Proposal
System for Motor Control in a
Solar Powered Electric Race Car
ECE4007 Senior Design Project
Section L01, Solar Jackets – Motor Controller Team
Project Advisor, Dr. Whit Smith
Alex Jenkins
Ed Kfir
Pavel Rybakov
Jay Oatts
Duncan Thompson
Submitted
September 22, 2010
Table of Contents
Executive Summary ..................................................................................................................... iii
1.
1.1
1.2
1.3
Introduction ........................................................................................................................... 1
Objective .............................................................................................................................. 1
Motivation ............................................................................................................................ 2
Background .......................................................................................................................... 3
2.
Project Description and Goals ............................................................................................. 3
3.
Technical Specifications ........................................................................................................ 5
3.1
3.2
3.3
3.4
3.5
3.5
Motor Controller Specifications .......................................................................................... 6
Battery Array Specifications ................................................................................................ 6
Electric Motor Specifications .............................................................................................. 7
Single Board Computer Specifications ................................................................................ 8
Driver Display Specifications .............................................................................................. 8
Control Specifications .......................................................................................................... 9
4.
Design Approach and Details ............................................................................................ 9
4.1
4.2
4.3
Design Approach ................................................................................................................. 9
Codes and Standards .......................................................................................................... 15
Constraints, Alternatives, and Tradeoffs ........................................................................... 16
5.
Schedule, Tasks, and Milestones ........................................................................................ 17
6.
Project Demonstration ........................................................................................................ 18
7.
Marketing and Cost Analysis ............................................................................................. 18
7.1
7.2
Marketing Analysis ............................................................................................................ 18
Cost Analysis ..................................................................................................................... 19
8.
Summary .............................................................................................................................. 21
9.
References............................................................................................................................. 22
Appendix A – Gannt Chart ........................................................................................................ 24
Appendix B – Motor Controller Pin Outs ................................................................................ 25
Solar Jackets – Motor Controller (ECE4007L01)
ii
Executive Summary
The Georgia Tech Solar Jackets club is in need of a motor controlling system as part of a
lightweight, highly-efficient, solar-powered race car that is in development for competition in the
2011 Global Green Challenge (World Solar Challenge) and 2012 American Solar Challenge
events. The motor controlling system is comprised of five basic interconnecting components:
power source (batteries), motor controller, electric motor, single board computer, and driver
display. The team is restricted to using a donated motor controller and electric motor, which
limits the initial design approach to interface with these exclusively. In order to simulate a
cockpit scenario, pedals for throttle/brake, buttons for cruise control, and various enabling
switches will be the inputs to the system, while lights for braking/reversing and a driver display
will be the outputs. The driver display will feature live updating of speed, RPM, supply voltage,
brake regeneration, motor temperature, direction, and cruise control status. Projected total cost
for development is $78,203.75, of which $18,203.75 is for equipment costs and $60,000 is for
estimated labor cost. The proposed motor controlling system will be a laboratory-based
prototype design, and is a subsystem of a solar powered race car that is in the earliest stages of
development. Modular component construction will provide for portability to the race car after
project completion.
Solar Jackets – Motor Controller (ECE4007L01)
iii
System for Motor Control in a Solar Powered Electric Race Car
1.
Introduction
The Georgia Tech Solar Jackets club is in the process of designing and building a solar
powered race car to be used in the American Solar Challenge (ASC) [1] and the Global Green
