GLV LED is on.The SAFETY LED is on.The AIRs LED is on.The FAULT LED is off.The AIRs in the packs closed.PASS3.0Shutdown- All GLV power turns off when the GLVMS or exterior BRBs turn off.Power was supplied to the AIRs following the procedure in test 2.0. The GLVMS was opened, while checking the output to the J10 pin on the GLV enclosure. This was repeated for both exterior BRBs.All LEDs turned off.0V was measured on J10.GLV Subsystems deenergizedPASS4.0Fault- GLV System stops supplying power to the AIRs in the following situations.The AIRs were energized following the procedure described in test 2.0. The following faults will be tested. The Master Reset and Drive Reset were pressed at the end of each test to ensure these inputs do not reenergize the AIRs during a fault.Pass Tests 4.1-4.3PASS4.1Subsystem FaultA subsystem breaks the safety loop. This was tested by removing the final jumper on the SL2TSI J9 Connector on the GLV interconnect panel.The GLV LED is on.The SAFETY LED is off.The AIRs LED is off.The FAULT LED is on.PASS4.2Driver E-Stop FaultThe Driver E-Stop was pressed.The GLV LED is on.The SAFETY LED is on.The AIRs LED is off.The FAULT LED is off.PASS4.3TSVMS FaultThe TSVMS was turned off.The GLV LED is on.The SAFETY LED is on.The AIRs LED is off.The FAULT LED is off.PASS5.0Reenergize AIRs after fault.The faults in test 4.0 should be resettable in the following ways so that the AIRs can be reenergized without cutting power to the GLV powered subsystems.Pass Tests 5.1-5.3PASS5.1AIRs Reenergize after Subsystem FaultRan test 4.1. Fixed the safety loop fault in the subsystem. This was done by plugging the safety loop jumper back into the TSV battery packs, closing the safety loop. Pressed the Master Reset and then the Crash Protection Reset.The GLV LED is on.The SAFETY LED is on.The AIRs LED is on.The FAULT LED is off.The AIRs in the packs closed.PASS5.2AIRS Reenergizeafter Driver E-Stop FaultRan test 4.2. Closed the Driver E-Stop. Pressed the Master Reset and then the Crash Protection Reset.The GLV LED is on.The SAFETY LED is on.The AIRs LED is on.The FAULT LED is off.The AIRs in the packs closed.PASS5.3AIRs Reenergizeafter TSVMS FaultRan test 4.3. Reengaged TSVMS. Pressed the Master Reset and then the Crash Protection Reset.The GLV LED is on.The SAFETY LED is on.The AIRs LED is on.The FAULT LED is off.The AIRs in the packs closed.PASS6.0Connectivity- The safety loop is wired as shown by the schematic in Appendix A.The safety loop circuit was traced with an ohmmeter to ensure each connection occurred expected.Each component was connected as expected.PASS7.0Unexpected Input- The reset buttons should not have any effect on the system if pressed at an unexpected time or in the wrong order.The following unexpected inputs did not affect the system.Pass Tests 7.1-7.2PASS7.1Master Reset or Driver Reset pressed after AIRs energized.Followed procedure in test 2.0 to energize the AIRs. Pressed the Master Reset. Pressed the Driver Reset.No changed occurred.PASS7.2Driver Reset pressed before master reset when energizing AIRs after startup.Followed procedure in test 1.0 to energize GLV powered subsystems. Ensured there were no subsystem safety