MSD P15280
RIT HOT WHEELZ
TEST BENCH
AGENDA
❖ Detailed Design Review
➢ Competition Benchmarking
➢ Mechanical
● Motor Mount & Baseplate
● Modular Cart Design
● Motor Coupling Design
➢ Electrical
● Dyno Interface
● Sourced Components
● KGCOE Dynamometer Lab Quick Start Guide
Formula Hybrid Competition 2015- Benchmarking
❖ Variety of Designs
❖ Lack of Preparation
❖ Strenuous Inspection
Procedure
❖ Attention to Detail is Critical
Formula Hybrid Competition 2015- Benchmarking
❖ 2+ Teams using Emrax Electric
Motors
❖ Benchmarking the Motor
Mounting
Formula Hybrid Competition 2015- Benchmarking
❖ Suggestion to use Rinehart
Controller
➢ User Friendly
➢ Isolation Built-in
❖ PM100 - 100kW Class
➢ 300 Arms Continous
➢ 350Arms Peak
➢ 160-360VDC
UPDATED DESIGN CONCEPT CONT.
Mounting Design Concept- Revision 1
Issues
❖ Easily change position to mount
to the chain
❖ Adaptable to different
configurations
❖ Failed FEA under maximum
loading conditions
❖ Covered critical ports into the
motor
Mounting Design Concept- Revision 2
❖ More robust design
❖ 304 Stainless Steel
➢ 0.25” Baseplate
➢ 0.5” Upright Mount
❖ Incorporates proper hole pattern
of the motor
Mounting Design Concept- Revision 2
❖ Added Gussets for Strength in
Bending at the base
❖ Fillet Welds will be used to join
the gussets, the base plate and
the upright mount
Mounting Design Concept- Assembly
Mounting Design Concept- Base Plate
❖ Slotted Base Plate to Match Current Dyno
Mounting
❖ Allows for adjustability when lining up the
chain
❖ 0.25” X 10” X 10” 304 Stainless Steel
Mounting Design Concept- Motor Mount
❖ 100 N/m Torque on Each Bolt
Hole ~800 N/m combined
loading
❖ 0.03 mm of Maximum
Displacement
❖ Does not exceed yield strength
of 304 Stainless Steel
❖ Minimum Factor of Safety of
2.5
Mounting Design Concept- Assembly
Mounting Design Concept- Moving
Forward
❖ Detailed Budget
❖ Weight Minimization to use the
same design on the car
DETAILED CART DESIGN
❖ A 30” X 60” cart was sourced
from Global Industrial bases on
the cost saving between building
a cart and buying one.
➢ ~$700 for raw materials &
mounting accessories
➢ ~$500 for base cart &
mounting accessories
❖ Cart Specifications
➢ 1000 lb capacity
➢ 5” Wheel Diameter
➢ Removeable Handle can be
mounted on either side
http://www.globalindustrial.com/p/material-handling/platform-trucks/wood/steel-bound-wood-deck-truck-60x30-1000-lb-capacity
DETAILED CART DESIGN CONT.
Cart Components & Mounting
Controller
DETAILED CART DESIGN CONT.
Battery Enclosures & Mounting
Battery Specifications
Width (in):
9.65
Depth (in):
14.09
Height (in):
11.22
Quantity:
4.00
Weight (kg):
24.00
Weight (lbs)
52.91
Total Weight (kg):
96.00
Total Weight (lbs):
211.64
DETAILED CART DESIGN CONT.
Battery Enclosures & Mounting
Battery Assembly
Mounting Plate
NEXT STEPS
❖ Waiting on CAD files & more dimensions of the Cart to
finalize Motor Mount design dimensions
❖ Finish mounting hole pattern
❖ Finalize layout options for the Hot Wheelz Components
MOTOR COUPLING DETAILED DESIGN
Current Dyno
Existing Idler / tensioner system
MOTOR COUPLING DETAILED DESIGN
●
Chain
○ Heavy Duty, ⅝” pitch, 1620
lb working load
○ Length TBD
●
Idler Sprocket
○ OD not critical
○ Built-in bearing for ease of
mounting to shaft
*images from McMaster-Carr
MOTOR COUPLING DETAILED DESIGN
●
Transmission Sprockets
○ Hot Wheelz team gear ratio (2)
○ Pinion (~4” OD)
■ Keyway to fit motor output shaft
● Multiple keyways in consideration
● Unknown bore size
■ http://www.mcmaster.com/#6280K259 (20 teeth)
○ Gear (flat, ~8” OD)
■ Machinable to fit existing dyno mount
■ http://www.mcmaster.com/#2299K57 (40 teeth)
MOTOR COUPLING DETAILED DESIGN
Pinion
Gear
*images from McMaster-Carr
*images from McMaster-Carr
MOTOR COUPLING DETAILED DESIGN
●
Idler
○ Creating our own
MOTOR COUPLING DETAILED DESIGN
●
Idler
○
Fits existing dyno table hole pattern
■
Slots allow for position adjustment
○
Two springs provide tension to chain
○
Height adjustable to take up chain slack
■
Locked in place with 4 screws
Sensor Sourcing
Overall Preliminary Wiring Diagram
Dyno Room
Control Room
Dedicated thermocouple DAQ
Custom PCB Diagram
1N5818: Schottky diode with maximum reversed voltage of 30V, and
nominal forward voltage of ~0.5V
L78S10CV: Linear 10V 2A voltage regulator
Equivalent Resistances determined by maximum supply current for
corresponding sensors
Wiring Harnesses
Dummy Connector
Dyno-Control Harness
Sensor Terminal
Harness
Sensor-PCB Harness
PCB-DAQ Harness
-
Twisted pairs for signal paths
Molex or APP connectors
18 AWG
KGCOE Dynamometer Lab Quick Start
Guide
❖ Quick Start Guide
■
Document can be found on the P15280 edge site under
/public/Final Documents
■
Overview of the environment
●
■
■
Dyno room & Controller room
Steps to operate the Dyno without a DUT
●
Manually with push buttons on Dyn-Loc IV Controller
●
Digitally with RealTerm software.
Problems encountered and discrepancies with official manual
QUESTIONS?
FEEDBACK?
SUGGESTIONS?