Challenge (World Solar Challenge) [2] events, and they are in need of a computer system that
will operate the motor controller. There has been no previous development of this system, so the
design will be from the ground up. The main goals of the project will be to setup the electric
motor and the motor controller, send commands to the motor controller through a single board
computer (SBC), and output car statistics to an LCD screen. The Solar Jackets – Motor
Controller team is requesting $78,203.75 to design and build the motor controller system.
1.1
Objective
The motor controller system will be part of a solar powered race car that the Solar Jackets
club will require to operate the vehicle. The motor controller has several important functions for
the motor including acceleration and regenerative braking. A DC brushless motor will be used,
which has three phase lines that connect to the motor controller in order to power it. The
controller also has two serial interfaces, one that connects to the motor, and another that connects
to a computer system and input controls. These input controls are used for forward and reverse
direction toggling, regenerative braking, throttling, and various enabling switches. The motor
controller will output fault messages and speed pulse measurements through the serial
connection as well. The SBC connected to the motor controller will also be connected to a LCD
screen via an RS-232 connection. The screen will display measurements made from the motor
controller and any fault messages outputted through the motor controller. The high-level setup of
Solar Jackets – Motor Controller (ECE4007L01)
1
the motor controller system is shown in Figure 1. Since this system will be running off solar
power, it should be designed so that it will consume as little power as possible.
Figure 1. Basic overview of the motor controlling system.
1.2
Motivation
The solar powered race car, which the Solar Jackets are developing, will ultimately be
used in the ASC and the Global Green Challenge, so an efficient and reliable system to operate
the motor controller will be an essential component in order to make the car competitive. The
driver must be kept up to date with car information so that the vehicle can be driven as
effectively as possible, making the LCD output to the driver an essential component as well. The
computer system will be designed to interface with the NuGen NGM-EV-C200 Motor
Controller; however, it could be adapted to work with other similar models of NuGen motor
Solar Jackets – Motor Controller (ECE4007L01)
2
controllers [3]. The modular system design could also be adapted for some components to be
used with everyday consumer vehicles.
1.3
Background
Most solar race cars have similar layouts for the motor controller system setup. Istanbul
Technical University (ITU) has designed solar race cars for the years 2006, 2007, and 2008 and
have consistently finished near the top in the races which they have taken part in [4]. ITU’s
motor system consists of, “an Integrated Power Module (IPM), an 8 bit microcontroller and an
electronic control card” [4]. The microcontroller in ITU’s system collects all electrical and
mechanical information and sends it out to the other related units through an RS-232 connection.
ITU’s driving information is outputted to an LCD screen using software developed in Visual
Basic 6.0. The LCD displays information such as “elapsed time, completed distance and laps,
consumed energy, powers at terminals of solar panel and battery bank, SOC and, etc.” [4].
A different type of system is used in the solar car developed by The Center for
Product Design and Manufacturing (CPDM) of University Malaya [5]. CPDM uses the
CompactRIO (cRIO), a controller that has the computer functionality built into it. The cRIO
device, which has Lab VIEW software built into it and communicates with other devices through
an RS-232 connection, logs all of the data as well as computing real time data [5].
2.
Project Description and Goals
The motor controller will be connected to a SBC, throttle, and brake through a serial
DB25 connection and to the motor through a serial DB15 connection. The SBC will be sending
the motor controller commands in order to accelerate, brake, and change directions. An LCD
screen will also be connected to the SBC in order to display vital motor statistics to the driver
such as speed, RPM, battery voltage, motor temperature, brake regeneration. The driver will also
Solar Jackets – Motor Controller (ECE4007L01)
3
be able select forward or reverse and use cruise control settings, which include set speed,
accelerate, coast, and decelerate.
Testing Motor and Motor Controller
A bench setup must be built in order to test the motor and the motor controller. Eight car
batteries will have to be put in series in order to supply the motor with the required amount of
power. This power, in addition to motor rotation, will make safety a major concern while testing.
Since the car batteries are exposed and could cause major harm to someone if connected
incorrectly and the motor will spin rapidly, safety enclosures will have to be built for the
batteries and motor. A pre-charge circuit will be made so that an initial power surge will not
harm the motor when the car batteries are first turned on. The motor and the motor controller are
both donated parts, so their working condition is currently unknown. The goals for testing the
parts and setting up the test bench are listed below:

