Multidisciplinary Senior Design

Project Readiness Package

Project Title: / Electric Superbike Off-board Charger
Project Number:
(MSD will assign this) / P15261
Primary Customer:
(provide name, phone number, and email) / EVT, Josh Jones, Wheeler Law, Derek Gutheil
Sponsor(s):
(provide name, phone number, email, and amount of support) / MSD Senior Design department
Preferred Start Term: / Spring 2015
Faculty Champion:
(provide name and email) / Prof. George Slack,
Other Support:
Project Guide:
(MSD will assign this) / Slack
EVT, Josh Jones, Derek Gutheil / January 2015
Prepared By / Date
Received By / Date

Project Information

Overview:

The RIT Electric Vehicle Team is a student run organization dedicated to promoting the viability of electric vehicles through real world demonstrations of electric drivetrains in action. The team aims to educate people on the principles of electric vehicle design by engaging students in challenging and rewarding projects that cover a wide variety of academic disciplines. The team’s main project is to design, build, and race a high performance electric motorcycle for competition in the 2015 eMotoRacing all-electric race series. The current bike is based off of the frame from a 2005 Kawasaki Ninja ZX6RR, and utilizes two Zero Z-Force 75-7 motors paired with two Sevcon Size6 controllers. In house engineering includes the design and fabrication of a battery management system, battery containment modules, structural framing for the mounting of the powertrain, as well as advanced data collection and analysis software. Based on this, the team is currently in need of a high powered charger that can charge the bike's battery pack in a reasonable amount of time.

Project Goals:

The R.I.T. Electric Vehicle Team proposes a portable off-board charger for an electric super bike. In order to compete in the E-Moto Racing series, the team requires an efficient and reliable method of charging the bike's 12 Kwh battery pack. Unlike traditional battery chargers, the superbikes charger must conform to the J-1772 electric vehicle charging standard.

References:

[1]

[2]

[3]

[4]

Customer Requirements (CR):

This list of customer requirements of anticipated activities.

CR # / Imp. / Customer Need / Description
CR1 / 1 / Battery connection / Able to safely connect and discount battery.
CR2 / 1 / Power on / off / Able to safely power on and power off charger
CR3 / 4 / LCD Display / Able to know the charging rates, state of charge, charging time, etc.
CR4 / 3 / Adjustable / Able to select voltage and current
CR5 / 1 / J-1772 standard / Able to implement given standard(s)
CR6 / 3 / Communication with the Superbike / Able to communicate with the Superbike's BMS via CAN
CR7 / 1 / Wall connection / Able to charge via J-1772 or 120V Wall connection
CR8 / 3 / Documentation / Every facet of the project must be well documented with instructions where necessary
CR9
CR10

Engineering Requirements (ER):

  1. Power Requirements
  2. The charger must be capable of charging a battery from full discharge to full charge in no more than 4 hours while using the J-1772 standard charging station
  3. The charger must also be capable of operating through standard 120V 15A 60Hz wall outlets. While in this low power mode, the charger must be capable of charging the battery in no more than 12 hours
  4. The charging system must automatically detect and switch between the low and high power modes
  5. Control Requirements
  6. The charger must be able to output voltage and current to within 20% of the nominal values in either mode. These outputs must also be regulated to within 1% of their set values
  7. The charger must be able to vary voltage and current through both software and a user interface
  8. Communication Requirements
  9. Needs to conform to the J-1772 communication protocol for use in high power mode
  10. During all modes of operation, the charger must be capable of communicating over CAN

Constraints:

Safety is of the upmost importance. It will be a factor in every aspect of the design. The batteries on the Superbike that will be charged have a large capacity, and as such, will not be readily available for testing. The Electric Vehicle Team has access to them and can provide them upon request. Most EVT members can be made available with a reasonable notice for assistance. EVT members will also be a regular part of the design process ensuring that their goals are met.

Project Deliverables:

Minimum requirements:

●All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test results)

●working prototype

●technical paper

●poster

Additional required deliverables:

●List here, if applicable

Budget Information:

List major cost items anticipated, and any special purchasing requirements from the sponsor(s).

Intellectual Property:

There are no IP restrictions on this project

Project Resources

Required Resources (besides student staffing):

Describe the resources necessary for successful project completion. When the resource is secured, the responsible person should initial and date to acknowledge that they have agreed to provide this support. We assume that all teams with ME/ISE students will have access to the ME Machine Shop and all teams with EE students will have access to the EE Senior Design Lab, so it is not necessary to list these! Limit this list to specialized expertise, space, equipment, and materials

Faculty list individuals and their area of expertise (people who can provide specialized knowledge unique to your project, e.g., faculty you will need to consult for more than a basic technical question during office hours) / Initial/date
Josh Jones, Derek Gutheil
Environment (e.g., a specific lab with specialized equipment/facilities, space for very large or oily/greasy projects, space for projects that generate airborne debris or hazardous gases, specific electrical requirements such as 3-phase power) / Initial/date
EVT lab, MSD space, J-1772 connectors in parking lot
Equipment (specific computing, test, measurement, or construction equipment that the team will need to borrow, e.g., CMM, SEM, ) / Initial/date
Standard lab equipment, J-1772 connector
Materials (materials that will be consumed during the course of the project, e.g., test samples from customer, specialized raw material for construction, chemicals that must be purchased and stored) / Initial/date
Batteries are purchased and stored by EVT.
Other / Initial/date

Anticipated Staffing By Discipline:

Indicate the requested staffing for each discipline, along with a brief explanation of the associated activities. “Other” includes students from any department on campus besides those explicitly listed. For example, we have done projects with students from Industrial Design, Business, Software Engineering, Civil Engineering Technology, and Information Technology. If you have recruited students to work on this project (including student-initiated projects), include their names here, as well!

