UWash_ECE_Presentation
- 1. James Goin and Hunter Goforth Electrical and Computer Engineering Presentation
- 2. Torque Vector Series PHEV Performance • IVM-60mph: 5.3 s • 50-70mph: 2.9 s • Top speed: 137 km/h (85 mph) • EV range: 80 km (50 miles) • Power: 400 kW (536 hp) • Torque: 4200 Nm (3098 lb ft) Unique Characteristics • Torque vectoring • Fully electric drivetrain FRONT REAR Fuel Tank Generator Bosch SMG 180 80kW Engine: 0.8L E85 78 kW Gearbox 4.2:1 Gearbox 4.2:1 Motor: Enstroj EMRAX 268 200kW Charger: Brusa NLG513 ESS: A123 7-‐ mod 15s3p Kit 18.9 kWh Motor: Enstroj EMRAX 268 200kW
- 3. LV System Design and Integration
- 4. LV Harness Design Methods Identify components and signals – Connector assemblies – Controls team • GPIO/analog • CAN – Mechanical team • Possible routing • Space claim
- 5. LV Harness Documentation Mentor Graphics Vesys – Schematic design • 12V power • CAN communications • Analog/digital I/O – Routing • Component placement • Bus design – Validation • Continuity • Simulation – Documentation • Signal tables
- 6. LV Harness Routing RELAYS CHARGER RELAYS INVERTER GENERATOR CABIN ELECTRONICS ESS MOTOR CONTROLLER MOTOR CONTROLLER COOLANT PUMP HSC RELAYS HSC FRONT ACCM
- 7. LV Harness Routing RELAYS CHARGER ACCM INVERTER GENERATOR CABIN ELECTRONICS ESS MOTOR CONTROLLER MOTOR CONTROLLER COOLANT PUMP HSC RELAYS HSC 12V FRONT
- 8. RELAYS CHARGER RELAYS INVERTER GENERATOR CABIN ELECTRONICS ESS MOTOR CONTROLLER MOTOR CONTROLLER COOLANT PUMP HSC RELAYS HSC FRONT LV Harness Protection ACCM Example 1 Single-harness design • Serviceable exterior routing • Protected under body panel
- 9. ACCM LV Harness Protection RELAYS CHARGER RELAYS INVERTER GENERATOR CABIN ELECTRONICS ESS MOTOR CONTROLLER MOTOR CONTROLLER COOLANT PUMP HSC RELAYS HSC FRONT ACCM Example 1 Single-harness design • Serviceable exterior routing • Protected under body panel Exterior routing • Debris from road • Liquids • Mounting Passing into engine bay and trunk • Abrasion • Tension strain
- 10. ACCM LV Harness Protection RELAYS CHARGER RELAYS INVERTER GENERATOR CABIN ELECTRONICS ESS MOTOR CONTROLLER MOTOR CONTROLLER COOLANT PUMP HSC RELAYS HSC FRONT ACCM Example 2 Route to cabin electronics • Competition required LEDs/switches • Shifting embedded controller • Ease of access to engine bay harness
- 11. CCM LV Harness Protection RELAYS CHARGER RELAYS INVERTER GENERATOR CABIN ELECTRONICS ESS MOTOR CONTROLLER MOTOR CONTROLLER COOLANT PUMP HSC RELAYS HSC FRONT ACCM Example 2 Route to cabin electronics • Competition required LEDs/switches • Shifting embedded controller • Ease of access to engine bay harness Engine • Vibration • Heat Passing Into Cabin from Engine Bay • Abrasion • Tension and strain relief
- 12. LV Harness Protection Protection Methods • Shielded Champlain® CAN cable • Layers of protection • Taped wire bundle • Split loom • Thermal tape • Outer layer Tesa® acrylic adhesive Abrasion resistant Noise damping Temperature resistant Strength ideal for bundling
- 13. LV Harness Protection Justification Adherence to electrical design rules for competition: • “SAE J1128 or J 1127 standard for wire, automotive rated insulation” • “Exterior routing must use split loom” • “Protection by cable grommets at pass- through locations” • “Wiring cannot be installed below components containing liquids” • “Strain relieved and securely fastened to prevent movement”
- 14. LV Fusing and Relays 12V BaTery Front Fuse/Relay Box Radiator Fans Generator Control ACCM HVIL CompeYYon LEDs Front Cooling Pump Rear Fuse/Relay Box HSC BMS Motor Controllers Rear Cooling Pump Team-added components
- 15. LV Fusing • Multiplexed Vehicle Electrical Center (MVEC) – Power distribution slave module – CAN controlled – 8 relays and 16 fuses – 30 A per output pin – 200 A maximum rating – 2 MVECs used
- 16. LV Fabrication Methods • Champlain EXRAD 150UT Powertrain Wire • Best practices for – Crimping – Soldering – Strain relief – Packaging – Shielding – Abrasion / thermal protection methods – NASA guidelines • Weekly training workshop
- 17. LV Validation Methods Hardware-in-the-Loop (HIL) Testbench – Fabricated harnesses testbenched with dSPACE HIL Simulator – Determines potential harness connection faults – Confirms component functionality
- 18. LV Design Planned but un- integrated LV harness locations Motor controllers RouYng from engine bay to rear Full integration of LV harnesses part of Vehicle Development Process Year 3
- 19. LV Integration Engine Bay Engine MVEC Inverter/Converter
- 20. LV Integration Split loom conduit • Abrasion resistance • Protects from liquids, debris • SYffness preserves bend radius
- 21. LV Integration Adhesive thermal padding and grommet for pass-‐through • Provides sealing of cabin from engine bay • Protects harness at point of pass-‐through • Restricts harness movement