Design car battery array

Build pre-charge circuit for controller

Develop control interface cable to motor controller

Build battery array enclosure

Mount for motor and enclosure
Programming Single Board Computer
The SBC will be run from a Linux operating system using C code to communicate with
the motor controller. Connections from the SBC to the motor controller exist through the serial
RS-232 connection. The SBC will also output various statistics to the LCD display for the driver
to monitor. The features related to programming the SBC are listed below.
Solar Jackets – Motor Controller (ECE4007L01)
4

Control motor via physical inputs (pedals, switches, buttons)

Control brake and reverse lights

LCD display of live status of system data (battery voltage, speed, etc.)

Cruise control
3.
Technical Specifications
The design of the motor controller system is comprised of five major components (plus
external controls). In order of description, the components are the

Motor controller

Battery array

Electric motor

Single board computer

Driver display

Controls
Table 1 shows overall specifications of the completed system.
Table 1. Overall Specifications
Feature
Operating Temperature
Max Power Consumption
Input Voltage
Total weight
Inputs
Outputs
Solar Jackets – Motor Controller (ECE4007L01)
Specification
-20 ºC to +70 ºC
14.5kW
+96V
205kg
3 switches, 2 pedals, 4 push buttons
1 LCD screen, 4 LEDs
5
3.1
Motor Controller Specifications
Table 2. EVC-C200-092 Motor Controller Specifications [6].
Feature
Specification
Internal
Peak Current (A)
Nominal Bus Voltage (V)
Maximum Operating Voltage (V)
Minimum Operating Voltage (V)
Maximum Voltage (V)
Size (HxWxL) (in.)
Weight (lbs.)
Interface
Motor Communications (J1)
Control Communications (J2)
Cooling Fan Power (J3)
Pos./Neg. Power
Phase A,B,C
Peripherals
Fans
Connections
3.2
150
66-108
135
50
160
5.29 x 6.13 x 13.06
10.8
DB-15 (F)
DB-25 (F)
AMP Series 1 CPC 11-4
Bus bar ¼ in. diameter
Bus bar ¼ in. diameter
2 Muffin Type
5 ¼ in. 20 UNC
bolts/nuts/washers
Battery Array Specifications
The power supply consists of a battery array of eight 12V car batteries connected in
series to provide 96V DC. All batteries are secured in container to prevent accidental spills of
electrolyte and shock hazard. A pre-charge circuit is required between the motor controller and
battery supply as shown in Figure 2. Specifications for the battery array and pre-charge circuit
are in Table 3.
Table 3. Battery Supply Specifications
Component
Maximum Voltage
Maximum Current
Battery Container Size
Weight
Resistor R1
Resistor R2
Wiring
Solar Jackets – Motor Controller (ECE4007L01)
Specification
8 * 12V (96V DC)
1000A
320mm x 1400mm x 200mm
8 * 22kg (176kg)
4Ω (3 kW Power Rating)
Optional 150A Shunt
AWG 4 Wire
6
.
Figure 2. Pre-charge circuit schematic connecting the battery supply and motor controller.
3.3
Electric Motor Specifications
Specifications for the NuGen Mobility SC-M150-08 Axial Flux, Brushless Permanent
Magnet Electric Motor are presented in Table 4 [7, 8]. The motor mounts to a single front or rear
wheel for propulsion. A variable air gap mechanism allows for external torque constant change
to be made on the fly to optimize acceleration and top speed. Three phase wires connect and
power the motor from the controller, while the sensor cable transmits data from the motor back
to the controller.
Table 4. SC-M150-08 Motor Specifications
Feature
Internal
Peak Power (kW)
Continuous Power @ Vnom (kW)
Speed @ Peak Power (RPM)
No-Load Speed (RPM)
Peak Torque @ 125 ARMS (Nm)
Air Gap Range (mm)
DC Bus Nominal Voltage (V)
Bus Voltage Range (V)
Motor Dimensions (D x W)
Weight (Kg)
Interface
Phase Cables (A,B,C)
Sensor Cable
Solar Jackets – Motor Controller (ECE4007L01)
Specification
7.5
3.75
1300
1700
135
1.8-6.0
96
84-108
315mm x 70mm
20
AWG 4 Wire
DB-15 (M)
7
3.4
Single Board Computer Specifications
Table 5 presents the hardware and software specifications for the Technologic TS-7500
SBC [9]. The TS-7500 features small size, wide operating temperature, and quick boot time to
Linux environment important to the project design. Connections to the SBC will come from the
motor controller via RS-232, cruise control via push buttons, and display screen via RS-232.
Table 5. Technologic TS-7500 SBC Specifications.
Feature
Hardware
CPU
RAM
Flash
Card Slot
USB
Ethernet
UART
Interfaces
Operating Termparture (°C)
Dimensions (mm x mm)
Software
Operating System
OS Boot Time (s)
IDE
3.5
Specification
250MHz ARM9
64 MB DDR
4 MB NOR
1x Micro SDHC
1x 480 Mbit/s
1x 10/100 Mbit/s
8x TTL
33x DIO, SPI, I2C
-20 – +70
67 x 75
Linux 2.6
3
Eclipse Europa
Driver Display Specifications
Table 6. Matrix Orbital LK204-25 LCD Display Specifications [10].
Matrix Orbital LK204-25
Character Count x Line
Module Size
Operating Temperature
Operating Relative Humidity
Vibration
Shock
Supply Voltage
Minimum Current
Communication Protocols
Solar Jackets – Motor Controller (ECE4007L01)
Specification
20 x 4
98mm x 60mm x 31mm
-20ºC to +70 ºC
90% max non-condensating
4.9 m/s2 XYZ directions
29.4 m/s2 XYZ directions
+5Vdc ±0.25V
40mA typical
RS-232, TTL, I2C
8
3.5
Control Specifications
Throttle and brake control is done by two pedals like a standard vehicle. Both pedals act
