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 MountingA 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.
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
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.
Powertrain Transportation and HoldingAnother 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.
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.
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 CouplingLast 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.
The team is investigating the many options that can utilized for their coupling system.
Electrical Systems DesignThe 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 MountingIt 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.
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 DiagramFor 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.
Detailed Design ReviewOur 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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