Technical Review Agenda

Transcription

1 KGCOE MSD Technical Review Agenda P13261: Electric Motorcycle Powertrain Development Meeting Purpose: 1. To give the customers a better idea of what we had in mind for the scope of the project. 2. To confirm with the customers the various specifications and customer needs. 3. To review concepts that are necessary for the project to continue. 4. Propose system level design and preliminary detailed design. 5. Receive input and guidance. Materials to be reviewed: 1. 1-Page Summary of the project 2. Functional Decomposition/Block Diagram 3. Customer Needs 4. Customer Specifications 5. Traction Control and Mechanical Systems Schematic 6. Concept Development and Systems Level Design 7. Task Schedule 8. Risk Assessment Meeting Date: Monday, October 1st, 2012 Meeting Location: Innovation Center at RIT Meeting time: 6:00 pm - 7:00 pm Timeline Meeting Timeline Start time Topic of Review Required Attendees 6:00 Discuss Scope of Project John Kennedy, George Slack 6:15 Discuss Customer Needs and Specifications John Kennedy, George Slack 6:30 Discuss Systems Level Design John Kennedy, George Slack 6:45 Discuss Schedule and Risk Assessment John Kennedy, George Slack KGCOE MSD Page 1 of 15 Technical Review Agenda

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8 P13261 Concept Selection - Motor Types Segment AC Single DC Double DC Selection Criteria Weight Rating Weight Rating Weight Rating Power Weight Complexity Cost Energy Requirements Weight Efficiency Total Score Rank Continue? Yes No No 12 Concept Selection - System Controller Segment Microchip Controller MoTeC Controller Mission Motors Controller Selection Criteria Weight Rating Weight Rating Weight Rating Weight Cost Integrable Multi-Functional Programmability Size Technical Support Total Score Rank Continue Yes No No 20 KGCOE MSD Page 8 of 15 Technical Review Agenda

9 Traction Control Sensors Concept Selection Segment Wheel Speed (WS) Sensors Wheel Speed & Motor Sensors Motor Sensors w/ Gyroscope w/ Accelerometer w/ Potentiometer Selection Criteria Weight Rating Weight Rating Weight Rating Weight Rating Weight Rating Weight Rating Weight Input Complexity Algorithm Complexity Wheel Slip Wheel Lift Data Availably Part Availability Durability Total Score Rank Continue? KGCOE MSD Page 9 of 15 Technical Review Agenda

10 Concept Development Analysis for Control Station Component Importance (1-5) Feasibility (1-5) Complexity (-5-0) Total Emergency Stop Button Labview Program Running on Laptop Multiple Test Programs Data Log Output Display from Micro. Via Battery Monitoring Display Throttle Notes Would be a signal from the control station to the test bench, disconnecting power from the power supply. Labview would be the interface to the testbench, could incorporate blinking lights and other operation signals The test programs would be built in labview and would interact with the testbench/microcontroller Outputs the data that is being recorded by the traction control micro and possibly the motor controller. Output data from a BMS, if we have one, or from the micro, if code is implemented to gather that data Input to the traction controller that is adjusted based on other external sensors sensing traction control. KGCOE MSD Page 10 of 15 Technical Review Agenda

11 P13261 Project Task Schedule (Revised) Work Break Down Name 1. Choose Components Start Week Finish Week 1. Select a motor AC electric type James Select a motor controller James Select a micro-controller for the traction control system (programmable in C) Josh Determine a rough transmission design Dan Determine how many sensors we need Team What type of sensor (i.e. laser, accelerometer, gyroscope, etc..) E E Various circuit components (circuit protection, wiring..) James DC/AC converter Josh Spec System 9. Determine motor power consumption E E Choose a motor voltage range and current consumption James Determine power consumption of controller James Determine current rating of controller Josh Draw up a system design (i.e. visio schematic) James Control Systems 14. Emergency Stop James Rear Wheel Slip Control - Pseudo Code Josh TTXGP Safety requirements are met Andrew Front Wheel Lift Control - Pseudo Code Josh Power consumption/rpm level should follow an optimum curve Andrew System monitoring Battery Level, Battery Temp, etc Josh Determine Inputs report throttle position, gear position, front wheel speed, James rear wheel speed, etc Test Bed Design 21. Create numerical model for testing of transmission gearing Andrew Obtain a peg board with inputs and outputs from controller Josh MSD II LabView Simulation test interface/actual Motorcycle tests Andrew MSD II AutoCAD schematic design of test bed Dan/Sean 5 9 Start of MSD II Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 1 Week 2 Week 3 M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S KGCOE MSD Page 11 of 15 Technical Review Agenda

12 5. Math Model/Transmission Design 25. Understand Motorcycle dynamics M E Obtain motor curves Andrew Understand power consumption in order to optimize M E Determine braking acceleration Determine number of gears Andrew Create optimization algorithm to determine optimal gear ratios Design gear box via modification of existing Build gear box MSD II 6. Paperwork/MSD 1 Deliverables 33. Activity List Sean Specification List on EDGE Dan Page Summary Sean AC vs. DC decision matrix Josh James Andrew Risk-Assessment analysis Andrew Safety Assessment Andrew Design Review #1 Team Individual Roles and Responsibilities Dan Detailed Design 41. Chassis Stand CAD Drawing M E s Rear Wheel Mount Sean Front Wheel Tie Down and Hard Stop Sean Rolling Drum Assembly Dan Rear Rolling Drum Assembly Dan Front Adjustable Rolling Drum Assembly Dan Bill of Materials Mechcanical Components M E s Assembly CAD Detail Drawing Sean / Dan Part CAD Detail Drawing Sean / Dan Powertrain Schematic for motor controller James Powertrain Schematic for traction controls system Josh Bill of Materials for Electrical Componets E E s Manufacturing Plan M E s Math Model (Transmission Deliverable) Andrew Lab View Diagram Interface Josh MSD II CAD Model of Peg Board and Inputs Sean MSD II Test Planning Team 8 10 KGCOE MSD Page 12 of 15 Technical Review Agenda

