Executive Summary - Computer Action Team



CycloPowerFinal Report – Spring 2015Team MembersNicholas BreningerCasey FreemanGreg LaughlinTerry RigdonAlysia StricklandJustin WoodardFaculty AdvisorFaryar EtesamiExecutive SummaryCycloPower has experimented with current technology and investigated the feasibility of a selective resistance, multi-person, electrical bicycle. This report outlines the final product design and evaluation of the mechanical and electrical systems required to build such a product. Research on previous and current electrically regenerative bicycle systems and multi-person mechanical bicycle designs provided baseline information to structure the product design specifications and select components.Although construction and testing of a full-scale prototype was beyond the scope of this project, CycloPower’s electrical subsystem team designed and constructed a small-scale system to demonstrate selective resistance feasibility, while the mechanical subsystem team designed and conducted failure analysis of the full-scale modular bicycle design. The extensive research and recommendations detailed throughout this report may be used to construct a modular multi-person, selective resistance, electrical bicycle or enhance current multi-person mechanical bicycle designs.Table of Contents TOC \o "1-3" Executive Summary PAGEREF _Toc421211021 \h iTable of Contents PAGEREF _Toc421211022 \h iiIntroduction PAGEREF _Toc421211023 \h 1Main Design Requirements PAGEREF _Toc421211024 \h 2Alternate Design PAGEREF _Toc421211025 \h 3Final Design PAGEREF _Toc421211026 \h 4Mechanical Design PAGEREF _Toc421211027 \h 4Module PAGEREF _Toc421211028 \h 4Chassis PAGEREF _Toc421211029 \h 5Electrical Design PAGEREF _Toc421211030 \h 6Block Diagram PAGEREF _Toc421211031 \h 7Resistance Control PAGEREF _Toc421211032 \h 8Electrical System PAGEREF _Toc421211033 \h 9Final Product Evaluation PAGEREF _Toc421211034 \h 11Structural Analysis of Mechanical Components PAGEREF _Toc421211035 \h 11Safety and Ergonomics PAGEREF _Toc421211036 \h 14Maintenance & Cost PAGEREF _Toc421211037 \h 15Conclusion PAGEREF _Toc421211038 \h 17Appendix I: Product Design Criteria PAGEREF _Toc421211039 \h 18Appendix II: Research (Sources) PAGEREF _Toc421211040 \h 20Appendix III: Alternate Designsrduino Code PAGEREF _Toc421211041 \h 21Appendix IV:Arduino Code Electrical Component Specifications PAGEREF _Toc421211042 \h 38Appendix V: Electrical Components SpecificationsModule-generator Design Matrix PAGEREF _Toc421211043 \h 43Appendix VI: Modular-generator Design MatrixAssembly Drawings PAGEREF _Toc421211044 \h 447Appendix VII: Assembly DrawingsFEA PAGEREF _Toc421211045 \h 468Appendix VIII: FEA …………………………………………………………………………....50IntroductionMulti-person bicycle tours have been growing in popularity over the last few years. Most of these bicycles resemble a trolley car rolling down the street with space for eight to sixteen people pedaling and one person, generally a tour guide, driving. Some bikes are 100% human-powered by means of a single gear connecting each pedaler, while others are operated in areas with rough terrain and require electric assistance in addition to the human power.Customers have commented that using a single gear for all pedalers makes it exceptionally difficult for one user, while the rest of the group reaps the benefits of that user’s strength. Meanwhile, drivers have been concerned with the possibility of the machine assist running out of energy with less experienced pedaler groups, leaving the tour stranded until users can exert enough energy, or the machine assist is electrically charged or fueled. To provide both the customer and the driver a more enjoyable experience, CycloPower has researched and designed an electromechanical alternative to address these concerns.Still utilizing the mechanical energy generated by individuals pedaling, we have removed the universal single gear system connecting all pedalers, and replaced it with multiple modular pedaling systems. The modular system provides electrical power which is mechanically generated by an individual pedaling, while a standard bicycle tire drives an electric generator at a twenty-six-to-one gear ratio. Each operator is able to select his or her own resistance by means of a tablet device that interfaces directly with the generator. The power produced by each operator is then directed to either an electric motor driving the bike or a backup battery system that is capable of energizing the electric motor in the event that the operators cannot produce enough power.Main Design Requirements The CycloPower design will achieve a maximum speed of 10 miles/hour and cover distances exceeding five miles without battery regeneration, or more specifically, without pedaling. The final design allows the safe transportation of 