- 22. LV Integration LV routed away from HV • Avoid harmful EMI issues • Simplifies rouYng
- 23. LV Integration LV routed away from liquid holding components • No risk of spillage on electronics
- 24. HV System Design and Integration
- 25. HV Component Location Component • Energy Storage System (ESS): A123 7 module 15s3p LiFePo4 battery pack. Front Energy Storage System (ESS) Requirements • Simpler space claim • Simplified routing • Improved consumer acceptability • Protection Tradeoffs • Less accessible for maintenance
- 26. Requirements • Allows torque-vectored design • Controller/inverter near motors, simplified routings Tradeoffs • Weight distribution HV Component Location Component • Motors: EMRAX 268 200kW motors • Inverters: Bamocar D3 motor controller / inverter Motor Energy Storage System (ESS) Motor Inverter Inverter Front
- 27. Requirements • Space claim with ESS location • Weight distribution Tradeoffs • Heat/vibration/noise near other components HV Component Location Component • Engine: 800 cc E85 • Motor: Bosch SMG 180 Motor Energy Storage System (ESS) Motor Inverter Inverter Motor Engine Front
- 28. Requirements • Gensert proximity to engine • Proximity to 12V batter Tradeoffs • Must route more connections through junction box • Less room for additional components in engine bay HV Component Location Component • Inverter: INVCON generator controller / inverter with built in 12V DC / DC converter and ACCM power. Motor Energy Storage System (ESS) Motor Inverter Inverter Motor Inverter Engine Front
- 29. Requirements • Proximity to front junction box for routing • More trunk space Tradeoffs • Proximity to engine • Long route to ESS HV Component Location Component • Charger: Brusa NLG513 liquid cooled • Charge port: Chevrolet Volt charge port Motor Energy Storage System (ESS) Motor Inverter Inverter Charger Motor Charge Port Inverter Engine Front
- 30. Requirements • More trunk space • Protection • Easy routing to front junction box Tradeoffs • Heat/vibration from engine • More HV routing in engine bay HV Component Location Component • Automatic Climate Control Module (ACCM): Denso ES34 electric compressor Motor Energy Storage System (ESS) Motor Inverter Inverter Charger Motor ACCM Charge Port Inverter Engine Front
- 31. Requirements • Appropriate fusing • Simplified HV routing • Protection of fuses Tradeoffs • Less space in engine bay, and in rear assembly near motor controllers and motor Component • Mersen UL Rate Junction Boxes HV Component Location Motor Energy Storage System (ESS) Motor Inverter Rear JuncYon Box Inverter Front JuncYon Box Charger Motor ACCM Charge Port Inverter Engine Front
- 32. HV System Component Location
- 33. HV System Design Component Min Voltag e (V) Nominal Voltage (V) Max Voltage (V) Energy Storage System (ESS) 263 340 378 Onboard Charger 200 360 520 Generator (Built in DC/DC Converter) 150 370 410 AutomaYc Climate Control Module (ACCM) 200 300 420 Motors 50 320 700 Motor Controllers 200 300 700 Voltage (V)
- 34. HV System Design Component Min Voltag e (V) Nominal Voltage (V) Max Voltage (V) ConCnuous Power (kW) Peak Power (kW) Energy Storage System (ESS) 263 340 378 60 177 Onboard Charger 200 360 520 3.7 3.7 Generator (Built in DC/DC Converter) 150 370 410 42 85 AutomaYc Climate Control Module (ACCM) 200 300 420 8 8 Motors 50 320 700 80 200 Motor Controllers 200 300 700 60 140
- 37. HV System Integration • HV Junction Box Design – Mersen Design Reviews • 80+ hours of design review • UL certification for final design • Confirmation of simulation data • Components sent from Mersen, students assembled boxes
- 38. HV System Integration • HV Junction Box Design – Humidity and temperature – Heat generated – Vibration – Creepage and clearance – Isolation – Serviceability – Optimized wire routing – Minimal size
- 39. • Champlain EXRAD XLE shielded cable • Best practices for • Wire sizing • Crimping • Soldering • Insulating • Strain relief / bend radius • Shielding • Abrasion / thermal protection Methods • NASA guidelines • Training workshops HV Fabrication
- 40. HV Validation – Creepage/clearance – Resistivity of connections – Isolation resistance testing – Ground fault detection – Bus ripple – Bus bleed-down Ripple Analysi s Frequency (Hz) 5,570.42 10,345.07 19,098.59 Voltage Ripple (V) 5 6 4 Current Ripple (A) 6 8 2
- 41. HV System Integration Engine Bay Design vs. Integration: Rotation of junction box 180 degrees to fit bend radius
- 42. HV System Integration Front Junction Box
- 43. HV System Integration Front Rear Engine Bay to Rear Subframe Design vs. Integration: Routing between fuel tank and transmission tunnel to ensure HV is not lowest point on vehicle and avoid routing underneath liquid-holding components.
