P17280: Hot Wheelz Thermal Management System
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Systems Design

Table of Contents

Team Vision for System-Level Design Phase

Our team planned to identify whether or not liquid cooling would be necessary for this project, as this would add complexity and cost to the project. We also planned to conduct preliminary temperature testing on the motor controller to develop a more quantitative understanding of the problem. From there, we planned to create a preliminary model to rough estimate the amount of heat being generated from the controller and then be able to select a system concept to move forward with that coincided with the needs that we identified.

Preliminary testing was performed on the vehicle. This aided in the model development, as well as the analysis of the system concepts in the Pugh Chart. After we knew what kind of heat would be present, we were able to make more educated decisions regarding a concept selection. Our team successfully completed all of our primary goals for the System-Level Design phase and has concluded that liquid cooling will not be necessary for this application.

Our work breakdown structure from Phase 2 can be viewed here.

Functional Decomposition

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A working document can be found here.

Engineering Requirements Mapping

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A working document can be found here.

Benchmarking

Fans

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A working document can be found here.

Current Device: Component Placement and Mounting Tabs

After a preliminary interview with the Hot Wheelz Vehicle Dynamics Subgroup regarding mounting components to the frame, we learned the following:

Current Device: Motor Controller

After a preliminary interview with the Curtis Controller Representative/Mentor for the Hot Wheelz team, we discovered the following:

The full interview cannot be shared due to it being Proprietary Information.

Current Device: Battery Management System (BMS)

After a preliminary interview with the Hot Wheelz Safety Systems Subgroup regarding controlling fans with the BMS, we learned the following:

The full interview can be found here, where there are also some excerpts from the BMS manual regarding the subject.

Protecting Devices

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A working document can be found here.

Materials

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A working document can be found here

Morphological Chart

P17280 Morphological Chart

P17280 Morphological Chart

A working document can be found here.

P17280 Concept Selection

P17280 Concept Selection

A working document can be found here.

Concept Development

Selection Criteria

Criteria Explanation
Does not leak Components in the system are not likely to leak fluids
Difficulty to waterproof Components in the system are waterproof or can be waterproofed
Removes heat quickly Components in the system remove heat from the motor controller and batteries quickly
Pulls minimal current/power Components in the system pull minimal current/power from the GLV battery
Lightweight Components in the system are light
Cost effective Components in the system are inexpensive
Doesn't take up a lot of space Components are small/can fit on the vehicle without taking up much space
Is safe Components pose little to no danger or risk to users, installers, or other persons
Easy to install Components in the system take little time to install on the vehicle
Easy to manufacture Components in the system take little time to manufacture
Doesn't break easily Components in the system are durable and not easily broken
Can be built quickly Components in the system can be built or assembled in little time
Accuracy of measurement Components measuring the temperature are accurate
Ease of data processing It will take little time and is easy for the team to process the temperature data
Ease of use for driver System will require little to no effort from the driver to operate

Pugh Charts

Pugh Chart with Concept 1 (Current System) as the Datum

Pugh Chart with Concept 1 (Current System) as the Datum


Pugh Chart with Concept 6 as the Datum

Pugh Chart with Concept 6 as the Datum


Pugh Chart with Concept 5 as the Datum

Pugh Chart with Concept 5 as the Datum


A working document can be found here.

Feasibility: Prototyping, Analysis, Simulation

Weather Data

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Voltage/Current Draw

CR6: System pulls minimal current/power from Hot Wheelz 12V battery

ER2: Maximum current draw marginal value is 0 - 10A

ER3: Maximum operating voltage marginal value is 12V

Benchmarked components can be found here.

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A working document can be found here.

Motor Controller Temperature Data

The test plan and procedure for collecting the motor controller temperature data can be found here.

T1: On the front, right surface of the motor controller heat sink

T2: On the front, left surface of the motor controller heat sink

T3: Air temperature in the motor controller enclosure

T4: On the back, left surface of the motor controller heat sink

A video of our test run can be viewed here!

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A working document of the temperature data can be found here.

Initial Heat Transfer Model for the Motor Controller

An initial model was created for the motor controller subsystem. The battery subsystem has not been explored yet, as the customer has not finalized the battery pack or location. Additionally, we decided not to evaluate the heat from the BMS after consulting with the customer and researching the device. The data used for the model was taken from the test run on 9/25/16. Although 70W is a small amount of energy, the test was run at steady state conditions and the controller was not working at full capacity. This will be explored further in later tests to be completed in the next phase.

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A PDF of the above work can be found here.

Concept Selection

Sketches

Primary Concept

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Secondary Concept

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Concept Selection

Systems Architecture

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Risk Assessment

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A working document can be found here.

Have you updated your risk list (started during Problem Definition) to include new items specific to your chosen concept?

Test Plans

Goals for Next Phase

At our next review, we hope to have identified the following:

Project Plan

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The PDF can be viewed here, and the actual MS Project file can be viewed here.

Individual Plans

Missy Miller's Three Week Plan
Caitlin Babul's Three Week Plan
Jordan Short's Three Week Plan
Kristin Zatwarnicki's Three Week Plan

Work Breakdown Structure

public/Systems%20Level%20Design%20Documents/Plans_Work%20Breakdown%20Structure_Phase3.JPG?rev=0

A working document can be found here.


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