1500 pounds of cargo, equating to approximately six users and an operator. The completed prototype will be in operation amongst the everyday traffic day and night, which requires the implementation of a headlight capable of projecting a minimum of 500 feet and two taillights. The individual generators that are powered by each user will be equipped with a change/fix voltage dividing controller mechanism, allowing the power generated to be directed where it can be used most efficiently: either the battery for power storage, the motor for its direct use in moving the vehicle forward. The voltage divider will also be used to disperse generated wattage and power an interactive display logging individual power generation data, which allows users to have an understanding of how much they are contributing to the function of the vehicle. This will allow customization of where users desire to send individual produced power via a calibrated spinning knob. The different knob settings will reflect the different power destination options. An electric motor capable of pushing one ton of weight to a maximum of 10 miles/hour must be implemented and paired with the necessary steering and braking components capable of operation under the specific load. The prototype must satisfy the Federal low speed vehicle standards, as well as the Federal passenger vehicle standards outlined in REF _Ref295060214 \h Appendix II: Research (Sources).Alternate DesignMechanicalFor the module there were other designs considered on what type of generator system to be incorporated. An alternative design would be a direct-drive generator as seen in Appendix III. This design would be ideal for the least amount of components, however the cost of the controlling unit as well as the feasibility of its programming proved unachievable for the scale of the Capstone team. The direct-drive generator runs at a 1:1 ratio; at a higher ratio the generator would create more power and be more efficient. ElectricalThe feasibility test of the individual resistance control setting required a test stand to be made for the power generating system. An alternative design for the test stand is a flipped bike with seat. This design would allow the user to sit more comfortably as if they were riding a recumbent bike, but resources limited this design. An example of the alternate design is in Appendix III.would be theFinal DesignTo ensure a full detail design of the multi-person bicycle system, CycloPower focused on mechanical and electrical design aspects. The basic mechanical design of the bicycle system starts with the assumption of needing each pedaler to drive a one inch diameter generator shaft, while the bicycle system needs to be driven by an electric motor operating at 3000 rpm, and a location for the backup batteries has to be secured. The electrical design focuses on which electrical components would be required to create individual selective resistance, and direct the power produced by the generators to either the electric motor or the backup battery system.Mechanical DesignThe team responsible for the mechanical design of the bicycle system focused on four key features: 1) individual modules to be placed along the chassis frame, 2) the chassis, 3) placement of electrical components, and 4) safety and luxury accessories. The structures, such as the module and chassis, were then analyzed for displacement and stress under maximum loading.ModuleFor the module design, the goal was to create a stand-alone unit which could be replicated and installed in various quantities based on the end user’s application. A lightweight and portable design offer ease of disconnect and removal of the module for preventative maintenance, or in the event of individual module failure. The design would also allow for a large variety of different seating configurations and orientations, because the electrical and mechanical components of each module are independent from adjacent modules.Each operator is able to adjust his or her seat height for comfort and proficiency. As the operator pedals, the bicycle chain attached to the crankset rotates a standard 26-inch bicycle rim connected to an electrical generator by a V-belt for maximum efficiency. The operator can adjust his/her pedaling resistance by means of a tablet on their tabletop integrated with relays controlling the generator.Figure SEQ Figure \* ARABIC 1: Module DesignChassisIndependent front suspension was selected for increased handling to accommodate the basic rack and pinion steering system. At the vehicle’s low speed requirements, steering becomes compromised without the use of a hydraulic or electrical assist. A double wishbone configuration was chosen, paired with a coil spring for ease of kinematic tuning, wheel movement optimization, lightweight characteristics, market