as potentiometers and transmit information directly to motor controller. Toggle switches are
required for safety purposes and to enable forward/reverse operation of the vehicle. LEDs will
act as brake lights and reverse lights. Push buttons are required to operate cruise control. Table 7
shows technical requirements for the controls
Table 7. Control Specifications.
Part
Quantity
Specifications
Pedal
2
4kOhm-20kOhm
+5V
0.125A
Toggle
Switches
3
+10V
0.125A
LED
2 white
2 red
+5V
100mA
Push
Buttons
4
+5 V / TTL
4.
Design Approach and Details
4.1
Design Approach
The project will be divided into two main parts that strategically separate the safety and
power electronics from the low voltage circuitry and programming. Due to time constraints, team
members assigned to the programming tasks must assume that the motor and controller operate
as specified in the operating manual and will not be defective. Since the functionality of these
donated components is unknown, they must be tested as part of our design. Figure 3 is an
overview of the components and connections in the motor control system.
Solar Jackets – Motor Controller (ECE4007L01)
9
Figure 3. Overview of the component modules and connections in the motor controlling system.
Solar Jackets – Motor Controller (ECE4007L01)
10
Critical Paths
According to [6], the pre-charge circuit (Figure 4), which connects the controller to the
power system, serves to prevent large start-up currents from destroying the controller. S1 will
serve as a master switch that can cut off the battery from the controller. At start-up, S2 will be
open and S3 will be closed. The resistor R1 connected to S3 will help prevent current spikes at
start-up from damaging the motor controller. The team has determined that R1 should be a 4 Ω
resistor with a power rating of at least 15 kW. R2 is an optional shunt resistor, used to measure
controller current, but will be omitted from the design. This circuit will prove to be crucial before
any tests are run with the controller and presents a critical path to advancement to subsequent
stages in the project.
Figure 4. Pre-charge circuit schematic connecting battery supply to motor controller
The construction of a test bench and enclosure for the motor will also be a critical task
before testing of the motor can begin. Although the success of the project ultimately depends on
the success of this particular task, other tasks will be undertaken in parallel under the assumption
that this task will be completed successfully.
Solar Jackets – Motor Controller (ECE4007L01)
11
Battery Array
A 120V AC charger will be used to recharge each 12 V battery individually when
required. The eight battery array will be connected in series to the positive and negative
terminals on the motor controller using AWG 4 wire for sufficient current flow. An enclosure
will be built for the battery array for safety and will consist of a metal frame with plastic
transparent walls.
Motor Controller
The motor controller self regulates temperature by powering two cooling fans connected
in parallel to J3 on the controller’s front panel interface using an AMP Series 1 CPC 11-4
connector. The operating manual specifies these fans as “muffin fans” but no other specifications
are provided [6]. The team will determine what fans are compatible with the given controller.
Three phase leads will be used to send pulses from the controller to provide power to the
motor. Two of the three phase cables from the donated motor are unmarked. Whether or not this
presents a safety risk is currently unknown. The operating manual states that “RED corresponds
to Phase A, GREEN to Phase B and BLACK to Phase C” [6]. However, there is no other
distinguishing characteristic for each of the individual phase cables. A motor communication
link between the motor and controller (J1 on front panel), will be used by the controller to obtain
data about the motor. This link is defective (missing pins) on the motor and will need to be
rewired to a new DB15 male plug.
The control inputs to the motor controller will link through the J2 connector on the
controller front panel. A pin diagram of both the serial RS-232 and discrete connections is shown
in Figure 5.
Solar Jackets – Motor Controller (ECE4007L01)
12
Brake Lights
Reverse Lights
Figure 5. Wiring schematic for the control interface cable.
The serial input and output (pins one and two in Figure 5) will be connected to the SBC.
Analog inputs, throttle and regenerative braking (regen), will be connected to J2 through pedals
that function as potentiometers. The discrete inputs enable, throttle enable, and forward/reverse
will be wired to switches. Alternatively, the discrete outputs reverse and brake will power the
reverse and brake lights (LEDs).
Single Board Computer
The SBC will be used to send commands to the controller through the serial interface J2.
Data stored in registers will be read from the controller and used as feedback influencing
subsequent commands sent by the SBC to the controller. Fault detection will also be used in
decision making. A cruise control program will be implemented and controlled by reading
Solar Jackets – Motor Controller (ECE4007L01)
13