Disc. / # Req. / Expected Activities
EE / 3 /
  • High power electronics capable of complying with J-1772 standard or wall outlet specifications while charging the Superbike.
  • Sensing capable of detecting the charge rates.
  • Interface a microcontroller with analog circuitry to measure charging rates.
  • Report this data over CAN to other microcontrollers.

ISE / 0-1 /
  • Direct systems engineering processes and then guide operation of the entire system.
  • Ensure team members are aware of each other's progress, risks and issues.
  • Assist in software algorithms and programming, where possible.

ME / 0-1 /
  • Design enclosure capable of dissipating reasonable amounts of heat while being portable,
  • Ease of use, and
  • As portable and light as possible.

Skills Checklist:

Indicate the sills or knowledge that will be needed by students working on this project. Please use the following scale:

1=must have

2=helpful, but not essential

3=either a very small part of the project, or relates to a “bonus” feature

blank = not applicable to this project

Mechanical Engineering

ME Core Knowledge / ME Elective Knowledge
2 / 3D CAD / Finite element analysis
Matlab programming / 1 / Heat transfer
2 / Basic machining / Modeling of electromechanical & fluid systems
2D stress analysis / Fatigue and static failure criteria
2 / 2D static/dynamic analysis / Machine elements
Thermodynamics / Aerodynamics
Fluid dynamics (CV) / Computational fluid dynamics
LabView / Biomaterials
Statistics / Vibrations
IC Engines
GD&T
Linear Controls
Composites
2 / Robotics
Other (specify)

Electrical Engineering

EE Core Knowledge / EE Elective Knowledge
1 / Circuit Design (AC/DC converters, regulators, amplifies, analog filter design, FPGA logic design, sensor bias/support circuitry) / 3 / Digital filter design and implementation
1 / Power systems: selection, analysis, power budget / 3 / Digital signal processing
1 / System analysis: frequency analysis (Fourier, Laplace), stability, PID controllers, modulation schemes, VCO’s & mixers, ADC selection / 1 / Microcontroller selection/application
1 / Circuit build, test, debug (scope, DMM, function generator / Wireless: communication protocol, component selection
2 / Board layout / Antenna selection (simple design)
2 / Matlab / 1 / Communication system front end design
2 / PSpice / 1 / Algorithm design/simulation
2 / Programming: C, Assembly / 3 / Embedded software design/implementation
2 / Electromagnetics: shielding, interference / Other (specify)

Industrial & Systems Engineering

ISE Core Knowledge / ISE Elective Knowledge
Statistical analysis of data: regression / Design of Experiment
Materials science / 2 / Systems design – product/process design
Materials processing, machining lab / 2 / Data analysis, data mining
Facilities planning: layout, mat’l handling / Manufacturing engineering
Production systems design: cycle time, throughput, assembly line design, manufacturing process design / DFx: manufacturing, assembly, environment, sustainability
2 / Ergonomics: interface of people and equipment (procedures, training, maintenance) / Rapid prototyping
Math modeling: OR (linear programming, simulation) / 1 / Safety engineering
2 / Project management / Other (specify)
Engineering economy: Return on Investment
Quality tools: SPC
Production control: scheduling
Shop floor IE: methods, time studies
Computer tools: Excel, Access, AutoCAD
2 / Programming (C++)

Biomedical Engineering

BME Core Knowledge / BME Elective Knowledge
Matlab / Medical image processing
Aseptic lab techniques / COMSOL software modeling
Gel electrophoresis / Medical visualization software
Linear signal analysis and processing / Biomaterial testing/evaluation
Fluid mechanics / Tissue culture
Biomaterials / Advanced microscopy
Labview / Microfluidic device fabrication and measurement
Simulation (Simulink) / Other (specify)
System physiology
Biosystems process analysis (mass, energy balance)
Cell culture
Computer-based data acquisition
Probability & statistics
Numerical & statistical analysis
Biomechanics
Design of biomedical devices

Computer Engineering

CE Core Knowledge / CE Elective Knowledge
Digital design (including HDL and FPGA) / Networking & network protocols
Software for microcontrollers (including Linux and Windows) / Wireless networks
Device programming (Assembly, C) / Robotics (guidance, navigation, vision, machine learning, control)
Programming: Python, Java, C++ / Concurrent and embedded software
Basic analog design / Embedded and real-time systems
Scientific computing (including C and Matlab) / Digital image processing
Signal processing / Computer vision
Interfacing transducers and actuators to microcontrollers / Network security
Other (specify)
RIT – Kate Gleason College of Engineering
Multidisciplinary Senior Design / Project Readiness Package
Template Revised Jan 2015