availability, as well as its high reliability and low maintenance. The double wishbone also offers pedalers a smooth ride by adapting to road imperfections such as potholes or bumps, as compared to other available suspension. The final design chosen is modeled below in REF _Ref421174594 \h Figure 3.Figure SEQ Figure \* ARABIC 2: Double wishbone front suspensionLeaf springs were chosen for the rear suspension to assist the motor-driven straight axle in distributing the load of the battery, motor, and gearbox system over a three-foot section of the chassis rather than a single point with coil springs. The main motivation for this decision was that leaf springs are readily available and cost effective, as well as requiring minimum machining for mounting.Electrical DesignThe electrical portion of the design team focused their efforts on constructing a test system comprised of a DC motor and battery, which are both powered by a bicycle-driven generator. An Arduino UNO controls the test system. The system implemented selective resistance by acquired power output needed from the generator. Through the use of a small-scale test stand, the team performed an analysis on how the system operated, most importantly how the power went to the backup battery system and the motor. Eleven different resistance settings were observed and analyzed in order to control how the system was being powered. Each component used in the system is fully explained in detail in the following subheadings with the complete specifications laid out in REF _Ref295062911 \h \* MERGEFORMAT Appendix IV: Electrical Component Specifications.Block DiagramThe power-generating system with individual selective resistance can be seen in the block diagram in Figure 3. The generator sends power to a PWM switching device, which is controlled by an Arduino UNO and potentiometer. Depending on the state of the potentiometer, the microcontroller diverts power to either the charge controller or voltage regulator. The PWM switching system is implemented using relays to direct power. Power sent to the battery is first passed through a charge controller. Depending on the actual battery voltage, power transmission through the charger is regulated. The PWM switching system also sends power to the BLDC motor. The voltage regulator limits the power sent to the motor, keeping it from burning up.Figure SEQ Figure \* ARABIC 3: Block DiagramResistance ControlThe resistance control system is put in place to give the user or pedaler the ability to change the resistance or difficulty of pedaling by the turn of a knob (potentiometer). Each module has a knob placed arm's length away in front of the pedaler. The resistance of the pedaling happens by the generated power being split into two directions: one to a voltage regulator to motor (Heavy load) and the second to a charge controller to 12V battery (Light load). Both of these connections have a relay between them. The relays are used as “ON” and “OFF” switches. The Arduino is programmed to turn “ON” and “OFF” the relays based on where the knob is positioned, which is an application of PWM. The Arduino is programmed to have 11 resistance settings as seen in Table 1. The programing code can be found in REF _Ref295061464 \h Appendix IV: Arduino Code.Table SEQ Table \* ARABIC 1: Distribution of voltage per settingThe range of the knob is divided into these 11 settings. The duty cycle for optimal efficiency is 100 milliseconds. At Setting 1 the Arduino is programmed to turn “ON” the relay going to the battery for 90 milliseconds and “OFF” for 10 milliseconds sending 90% of the voltage generated to the battery to charge. Also at setting 1, the program is to turn “ON” the relay going to the motor for 10 milliseconds and “OFF” for 90 milliseconds sending 10% of the voltage generated to the motor. At this setting it will be at a light resistance. This same effect happens for all the settings with the given percentage seen in REF _Ref421174875 \h Table 1.Electrical SystemGeneratorThe rear bicycle wheel is directly connected to a friction wheel attached to the shaft of the generator. This generator uses the power produced by the bike to go into the beginning of the system as shown in Figure 3. This power is split using Pulse Width Modulation so the generated power is always going somewhere where it is needed, whether that is to charge the battery, to directly power the motor, or somewhere in between.Arduino (PWM Switching)The Arduino Uno is a microcontroller board based on the ATmega328, which is a 8-bit microcontroller. It has 14 digital input/output pins (of which 6 can be used as Pulse Width Modulation [PWM] outputs), 6 analog inputs, a 16-MHz ceramic resonator, a USB connection, a power jack, an ICSP header, and a reset button. A picture of the Arduino Uno