James Kast
Andrew Kuharske
Timothy Lenberg
Daniel Taylor
1

Objective:
• To advance the development of an in house hybrid electric
vehicle for use in testing Dr. Dean Edwards' experimental lead
acid batteries.

Background:
• Existing platform containing Dr. Edwards’ batteries
• Components from HUMV

Specs
•
•
•
•
APU
PEU/Motor
Exhaust
Safety
2
 Axels
installed
 First Battery Isolation Test
 Voltage Controlled Fuel Test
3
4
Control Method Options
 Mechanical Control
 Electrical Control
5
Controller Choice
 Familiarity
 Analog Inputs
APU Control Scheme Options
 Linear Organization
 RTOS Centered
6
Check Sensors
Check Charge
Parameters
Check for
Overvoltage
Increment
Coulomb Count
vtaskdelay
7
Check Buttons
Update LCD
Decode Buttons
Output LEDs
vtaskdelay
8
Connect Kill
Switch
Start
vtaskdelay(?)
Altern.
Voltage
Step Up
Voltage
Regulate
Voltage
Connect
9
Assess State
+/- Throttle
Voltage
vtaskdelay
10
Disconnect
Decelerate
Disconnect Kill
Switch
11
12
13
1
14
 Specifications
• 500Vdc rated
• Digital/Analog output
• Accuracy <= 1%
 CYHVS500T Sensor
• 500Vdc rated
• 4V-5V analog output
• Accuracy <= 1%
• -10 C to +70 C
• Cost ~ $80
15
 Specifications
• 300 Amp rated
• Digital/Analog output
• Accuracy <= 2%
 LEM HTR 300 Sensor
• 300 Amp rated
• 4V analog output
• Accuracy <= 2%
• -10 C to +70 C
• Cost ~ $180
16
 Required User inputs
• Force APU on
• Force APU off
• Regen braking on/off
• Reset Coulomb count
 Specifications
• Minimal distraction
• Easy to reach
• Quick to implement/build
17
 On
Steering Wheel
• Pros:
 Easy to reach
 Won’t have to glance over
• Cons:
 Difficult to install
18
 Ground
Next to Driver
• Pros:
 Easy to place build
 Can be easily moved
• Cons:
 Driver must look down
19
 Podium
Next to Driver
• Pros:
 Easy to reach
 Adaptable
• Cons:
 More materials required
20
 Side
of Seat
• Pros:
 Buttons are easier to reach
 Eyes can stay on road
• Cons:
 Unconventional setup may confuse people
 Buttons not visible
21
 Build
ground setup first
• Quick build time gives us more time for testing
 Build
Podium
• The ground button setup can be placed directly on the
podium without much extra work
22
 Work
Cited
• Current Sensor:
http://www.lem.com/hq/en/component/option,com_cata
log/task,displaymodel/id,70.22.46.000.0/
• Voltage Sensor:
http://www.hallsensors.de/HallVoltage.htm
• Button:
http://www.grainger.com/Grainger/SCHNEIDERELECTRIC-Illuminated-Plastic-Operator6HW87?Pid=search
23
 Basic
Requirements/Restrictions
 Design Sketches
• Pros and Cons
 Chosen
Design
 Safety - Heat Shielding
 Questions
24
 Restriction-Clearance
 Route
Exhaust
 Incorporate Muffler
 Eliminate Safety
Hazards
25
SHORT


MIDDLE
Pros – Geometry, Length
Cons – Routing


Pros – Routing
Cons – Geometry, Length,
Safety
26
SIDE


DUAL
Pros – Routing, Geometry
Cons – Length, Safety


Pros – Routing
Cons – Geometry, Length,
Safety
27
STACK (TOP VIEW)


STACK (SIDE VIEW)
Pros – Routing
Cons – Geometry, Location
28
29
EXHAUST WRAP
EXHAUST SHIELDING
30
31
 Fuse
Setup
 Radiator
Mounting Issues
32
BEFORE
AFTER
33
Rectifier
Fuse
PEU
360 V
34
35
36
1.
2.
3.
4.
5.
Voltage Sensors x2 = $160
Current Sensors x2 = $360
Micro Controller = $100
Exhaust = $350
Gear Oil x3 quarts = $27
Total = $997
*Prices are an estimate only
37
38
 Existing
Components
 Outsourcing
 Weather
 Time Constraint
39
40