13 Risk Assement Risk: Effect of Risk: Severity: Probability: Preventative Action: Club Funding Falls Through Unable to purchase components for system 4 4 Severe Member Illness or Loss Unable to form consensus on components Team loses a member resulting in an excessive work load for each other Resulting Severity Resulting Probability In the event club funding falls through the project can be scaled back to run on the PERM motor and controller from hellboy. The funding already allocated to the Sr. Design project should be sufficient to obtain sensors. A micro controller should be able to be obtained from the CE department 2 4 inidividual team member 5 1 none 5 1 Delay in specing system delays detailed system design 1 3 Rules for dealing with disagreements and lack of concsensus outlined in??? 1 3 Unable to find components that meet spec 5 1 Delay in lead time for control systems components Programmability of controller and micro-controller not as specified Failure or damage of equipment due to feedback Failure of parts or sensors to meet stated spec Non-Compatible Components Unable to get sufficient or accurate enough data to complete model Transmission not viable due to low efficiency increase Transmission not viable due to space and geometry of bike frame Causes the integration and debugging portion of the project to begin later than scheduled 2 2 In the event components are not available that meet spec a reassesment of the project would be needed. This is severely unlikely as the project can again be scaled down to run on the motor and controller from hellboy it would just be sensors and other components which are severly unlikely to be an issue 5 1 The identification of components and obtaining of components is to begin as early as possible (after the detailed design review) to maximize available integration and debugging time. 2 1 Causes a need to obtain new equipment increasing the budget, and lead time 4 1 Detailed conversations with manufacturers and suppliers prior to purhase 4 1 Creates a need to fix or purchase new equipment 4 2 Careful design of circuits to ensure no high voltage feedback through controller or micro 4 1 Whether through a bug or innacurate assesment may create a need to obtain new equipment Creates a need to return/re-purchase Entire system should be specced out so compatibility can be ensured prior to purchasing equipment 3 3 of components 3 1 Accuracy of model becomes significantly decreased 2 4 Makes the transmission no longer a viable option for the bike 5 1 Transmission becomes not easily integratable with the existing frame. 5 2 Model can be scaled up or down to available data. Necessary data which cannot be determined can be made available inputs left as unity for the function. 1 4 Ideal gear ratios will still be determined as well as what the total bike weight and efficiency changes would be for the smallest most lightweight transmission available. 2 1 The smallest lightest weight transmission possible will be designed with ideal gear ratios for the given track. Installing a transmission can then be reassesed by the club and potential changes to the clubs portion of the bike will be assesed by the club. 3 2 KGCOE MSD Page 13 of 15 Technical Review Agenda

14 Actions and Issues Meeting Purpose: Present/Discuss system level design with customer Materials Reviewed: Customer Needs, Test bench design, Functional decomposition, Traction control matrix, motor type selection, Safety & Risk Assessment Attendees: John Kennedy (Customer), Joshua Doores, Dan Brownlee, Andrew Robison, Sean Harriman, James Evans Recorded by: Joshua Doores Joshua Doores (signature of person recording meeting notes) Meeting Date: Monday October 1st Previous Open Action Items Reviewed: 1.) Type of motor to be used; AC or DC. It was decided that we would like to go with an AC motor, but based on the availability, we may have to use the clubs DC motor. Discussion: AC vs. DC matrix was created and discussed. Traction control system inputs/sensors matrix was built and discussed to determine the best set-up to use. A drawing of the test bench was created and reviewed. Action Items Item # Description Responsible Due Close Date Date A001 Sensors to be used for traction control Josh 10/19 A002 Safety Concerns Andrew, James 10/12 10/12 A003 Transmission system ME s 11/9 A004 Test bench set-up Sean, Dan 11/9 A005 Component Selection based on funding Team 11/9 Comments KGCOE MSD Page 14 of 15 Technical Review Agenda

15 Issues Item # Description Responsible Open Close Date Date I001 Complexity of traction algorithm, also what can we test. Josh 10/5 10/12 I002 What preventative measures should be James, taken for safety Andrew 10/5 10/12 How in depth is system, what are I003 deliverables? How many gears? What ME s 9/28 ratio? I004 How to create rear wheel slip and front wheel lift? Sean 10/5 How much funding will we have, when I005 do we decide to continue without the Team 10/5 funding. Comments Item # D001 D002 D003 D004 Description Start with 2 Hall Effect Sensors, and then incorporate other inputs such as motor speed and front suspension lift Power isolation, use of fuses and breakers for electrical protection More data needs to be obtained; however, the goal has been re-defined to creating a model that predicts the optimized gear number and ratio. Placing tires on rolling cylinders with a resistance level that the motor can exceed to create wheel slip Decisions Contributing Individuals Decision Date Josh, James 10/12 James, Andrew ME s D005 Make final decision by end of MSD I Team, Dan 10/12 TBD TBD Comments KGCOE MSD Page 15 of 15 Technical Review Agenda