buttons pushed by the user. The cruise control program will consist of four inputs: set speed,
accelerate, decelerate, and coast. Desired speed will be input to the motor controller from the
SBC until the user presses the throttle or brake pedal at which time the communication will
switch back to discrete, disengaging the cruise control. Programming will be primarily in C to
control the SBC at a low (bit) level.
The SBC will also be used to display relevant data from the controller on a simple LCD
display. A sample display is shown in Figure 6.
F/R
Motor Temperature: 80° C
Speed: 55mph
Cruise Set
RPM: 1200
Brake Regen: 0%
100%
Figure 6. Example layout of LCD display showing motor data.
The flow chart in Figure 7 illustrates how all of the components of the motor control
system will be connected and interfaced under our current model.
Solar Jackets – Motor Controller (ECE4007L01)
14
Cooling
Fans
120VAC Charger
AMP Series 1
CPC 11-4
8 x 12 V Car
Battery Series
Array
A
B
C
+ve
Power bus
(AWG 4 Wire)
-ve
SC-M150-008
Phase Leads
(AWG 4 Wire)
NGM-EV-C200-092
Motor Controller
96 V Effective
DB-15
Throttle Pedal
Motor
Communication
Link
Brake Pedal
Reverse Lights
Vehicle
Control
Signals
(DB-25)
Control
Interface
Cable
Axial Flux,
Permanent Magnet,
DC Brushless
Electric Motor
Wheel
(Load)
Brake Lights
RS-232
Switches
-Controller Enable
-Throttle Enable
-Forward/Reverse Toggle
Linux On-Board
Computer
RS-232
User Interface
LCD Screen
Speed
Supply Voltage
Motor Temperature
Brake Regeneration
RPMs
Direction
Cruise Control Buttons
-Set
-Accel
-Decel
-Coast
Figure 7. Complete motor controller system flow chart.
4.2
Codes and Standards
According to National Electric Code (NEC) Article 430-31 it is required to protect all
three phases on three-phase motors, not just two [11]. The motor must also be protected against
overload by a device which is rated or selected to trip by 125 percent of the motor full-load
current rating. The National Electrical Manufacturers Association (NEMA) also provides
standards for how to operate and test motor controllers.
Solar Jackets – Motor Controller (ECE4007L01)
15
The ASC rules and regulations have very few restrictions or guidelines for the motor
controller and or embedded systems controlling it [1]. One of the rules is that the car must be
under sole control of the driver, although cruise control is allowed. If cruise control is used, then
activation of the brakes must turn off the cruise control program [1].
4.3
Constraints, Alternatives, and Tradeoffs
The Solar Jackets club insists that we use the given NGM-EV-C200-092 Motor
Controller and the SC-M150-008 Axial Flux, Permanent Magnet, DC Brushless Electric Motor.
In previous American and World Solar Challenges, this particular motor and controller were
chosen by a majority of team. In addition, the relatively high cost of a new motor and controller
probably eliminates alternative motor and controller candidates.
In the case that the motor and/or controller are defective, we may request the Solar
Jackets club to buy another identical motor for us. However, the controller is about 11 years old
and its availability is not certain. In the case that we are not able to obtain the identical motor
controller, there are alternatives such as the Tritium WaveSculptor20 motor controller, priced at
$7,000, with similar specifications to the NGM-EV-C200 series controller. The problem with
this controller as well as most other controllers, however, is the shipping and delivery time.
Tritium, for example, mentions on their website that orders for the WaveSculptor20 would
require an 8 week lead time [12].
The final option would be to use a low voltage motor and controller pair, but this would
most likely be of little use to the Solar Jackets club. The safety concerns concerning the testing
of the motor will also present constraints in regards to where and how we test the motor.
Solar Jackets – Motor Controller (ECE4007L01)
16
5.
Schedule, Tasks, and Milestones
The expected project timeline for the solar car motor controller system is shown in Table
8. Major components of the project are shown in bold, while progress milestones are italicized.
Table 8. Project schedule, tasks, and milestones for motor controller system design and
development. Complexity ranks the challenge of the task from low to high, while importance
ranks the project dependence on the task from low to high.
Components of the project are focused into the two basic categories of test bench setup
(which includes testing the motor and controller) and programming the SBC. Owners will report
Solar Jackets – Motor Controller (ECE4007L01)
17
the status on his task(s) at the weekly meetings to keep track of progress. Appendix A contains
the complete Gantt chart for the project.
6.
Project Demonstration
Since the motor controller system is a component of a larger solar race car prototype, the
demonstration will take place in a laboratory where the test bench setup is housed. To highlight
the safety mechanisms of the project first, the enclosures (for batteries and motor), cooling fan
assembly, and enable switches will be shown and explained. Afterwards, the physical input and
output functionalities of the system will be demonstrated as follows:

Throttle Pedal – Increases rotational speed of the motor and appropriately drains power
from the battery array (verified by voltmeter).

Brake Pedal – Regenerates the batteries, decreases the motor speed, and lights up the
brake light.

Forward/Reverse Toggle – Motor rotates counter-clockwise in forward and clockwise in
reverse. Reverse light also turns on when toggled.

Cruise Control – Maintain constant speed, accelerate, decelerate, or coast with button
pushes.

LCD Screen – Shows vital operating statistics (speed, RPM, battery voltage, motor
temperature, brake regeneration, forward/reverse, and cruise control) on the screen with
live updating.
7.
Marketing and Cost Analysis
7.1
Marketing Analysis
Because the auto industry has adopted alternative and renewable energy sources, the
growth potential of electric vehicles is nearly limitless. The proposed motor controlling system
could be adjusted to meet specific needs of many different types of vehicles, depending on the
task the motor will be performing. Manufacturers such as Alltrax, NuGen Mobility and Kelly
Controls produce electric motor controllers for similar needs [3, 13-15]. Kelly Controls produces
Solar Jackets – Motor Controller (ECE4007L01)
18
a wide variety of electric motor controllers: low cost models, superior performance models, and
beta test models [13]. The Kelly superior performance model, KDH14201A, is most similar to
the controller in the proposed system. Both controllers have capabilities of thermal protection,
motor current limiting, brake regeneration, and speed/torque modes of operation. The
KDH14201A has three modes of operation; the additional is a balanced mode [14]. The
KDH14201A is a standalone motor controller. However, the proposed solution will include a
complete system incorporating user interface for displaying system status reports and cruise
control selection as well as accelerator and brake pedals for motor operation.
7.2
Cost Analysis
The total cost for development of the motor control system prototype is $78,203.75. The
equipment needed for development totals $18,203.75; labor costs total $60,000. Table 9 below
shows a breakdown of the total equipment costs, including donations received.
Table 9. Total Equipment Cost.
Product Description
Technologic TS-7500 Onboard Computer [9]
Matrix Orbital 20x4 Serial LCD Display [10]
SSC 10kΩ Potentiometer Foot Pedal [16]
Cooling Fan
Serial Cable
LED Light
Battery Cable (12 ft.)
Switch
Building Materials (wood, plastic, fasteners, etc.)
SUBTOTAL COST
Donations
NGM SC-M150 Motor (estimated)
NGM EV-C200-092 Motor Controller (estimated)
12 V Car Battery
TOTAL DONATIONS VALUE
Equipment Cost Total
Solar Jackets – Motor Controller (ECE4007L01)
Quantity
1
1
2
2
4
4
1
5
1
1
8
Unit Price
Price
$
139.00 $
78.95
88.90
10.00
5.00
2.00
40.00
2.00
$
$
139.00
78.95
177.80
20.00
20.00
8.00
40.00
10.00
150.00
643.75
12000.00 $
5000.00
70.00
$
$
12000.00
5000.00
560.00
17560.00
18203.75
19
The project costs are itemized in Table 10 below with labor costs at $50 an hour. The
estimated labor includes meetings, reports, system design, and implementation.
Table 10. Total Development Cost
Project Component
Test Motor Controller
Test Bench Design
Programming Controller
Interface Design
Lectures/Meetings
TOTAL LABOR COST
TOTAL EQUIP COST
Labor
Hours
140
180
360
120
400
1200
Total
Labor Cost Equip Cost
Component Cost
$7,000.00
$17,640.00
$24,640.00
$9,000.00
$327.80
$9,327.80
$18,000.00
$149.00
$18,149.00
$6,000.00
$86.95
$6,086.95
$20,000.00
$20,000.00
$60,000.00
$18,203.75
Total Project Cost
$78,203.75
The suggested retail price of the product is $32,000. Table 11 below shows the