can be found in Appendix V. The Arduino Uno can be programmed with the Arduino software having a similar language to C++. The Arduino was chosen simply because of ease of use and meeting specification needs.Speed Relay Shield (PWM Switching)The Relay Shield provides a solution for controlling high-current devices that cannot be controlled by the Arduino’s Digital I/O pins due to their current and voltage limits. The Relay Shield features four high quality relays, only two are used in this system, and provides NO/NC interfaces, four dynamic LED indicators to show the on/off state of each relay, and the standardized shield from factors to provide a smooth connection to the Arduino board or other Arduino compatible boards. This shield attaches to the Arduino that controls them. The relays are between the generator and the charge controller or voltage regulator. This Shield was chosen based off the low cost and it meets the right specifications.Voltage RegulatorThe step-down voltage regulator chosen is shown in Appendix V. The device has a maximum input voltage of up to 30 Volts. The regulator decreases the high voltage coming from the generator to a level that the 12-Volt brushless DC motor can accept. A potentiometer on the device was tweaked to adjust the highly variable generator voltage.MotorThe motor chosen is a quarter-horsepower, brushless DC (BLDC) motor which operates in an optimal range of 12-14 Volts. The specifications of the motor are listed in Appendix V. The motor was chosen because of its low cost, and nominal voltage, which matched with our 12-Volt battery. Charge Controller The charge controller chosen has a rating between 12-24 volts, and can take up to 10 amps of charging current. The battery can only take 12-14 volts at once so the charge controller is put in so that it gets an optimal amount to charge. This one was also chosen because of it’s ability to protect itself from overcharging which is a potential problem due to the amount of voltage going into it (from operating the test stand, even at steady, slower pedaling speed it’s possible to reach 25-30 volts without taking into account what the arduino is doing to the system).BatteryThe battery chosen is a deep cycle 12-Volt marine battery. It is used as a backup power supply and can directly power the motor. ?In the event that the bike is stopped, users can still send power into the battery.Final Product EvaluationStructural Analysis of Mechanical ComponentsThe frame was designed primarily with rectangular and square A36 mild steel tubing, selected for its low cost and easy weldability. A yield strength of 36,000 psi was judged to be sufficient for this application. Where possible, simple 90 and 45 degree angles were used to simplify fabrication and reduce production costs.The first design test was a torsional FEA model, where the frame was fixed by the rear leaf spring mounting points, and one of the front lower control arm tabs. This was done to allow the frame to twist, rather than bow upwards uniformly like a cantilever beam. A 1000lb upward force was applied to the coilover spring mounting point, to simulate the force of running over an obstacle with one front tire. Several iterations of frame layout and tubing thicknesses were tested, with the goal of minimizing total displacement and providing the highest overall torsional rigidity. The design that provided the minimum displacement was a cross-braced layout, with 0.250” wall thickness frame rails and braces. The peak von Mises stress was actually located on the front control arm tab, due to the fixture method that is available in the student version of SolidWorks FEA software. However, the stress throughout the rest of the frame was relatively minor, as shown in REF _Ref295059279 \h Figure 5. Figure SEQ Figure \* ARABIC 4: Von Mises Stress of Chassis FrameAfter the torsional analysis was run, a simulation of the overall sagging of the frame due to loading from the individual modules and passengers was done. An assumption of 250lbs per module and rider was made, and 6 individual downward forces were applied in line with the centerline of the modules. The four rear leaf spring mounts were fixed to the frame, and both front upper coilover spring mounts were also fixed to the frame. The maximum displacement was 0.0137”, which was assessed to be well within acceptable limits (see REF _Ref295059570 \h Figure 6). Maximum stress was also acceptable, with a safety factor of approximately 6:1. Figure SEQ Figure \* ARABIC 5: Von Mises Stress of Frame with Module LoadingThe final design of the frame came to a total weight of 729 lbs, less than half of the total empty vehicle weight. Compared to the approximately 2000 lbs of a similar sized mechanically powered vehicle, this represents a major decrease in overall mass from just