P15280: Hot Wheelz Test Bench
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Detailed Design

Table of Contents

During the detailed design phase of this project our team divided and conquered relevant mechanical and electrical design tasks as detailed below.

Mechanical Systems Design

One of the teams main goals is to integrate the powertrain system onto the dynamometer system safely and quickly. Portability, quick setup and tear down are critical requirements when using shared testing facilities.

Motor Mounting

A critical component of testing on the dynamometer is properly mounting the motor so that it can couple with the loading motor of the dynamometer. As seen below a motor mount has been created that matches the hole pattern of the Hot Wheelz Team Motor.
Base Plate that will mount to the exsisting dynamometer table and allow for mounting of the Hot Wheelz motor.

Base Plate that will mount to the exsisting dynamometer table and allow for mounting of the Hot Wheelz motor.

Will be directly connected to the Hot Wheelz Motor

Will be directly connected to the Hot Wheelz Motor

Connection between motor mount and the baseplate. Featuring slotted holes the motor can move to accommodate the chain positioning.

Connection between motor mount and the baseplate. Featuring slotted holes the motor can move to accommodate the chain positioning.

When the two components are assembled FEA analysis can be completed to identify areas of failure and need for improvement upon the initial design. FEA analysis was completed using the following parameters:

Motor Weight = 45 lbs

Rotation Speed = 3000 RPM

Force on Mounting Holes = 100 N/m

Initial FEA Analysis on Assembled Motor Mount

Initial FEA Analysis on Assembled Motor Mount

As seen above, the assembly exceeds the yield strength of AISI 1020 steel. Using this information the motor mount will be redesigned adding additional strength to accommodate worst case rotation forces that could be seen by the motor.

Although the motor mount design will be changed to accommodate the forces, below is an image of the total assembly with the motor as well as the assembly shown on the current dynamometer.

Total Assembly with the Hot Wheelz Motor

Total Assembly with the Hot Wheelz Motor

Motor Mount placed on the dynamometer

Motor Mount placed on the dynamometer

Powertrain Transportation and Holding

Another key facet to the design of this system is being able to easily transport the powertrain system from the Hot Wheelz team room to the testing facility. Using an industrial cart, the team will modify the cart to hold the batteries, controller and motor during transport and the batteries and the controller during testing. Seen below is the cart sourced to hold components.
Industrial Powertrain Transportation Cart

Industrial Powertrain Transportation Cart

The cart features additional mounting areas so that the team can add a place to mount the motor easily during transportation and easily detach the motor to assemble onto the dynamometer.

Concept Drawing of motor mounting during transportation

Concept Drawing of motor mounting during transportation

Design to mount the motor during transportation using the industrial cart.

Design to mount the motor during transportation using the industrial cart.

Moving forward, the cart will be outfitted with modular mounting options for the batteries and controller so that year to year the Hot Wheelz team can make changes and utilize the transportation cart.

Motor to Dynamometer Coupling

Last but certainly not least the Hot Wheelz motor and the loading motor need to be properly connected in order for proper testing. As discussed earlier it is essential that the team can easily setup and tear down on the test facility. An idler system is being designed to quickly attach and detach the chain from the system.
Current coupling setup on the dynamometer

Current coupling setup on the dynamometer

The team is investigating the many options that can utilized for their coupling system.

Gear system between Hot Wheelz Motor and loading motor

Gear system between Hot Wheelz Motor and loading motor

Idler Concepts that can be utilized

Idler Concepts that can be utilized

Electrical Systems Design

The electrical components of this project consist of many different aspects from sourcing the proper sensors to collect the necessary data to integrating with the Dyne Controller that is currently featured on the dynamometer.

Sensor Sourcing and Mounting

It is critical that data is collected on key components of the powertrain system including voltage, current, battery and motor temperature, rpm and torque.
Sensors that have been sourced to collect measurements. Highlighted in yellow is a component that is dependent on the DAQ device the team is able to acquire.

Sensors that have been sourced to collect measurements. Highlighted in yellow is a component that is dependent on the DAQ device the team is able to acquire.

Now that the sensors have been sourced, the team needs to work together to properly mount the sensors to the current design so that the sensors remain safe during test and transportation.

System Wiring Diagram

For this phase of senior design, a preliminary wiring diagram and a custom PCB diagram have been created prior to finalizing the electrical system. The wiring diagram consists of every physical wire with electrical connections that will be on the final deliverable. A wiring harness between the control room and the dyno room has also been identified in the diagram to ensure necessary communication between the devices in each room. For the custom PCB, it consists of the power supplying scheme for the sensors, possible filtering that may or may not be necessary depending on the selection of the NI DAQ, and built-in polarity protection by the Schottky diode.
Wiring Diagram

Wiring Diagram

PCB Design

PCB Design

Dynamometer Testing

 Description

Description

Test

Test

Detailed Design Review

Our team assembles a conclusive presentation at the end of each review to summarize our work which is located here: Phase 4: Detailed Design Review Presentation

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