production of 500 units over five years; listed are the recurring costs over the five years in
addition to the non-recurring product development cost. Employing technicians for product
assembly at $22.50 per hour, the labor cost listed in Table 11 is the cost associated with
producing four units per hour. The assembly includes the software and external hardware
installations of the system and quality assurance testing. This product will yield revenue of $16
million and a profit of approximately $4.7 million, or 29%.
Solar Jackets – Motor Controller (ECE4007L01)
20
Table 11. Total Production Cost
Recurring
Labor Costs
Materials
Fringe Benefits (25% of labor)
Process
Overhead (25% of labor, equip,
fringe)
Sales Expense (5% of selling price)
5-yr Warranty and Support
(5% of selling price)
Non-recurring
Development Costs
Total Production Cost
8.
$2,812.50
$9,007,875.00
$703.13
$0.00
$2,252,847.66
$1,600.00
$1,600.00
$78,053.75
$11,345,492.03
Summary
An NGM-EV-C200-092 motor controller and two SC-M150-08 DC brushless electric
motors have been donated to the team and are ready for testing. All three devices are heavily
worn and 11 years old, so functionality tests will be the top priority. Additionally, the supply of
eight car batteries is currently available, so construction of the battery array will begin as soon as
a suitable laboratory has been confirmed. The on-board computer, input pedals/switches, and
output LEDs will be obtained or ordered immediately to begin simultaneous work on
programming.
Solar Jackets – Motor Controller (ECE4007L01)
21
9.
References
[1]
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[Accessed Sept. 21, 2010].
[2]
World Solar Challenge, “Regulations,” World Solar Challenge, Sept. 16, 2010. [Online].
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[3]
NuGen Mobility, Inc. “Products,” www.ngmcorp.com. [Online]. Available:
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[4]
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[5]
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on, 19-21 March 2010, vol.1, pp.96-100.
[6]
New Generation Motors Corporation. NGM-EV-C200 series Controller Operating Manual.
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[Accessed Sept. 21, 2010].
[7]
New Generation Motors Corporation. SC-M150-00X Axial Flux, Permanent Magnet, DC
Brushless Electric Motor Operating Manual. Ver. 1. New Generation Motors Corporation.
[Online]. Available:
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[8]
New Generation Motors Corporation. SCM150-XXX Axial Flux, Brushless PM Motor
Specification Sheet. New Generation Motors Corporation, 2007. [Online]. Available:
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[Accessed Sept. 21, 2010].
Solar Jackets – Motor Controller (ECE4007L01)
22
[9]
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[Accessed Sept. 21, 2010].
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[Accessed Sept. 21, 2010].
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www.kellycontroller.com, 2008. [Online]. Available:
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[Accessed Sept. 21, 2010].
[15] Alltrax, Inc.,“Products Page”, alltraxinc.com, Oct. 19, 2009. [Online]. Available:
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[Online]. Available: http://www.ssccontrols.com/homepage-potentiometercontrols.htm.
[Accessed Sept. 21, 2010].
Solar Jackets – Motor Controller (ECE4007L01)
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Appendix A – Gannt Chart
Solar Jackets – Motor Controller (ECE4007L01)
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Appendix B – Motor Controller Pin Outs
Solar Jackets – Motor Controller (ECE4007L01)
25