the frame design.The frame of the module was designed with the purpose of mounting the passenger’s seat, pedal hub, generator, bicycle rim/chain, and a small tabletop. Welding two sections of ? “steel plate to the sides of the post, and securing the module to the frame rails via two ?” bolts in double shear created a mounting solution for the bottom of the main post. This makes for a robust, yet quick installation mounting method. A36 steel was specified, for the same reasons as the main vehicle frame.The challenges presented designing individual modules were minimizing stress concentrations and deflection under maximum loading. Finite Element Analysis (FEA) was used to analyze the module frame for total displacement and von Mises stress. The frame was fixed at the four bottom attaching bolt holes, and a 250lb downward force was applied to the end of the seat post. Several iterations of various tubing sizes, gusset thicknesses, and geometry were analyzed. The best result used 1” and 1.5” square 0.125” wall tubing, with a ?” thick gusset. Maximum displacement was 0.0785”, located at the end of the seat post. Maximum von Mises stress was 20,980 psi, located on the weld radius of the lower diagonal tubing member. This gives a safety factor of 1.72, assuming 36,000-psi yield strength. This optimization process resulted in a very stiff yet lightweight frame, at approximately 19.6 lbs.Electrical Feasibility of Resistance Control Implementation A test stand was made to check the feasibility of having a resistance control feature. The test stand design consist of a bike that attaches to a rear bike tire stand that is bolted to a platform for safety. A custom bracket was machined to attach the generator to the tire stand allowing the rear tire to connect to the friction wheel on the generator. The front tire rests on a stand that connects to the fork of the frame. The resistance control box is located at the head of the bike with the wires going down the frame to the back of the platform. A box was made and bracketed to the rear platform for the rest of the systems components (Arduino, charge controller, battery, voltage regulator, motor). The test stand follows: Figure 6: Test stand, generation system, and resistance control systemWith the full electrical system in place, the module was tested by multiple users at PSU ME prototype day. Every user experienced the resistance in pedaling by turning the resistance setting knob. From testing the full system with multiple users it is apparent that this feature will be feasible to implement into the module design.Safety and ErgonomicsThe completed prototype includes a removable vinyl roof protecting the users from the occasional shower, as well as too much sun. A step bar is also included on the chassis design offering safe access to the module seating without unnecessary strain. The tires included on the final prototype are ensured to have a small rolling coefficient; in other words, the force resisting the forward movement is minimal. The modular seating is adjustable allowing the users customization on seat height, avoiding possible injury stemmed from improper use. The prototype comes equipped with an adjustable rear seat. Following standard requirements, an emergency brake is included. Equipped with front disc brakes and rear drum brakes, the completed prototype offers exceptional stopping ability with respect to the vehicle’s top speed.Maintenance & CostThe individual modular design is unique with respect to maintenance. Upon potential failure, a module can be extracted by removing two bolts, allowing for convenient and quick repair. The bill of materials is listed ponentsQuantityPrice Ea.Total PriceVendorFront Crossmember1$220.00$220.00Upper Control Arms1$200.00$200.00Lower Control Arms1$300.00$300.00Coilover Shocks2$200.00$400.00Steering Rack1$150.00$150.00Spindles2$160.00$320.00Brake Rotors2$30.00$60.00Brake Calipers2$25.00$50.00O'Reillys Auto PartsCaliper Brackets2$12.50$25.00Axle Housing1$295.00$295.00Differential1$300.00$300.00Leaf Springs2$75.00$150.00Tie Rods4$14.00$56.00Master Cylinder1$47.00$47.00Batteries4$170.00$680.00Front Wheels2$45.00$90.00Rear Wheels2$45.00$90.00Front Tires2$35.00$70.00Rear Tires2$45.00$90.00Axles2$125.00$250.00Pedal Sets6$50.00$300.00Bike Rims6$35.00$210.00Bike Chains6$15.00$90.00Drive Belts6$20.00$120.00Bike Seats6$18.00$108.00Steering Wheel1$20.00$20.00LED Headlights2$22.00$44.00Tail Lights2$12.50$25.00Touch Screens6$99.00$594.00Horn1$15.00$15.00AutoZoneEmergency Brake1$102.00$102.00Voltage Regulator6$13.00$78.00Charge Controller2$12.00$24.00Generators6$250.00$1,500.00Motor1$500.00$500.00Subtotal$7,573.00MaterialsFeet$/FtPriceSource2x4 0.250" wall A36 Tube70$16.00$1,120.002x2 0.250" wall A36 Tube2210.75$236.501.5x1.5 0.125" wall A36 Tube24$4.75$114.001x1 0.125" wall