loop faults as indicated by on SAFETY LED. Pressed Driver Reset.The GLV LED is on.The SAFETY LED is on.The AIRs LED is off.The FAULT LED is off.The AIRs were not energized.PASSGLV BOB QA *all pin references are to only the GLV BOB rev.4.1 schematicTest#DescriptionTest MethodExpected ResultsPASS/FAIL1.0GroundingPass Tests 1.1-1.4PASS1.1Airs groundedContinuity TestConnection between GLV_RTN and AIRs-PASS1.2Can groundedContinuity TestConnection between GLV_RTN and CAN_GNDPASS1.3Temp Sensor groundedContinuity TestConnection between 5V_RTN and U2-14PASS1.4Volt and Amp Sensor Chip groundedContinuity TestConnection between 5V_RTN and U4-7PASS1.5Ground IsolationContinuity TestNo connection between 5V_RTN and GLV_RTNNo short between 5V_RTN and 5VNo Short between GLV_RTN and 24VPASS2.0Communication (CAN, I2C)Pass Tests 2.1-2.4PASS2.1CAN+Continuity TestDB9-p8 is connected to J7-p1PASS2.2CAN-Continuity TestDB9-p4 is connected to J7-p6PASS2.3CAN_SHIELDContinuity TestDB9-p3 is connected to J7-p3PASS2.4Display CAN dataCheck SCADAMotor Controller / TSI data is displayed by SCADAPASS2.5SDAContinuity TestSDA is connected to P1-p1PASS2.6SCLContinuity TestSCL is connected to P1-p3PASS2.7Display I2C dataCheck SCADAGLV temperature, current, and voltage sensor are displayed by SCADAPASS3.0PowerPass Tests 3.1-3.6PASS3.1GLV+ activeCheck LEDD7 is onPASS3.25V is activeCheck LEDD9 is onPASS3.3GLV+ supplyVolt MeterJ12-p1 is 24VPASS3.4Safety Loop 1 power lossRun Safety Loop QA test 2.0 and use Volt MeterJ6-p1 is 24VPASS3.5Safety Loop 2 power lossRun Safety Loop QA test 2.0 and use Volt MeterJ6-p2 is 24VPASS3.65V supplyVolt MeterP2-p1 is 5VJ10-pVBUS is 5VPASS3.7Power IsolationContinuity TestGLV+ is not connected to 5VPASS4.0RelaysPass Tests 4.1-4.8 (Must supply 24v to J2-p1 for the following)PASS4.1SCADA CONTROL ONSupply P1-p5 with 5V. Check SCADA LED.On board LED SCADA is onPASS4.2SCADA CONTROL OFFSupply P1-p5 with 0V. Check SCADA LED.On board LED SCADA is offPASS4.3MASTER RESET relay ONSupply J3-1 and J3-2 with 24V. Then remove 24V supply from J3-2. Check MRESET LEDOn board LED MRESET is onPASS4.4MASTER RESET relay OFFRun test 4.3 then remove the supply from J3-1. Check MRESET LEDOn board LED MRESET is offPASS4.5COCKPIT RESET relay ONSupply J5-2 and J5-4 with 24V. Then remove 24V supply from J5-4. Check CPR LEDOn board LED CPR is onPASS4.6COCKPIT RESET relay OFFRun test 4.5 then remove the supply from J5-4. Check CPR LEDOn board LED CPR is offPASS4.7DYNO relay ONSupply J3-p4 with 24V. Check DYNO LEDOn board LED DYNO is onPASS4.8DYNO relay OFFRemove J3-p4 with 24V. Check DYNO LEDOn board LED DYNO is offPASS4.9SCADA relay NC programmingDisconnect SCADA from GLV. Connect J4-p3 to J4-p2 with jumper. Continuity test between J6-p1 and J3-1.ContinuousPASS5.0SCADA relay NO programmingDisconnect SCADA from GLV. Connect J4-p1 to J4-p2 with jumper. Continuity test between J6-p1 and J3-1.DiscontinuousPASS5.1DYNO relay NO programmingConnect J11-p3 to J11-p2. Check pins J8-p1 and J8-p2. Resistance test.Resistance should be 1k ohm.PASS5.2DYNO relay NO programmingConnect J11-p1 to J11-p2. Check pins J8-p1 and J8-p2. Resistance test.Resistance should be Overload.PASS5.0LED & OPTOISOLATIONPass Tests 5.1-5.3PASS5.1Jumper DisconnectSupply 24V to J2-p1 without a jumper between J6-p1 and J6-p4. Volt MeterThe voltage on SAFETY LED is 0V.The voltage on Fault LED is 5V.The voltage on F1 is 0V.The voltage on F2 is 0V.PASS5.2Jumper ConnectSupply 24V to J2-p1 with a jumper between J6-p1 and J6-p4. Volt MeterThe voltage on SAFETY LED is 24V.The voltage on Fault LED is 0V.The voltage on AIRs LED is 0V.The voltage on F1 is 5V.The voltage on F2 is 0V.PASS5.3Air PowerSupply 24V to J6-p2.The voltage on AIRs LED is 24VThe voltage on F2 is 5VPASSErrataL19_GLV_07The BOB is a board that is meant to manage the GLV system within the Electric Vehicle used in Lafayette College. More specifically, the board is used to convert 24V to 5V for the SCADA system, as well as manage the relays for the safety loop, connect the resets and E-Stops to the safety loop, provide power to the TSI, Cockpit, Airs, and Cooling systems as well as several lights on the car.GLV BOB Errors:J5-p6 should be the Mreset_B signal so that the Safe light turns on in parallel with the SSOKs.R1 should be a pull-down resistorP3-4 should swap with P3-3. P3-5 should swap with P3-6. P3-1 should have a 3.3v supply and P3-2 should be a 5v supply.GLV BOB should have a 3.3v dc/dc converter for the RTCGLV BOB should be designed with connectors so that it interfaces with L19_GLV_02 more easily.The Cooling subsystem should only receive power when the AIRs close. L19_GLV_02The Top panel is supposed house the GLV BOB, SCADA, and their wiring. This panel is intended to be a panel that can be installed onto the car panel Errors:J10 should be larger so that the flange can be on the outside of the panel.The holes that hold both the GLV BOB and the SCADA should have 4-40 pressfit inserts so that the components don’t fall out accidentally.Appendix:GLV Parts Number List:Part#NameL19_GLV_018U Rack PanelL19_GLV_02Top PanelL19_GLV_03SCADA_Screen_MountBracketsL19_GLV_04Cockpit PanelL19_GLV_05Right Side PanelL19_GLV_06Left Side PanelL19_GLV_07Break Out BoardL19_GLV_08Shore PowerL19_GLV_09BatteryL19_GLV_10ChargerGLV Power Analysis:GLV Total system current consumption:RefDescriptionPeak Current (A)Quiescent Current (A)GLVGLV (including Safety Loop)6.7482.347TSITSI (only GLV powered components)4.5980.376TSVTSV (only GLV powered components)1.0570.008COOLINGCooling1.3150.000SCADASCADA0.2500.219MCMotor Controller1.0000.75014.9673.699Safety Loop current consumption:RefDescriptionManufacturerManufacturer P/NSupplierSupplier P/NQuantityPeak Current (A)Quiescent Current (A)Digital Display MultimeterBayite PZEN-311Rectangular LED Lights Amber/SSOKSuper Bright LED'sMDB-A12Super Bright LED'sMDB-A1220.180.18GLV BOB RELAY GEN PURPOSE SPDT 16A 24VOmron Electronics IncG5LE-1-E DC24DigikeyZ2618-ND40.070.08AIRSAccumulator Isolation RelaysGigavacGX14CB46.400.39Discharge RelayDigikeyZ1032-NDDigikeyZ1032-ND10.0830.0836.730.73GLV Powered System current consumption:GLV DescriptionSupplierSupplier P/NSupply (V)QuantityPeak Current/unit (A)Quiescent Current/unit (A)TPCTQCIC MONITOR PWR/CURR BIDIR 10MSOP (Current Monitor)Texas InstrumentsINA226AIDGSR 24.010.0000.0000.000.00OPTOISO 3.75KV 2CH DARLNG 8DIP (Opto-Isolator) DigikeyCLA186-ND 