Drive Train for an Electric Jet Ski Conversion.

Drive Train for an Electric Jet Ski

Conversion.

Alexander Beckley

Supervisor: Professor Thomas Br?unl

Department of Engineering

University of Western Australia

A thesis submitted for the degree of

Bsc/Be

Novemeber 2013

I would like to dedicate this thesis to my loving parents and my beautiful

and amazing girlfriend.

Acknowledgements

As a member of the Renewable Energy Vehicle (REV) Team I have many

people I would like to acknowledge:

Firstly my supervisor Professor Thomas Br?unl and the UWA electrical engineering department.

The whole UWA Rev Team for the opportunity to work on such an exciting

project. Specifically the members of the Rev Ski Team: Rajinda Jayamanna,

Rowan Clark, Dannis Savic, Don Madappuli, Riley White, Andrew Pham,

Christopher Corke and Megat Megathisham.

Our industry partners EV Works and Altronics for their sponsorship of the

project.

Submersible Motor Engineering for their work with the AC induction motor.

And the UWA Physics workshop for their generous donation of workshop

time.

Abstract

The jet ski is a small water craft designed to carry one or two people for short

distances on water, first commercially released in 1973, and commonly associated with water sports and family recreation. Although not as common as

the motorcar or motor bike, Jet skis have never been considered an environmentally friendly vehicle due to their high level of noise and environmental

pollution. Similar to small cars and motorbikes, they typically use 4 stroke

petrol engines with capacity around 1500cc, and with petrol tanks up to 78

Litres.

The RevSki project is the first of its kind in Australia as it will test the

performance characteristics of an entirely electric powered jet ski against a

conventional petrol powered jet ski. The aim is to determine if an environmentally friendly, low emission electric jet ski can be competitive with petrol

powered jet skis in the modern market. This thesis documents the design of

the electric drive train including an in-depth analysis of all key design decisions as well as the selection key components, made throughout the design

phase of the RevSki Project. The electric drive train includes the battery

system, high and low voltage wiring, the motor, safety systems and control

systems.

Contents

Contents

v

List of Figures

ix

List of Tables

x

Nomenclature

xii

1 Project Introduction

1.1 Project Overview . . . . . . . . . .

1.2 Project Goals . . . . . . . . . . . .

1.3 Project Stages . . . . . . . . . . . .

1.4 Drive Train Concept . . . . . . . .

1.5 Technology Selection Overview . .

1.6 Performance Test Design Overview

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2 Drive Train Design

2.1 Drive Train Design: Introduction . . . . . .

2.2 Drive Train Design: Literature Review . . .

2.3 Drive Train Design: Overview . . . . . . . .

2.4 Safety Design Considerations . . . . . . . . .

2.5 Batteries Design . . . . . . . . . . . . . . . .

2.5.1 Battery Mounting and Cell Layout .

2.5.2 Connecting the Batteries: Bus Bars .

2.5.3 Battery Management Systems . . . .

2.5.4 Battery E?ciency . . . . . . . . . . .

2.6 Wiring Design . . . . . . . . . . . . . . . . .

2.6.1 Wiring Design: Physical Disconnects

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