A36 Tube23$3.00$69.001.5 OD 0.125" wall A36 Tube19$5.37$102.031x1 0.125" wall 6061-T6100$2.25$225.00Subtotal$1,866.53Grand Total$9,439.53ConclusionThe completed prototype shows the design of the chassis, frame, suspension, gearing and the electrical components needed to fulfill the goal of having a human powered bike that has an individual selective pedaling resistance implemented as a key feature. Through finite element analysis, the mechanical design includes structurally sound components that maintain sufficient rigidity throughout operational loads and stresses. From building, designing, and testing an electrical system it is feasible to have a resistance control feature added to the module. Ensuring use of components readily available, the prototype was designed to include parts that can be conveniently replaced upon failure, minimizing operational downtime. Fulfilling the design requirements pushing the forefront of existing multi-person bicycles, the completed design is a model of a new innovative idea unique to the growing market, as well as renewable power generation. ????Appendix I: Product Design CriteriaPerformanceGreater than 70% efficient under optimum conditionsMaximum speed of 10 miles per hourExceed 5 miles of travel on batteries alone (no pedaling)Individual selective resistance to pedalingOptimum seat height and angleChassis and body to support 1000 lbs (5 operators)Controllers to regulate and divide energy to motor or batteryVisual display for individual power generation dataAesthetically pleasingLifetime of 10 yearsEnvironmentMinimal suspension for city road useCovered pedaler and driver seating for shelter from weatherWatertight electrical connectionsCorrosion resistant coating on environmentally exposed componentsErgonomicsPedalers and driver able to comfortably sit for 30 minute intervalsAdjustable seating to maintain proper ergonomics while providing highest efficiencyOperator interaction with controllers to be efficient, yet not cause additional stress by too rapid of an adjustmentSafetyRoadworthy to ODOT standardsHeadlight capable of projecting a minimum of 500 feetTwo taillightsFree of sharp edges and pinch pointsMaintenanceWeekly maintenance not to exceed 1 hourMud, grime, and debris removalQuarterly maintenance not to exceed 1 dayLubrication and securing fastenersAnnual maintenance not to exceed 1 weekReplacement of worn componentsMaterialsLightweight to maintain efficiencyCommercially available componentsAppendix II: Research (Sources)Solar charge controllers regulator (5-9V output) buck Powered applications Motor Inspiration Images Vehicle Information III: Alternate DesignsDirect-Drive GeneratorFlipped bike with seatAppendix IV: Arduino Codeint motor=7; ???????????????????//Relay between generator and motor controlled by pin 7int batt=6; ????????????????????//Relay between generator and battery controlled by pin 6int resistance=3; ??????????????//Analog reading from potentiometer set to pin A3int rval=0;int data=11;int clock=3;int latch=2;int leds=0;int relay1=LOW;int relay2=LOW;long trelay1=0;long trelay2= 0;long delay1=10;long delay2=20;long delay3=30;long delay4=40;long delay5=50;long delay6=60;long delay7=70;long delay8=80;long delay9=90;void setup() {?Serial.begin(9600);?pinMode(motor, OUTPUT);?pinMode(batt, OUTPUT);?pinMode(battMot, OUTPUT);?pinMode(data, OUTPUT);?pinMode(clock, OUTPUT);?pinMode(latch, OUTPUT);}void loop() {??rval=analogRead(resistance);?//Serial.println(rval);?int mrange= map(rval, 0 , 1023, 0, 10);?unsigned long m= millis();?int numLEDSLit=rval/180;?leds=0;?for(int i=0;i<numLEDSLit; i++) {??bitSet(leds,i);}updateShiftRegister ();??switch (mrange) ?{??????case 0:??????digitalWrite(batt, HIGH);???digitalWrite(motor,LOW);???Serial.print("Battery 100%");???Serial.print("\t");???Serial.println("Motor 0%");???break;??????case 1:???????Serial.print("Battery 90%");???Serial.print("\t");???Serial.println("Motor 10%");??????if ((relay1 == HIGH) && (m - trelay1>= delay9)) {??????????relay1=LOW;???trelay1=m;???digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay1)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay1)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay9)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}???break;??????????case 2:???????Serial.print("Battery 80%");???Serial.print("\t");???Serial.println("Motor 20%");??????????if ((relay1 == HIGH) && (m-trelay1>= delay8)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay2)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay2)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay8)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}???break;??????case 3:???????Serial.print("Battery 70%");???Serial.print("\t");???Serial.println("Motor 30%");??????if ((relay1 == HIGH) && (m-trelay1>= delay7)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay3)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay3)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,trelay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay7)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}???break;??????case 4:???????Serial.print("Battery 60%");???Serial.print("\t");???Serial.println("Motor 40%");??????if ((relay1 == HIGH) && (m-trelay1>= delay6)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay4)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay4)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay6)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}???break;??????case 5:???????Serial.print("Battery 50%");???Serial.print("\t");???Serial.println("Motor 50%");?????????if ((relay1 == HIGH) && (m-trelay1>= delay5)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay5)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay5)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay5)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}???????break; ????case 6:???Serial.print("Battery 40%");???Serial.print("\t");???Serial.println("Motor 60%");????????????????if ((relay1 == HIGH) && (m-trelay1>= delay4)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay6)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay6)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay4)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}???????break; ??????????case 7:???Serial.print("Battery 30%");???Serial.print("\t");???Serial.println("Motor 70%");????????if ((relay1 == HIGH) && (m-trelay1>= delay3)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay7)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay7)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay3)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}???????break; ?????????case 8:???????Serial.print("Battery 20%");???Serial.print("\t");???Serial.println("Motor 80%");?????????if ((relay1 == HIGH) && (m-trelay1>= delay2)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay8)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt,relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay8)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay2)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}????????break;??????case 9:???????Serial.print("Battery 10%");???Serial.print("\t");???Serial.println("Motor 90%");?????????if ((relay1 == HIGH) && (m-trelay1>= delay1)) {?????trelay1=m;?????relay1=LOW;??????digitalWrite(batt,relay1);?}?????else if ((relay1 == LOW) && (m-trelay1>= delay9)) {?????trelay1=m;?????relay1=HIGH;???digitalWrite(batt, relay1);??}???????if ((relay2 == HIGH) && (m-trelay2>= delay9)) {?????trelay2=m;?????relay2=LOW;??????digitalWrite(motor,relay2);?}?????else if ((relay2 == LOW) && (m-trelay2>= delay1)) {?????trelay2=m;?????relay2=HIGH;???digitalWrite(motor,relay2);??}?????????break;??????case 10:?????digitalWrite(batt, LOW);???digitalWrite(motor,HIGH);???Serial.print("Battery 0%");???Serial.print("\t");???Serial.println("Motor 100%");???break;?}}void updateShiftRegister() {?digitalWrite(latch, LOW);?shiftOut (data, clock, LSBFIRST, leds);?digitalWrite(latch, HIGH);}Appendix V: Electrical Component SpecificationsArduinoMicrocontrollerATmega328Operating Voltage5VInput Voltage (recommended)7-12VInput Voltage (limits)6-20VDigital I/O Pins14 (of which 6 provide PWM output)Analog Input Pins6DC Current per I/O Pin40 mADC Current for 3.3V Pin50 mAFlash Memory32 KB (ATmega328) of which 0.5 KB used by bootloaderSRAM2 KB (ATmega328)EEPROM1 KB (ATmega328)Clock Speed16 MHzLength68.6 mmWidth53.4 mmWeight25 gFigure SEQ Figure \* ARABIC 7: Arduino UNORelay ShieldFigure SEQ Figure \* ARABIC 8: Speed Relay ShieldGeneratorMotor Model No. MY6812Nominal voltage: 24 VDCSpeed at 24 VDC: 3000 RPMCurrent: 8 AmperesPower: 135 WattsFigure SEQ Figure \* ARABIC 9: Unite Motor Model MY6812Voltage RegulatorModule properties: non-isolated step-down module (BUCK) Input Voltage: DC 5-40V Output Voltage:DC 1.25-36V Output Current: 12AFigure SEQ Figure \* ARABIC 10: DROK DC Car Power Supply Voltage Regulator Buck ConverterMotorPower: 1/4 HPVoltage: 12 DCSpeed/Amps: 2600 RPM, 2.2 amps no load2300 RPM, 25 amps, 7 in.lbs. torqueFigure SEQ Figure \* ARABIC 11: 12V BLDC MotorCharge ControllerRated voltage: 12V or 24VRated charging current: 10ARated load current: 10AVoltage of stop power supply: *10.8V or 21.6VVoltage of resume power supply: *11.8V or 23.6VVoltage of stop charging: *14V or 28VFigure SEQ Figure \* ARABIC 12: Docooler Charge ControllerBatteryFigure SEQ Figure \* ARABIC 13: Energizer 12 VDC BatteryAppendix VI: Module-generator Design MatrixAppendix VII: Assembly DrawingsAppendix VIII: FEA ................
................

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

Google Online Preview   Download