24.020.0050.0050.010.01IC ADC I/O PORT (ADC/DAC & Temp I2C) Analog Devices Inc.AD5593RBRUZ 24.010.0020.0020.000.00IC REG LINEAR 5V 100MA 8SOSTMicroelectronicsL78L05ACD13TR24.010.0060.0060.010.01Digital Display Multimeter24.010.000.00Rectangular LED Lights Amber/SSOKSuper Bright LED'sMDB-A1224.020.090.180.180.36GLV BOB RELAY GEN PURPOSE SPDT 16A 24VOmron Electronics IncG5LE-1-E DC2424.040.020.080.070.33Accumulator Isolation Relays24.041.600.396.401.55Discharge RelayDigikeyZ1032-ND24.010.0830.0830.080.086.752.35TSI DescriptionSupplierSupplier P/NSupply (V)QuantityPeak Current/unit (A)Quiescent Current/unit (A)TPCTQCPrecharge RelayDigikeyGX14CB24.011.6500.0971.650.10Precharge Control RelayDigikeyAPAN310524.010.0220.0220.020.0224:24 DC/DC ConverterDigikeyTHN_30-2415WI24.011.2500.0101.250.01IMD RelayDigikeyG2R-1A-DC2424.010.0470.0470.050.0524:(5/10) DC/DC ConverterDigikeyPDQ10-Q24-D5-D24.011.4001.400.00TSI Board~~24.011.1000.2000.230.204.600.38TSV DescriptionSupplierSupplier P/NSupply (V)QuantityPeak Current/unit (A)Quiescent Current/unit (A)TPCTQCPIC32MZMicrochipPIC32MZ2048EFM064-I/PT24.010.2000.200.0024:5 DC/DC ConverterCUI IncPDM2-S24-S5-S24.010.0830.0080.080.01LT1763CS8-3.3-PBFLinear TechLT1763CS8-3.3#PBF24.010.5000.500.00Interface_CAN_LIN:MCP2551-I-SNMicrochipMCP2551-I/SN24.020.0000.000.00LTC6820Linear TechLTC6820IMS#3ZZPBF24.010.0060.010.00Isolator:TLP291ToshibaTLP291(GB-TP,SE24.050.0500.250.00LCD DisplayCrystalfontzCFA533-TMI-KC24.010.000.00Relay:G5Q-1AOmronG5Q-1A4 DC2424.020.0080.020.001.060.01Cooling DescriptionSupplierSupplier P/NSupply (V)QuantityPeak Current/unit (A)Quiescent Current/unit (A)TPCTQCYF-S201 1-30L/min Water Flow Hall Counter / Sensor Water control Water Flow Rate Switch Flow Meter Flowmeter CounterWINGONEERYF-S20124.010.0150.020.00PMP-500 Pump, G 1/4 BSPKoolancePMP-50024.011.3001.300.00Nextrox DC/DC Converter Regulator 24V to 12VNextrox~24.010.000.001.320.00SCADA DescriptionSupplierSupplier P/NSupply (V)QuantityPeak Current/unit (A)Quiescent Current/unit (A)TPCTQCRaspberry Pi 3b+~~5.010.5000.3000.500.30Mouse~~5.010.1000.1500.100.15Keyboard~~5.010.1000.1000.100.10RASPBERRY PI 7" TOUCH SCREEN LCDDigikey1690-1007-ND5.010.5000.5000.500.50PiCAN 2 BoardCopperHill~5.010.000.001.201.05Motor Controller DescriptionSupplierSupplier P/NSupply (V)QuantityPeak Current/unit (A)Quiescent Current/unit (A)TPCTQCMotor Controller emDrive500EmisisoemDrive50024.011.0000.7501.000.75Table SEQ Table \* ARABIC 1: This table shows the entire system current consumption. TPC represents Total Peak Current and TQC represents Total Quiescent Current. The emboldened values in their columns represent their respective subsystems final expected current.AcknowledgmentsThis document is largely based on the documentation used in the Class of 2018 and the Class 2017. We would like to acknowledge the Electrical and Computer Engineering Department and Mechanical Engineering Department for making this project possible.DisclaimerWhile we have made every attempt to ensure that the information contained in this document is complete, understand that there may still be unforeseen errors. ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download