- 44. HV System Integration Bamocar Motor Controller/Inverter
- 45. HV System Integration Rear Junction Box, Motors, ESS
- 46. HV System Integration 3-Phase Traction Motor Terminals
- 47. HV Fuse Overview Load Conditions • Nominal and peak current • Operating voltage • Load Type (capacitive or resistive) Source Conditions • Power output • Ambient temperature (derating) • Short-circuit current (I2t analysis) • Intended cycle life Standards • UL certified • IEC 60269 standard • Mersen design reviews
- 48. HV Wire Overview Exrad XLE Cable Specifications • High voltage and current • Automotive grade • High dielectric insulation • High temperature tolerance • High bend radius • Shielded (reduce EMI) • Orange Conditions • Fuse blows before cable fails Standards • UL 758 and ISO 6722 accordance • SAE certified
- 49. Selection Overview Note: load profiles approximated from supplier specification sheet Component Fuse Size (A) Wire Gauge (AWG) Wire Ampacity (A) Nominal Current (A) Peak Current (A) Charger 12 10 Shielded 80 12.25 12.75 Genset Inverter 300 1/0 Shielded 339 210 400 TPIM (Inverter) 200 1/0 Shielded 339 200 400 ACCM 20 10 Shielded 80 12.5 25.6 Junction Fuse 350 1/0 Shielded 339 250 500 ESS 350 1/0 Shielded 339 230 690
- 50. ESS Example ESS • V = 375 VDC • R = 0.05 Ω • isc= 7.34 kA Fuse • 350 A rated • Δtpeak >> 100 s • Max V = 700 VDC • Max isc = 100 kA Dual Motors • iavg = 230 A • ipeak = 690A • Δtpeak = 10 s Requirements • Capacitive load = time delay fuse to prevent nuisance blows • 1.5 x 230 A (nominal) ≈ 350 A (rule of thumb) • Allowed time at peak current: • 10 s (Motor Δtpeak ) < 150 s (fuse) < 300 s (cable) • Max voltage • 375 VDC (ESS) < 700 VDC (fuse) < 1000 VDC (cable) • Short circuit current • 7.34 kA (ESS) < 100 kA (fuse) 1/0 Cable LoadSource 1/0 Cable
- 51. ESS Fuse 350 A Fuse Specification Model: Mersen A70QS350 • Type: Time Delay • Max Voltage: 700 VDC • Impulse: 100 kA I.R • Temperature: 25°C Paramete r Current (A) Melt Time (s) Nominal 230 >> 100 Peak 690 >> 100 Extreme 1500 3 Short Circuit 7.3k < 0.01 Nominal 230A Peak 690A Extreme 1500A 3 s
- 53. ESS Design Trunk Installation • Rugged lid • Easy to access MSD
- 54. ESS Design Trunk Installation • Rugged lid • Easy to access MSD Two-tier Design • Simplified packaging • Improved routing • Serviceable hardware shelf
- 55. ESS Design Trunk Installation • Rugged lid • Easy to access MSD Two-tier Design • Simplified packaging • Improved routing • Serviceable hardware shelf Routing • Serviceable • Minimizes EMI noise • Bus bars • Connectors route easily to rear junction box
- 56. ESS Design 350V Output • Finger-proof • Pluggable • HVIL • Simplified routing
- 58. ESS Design Separation of HV and LV on shelf to minimize EMI risk
- 59. ESS Design Separation of HV and LV on shelf to minimize EMI risk
- 60. ESS Design Separation of HV and LV on shelf to minimize EMI risk
- 61. ESS Design Separation of HV and LV on shelf to minimize EMI risk
- 62. ESS Integration
- 63. ESS Integration
- 64. ESS Integration Design vs. Integration: Extra length in wire runs to meet bend radius
- 65. ESS Integration Design vs. Integration: Additional quick- disconnects to remove shelf
- 66. ESS Integration Bus bars and finger-proof covers
- 67. ESS Integration Pluggable, rotating HV connectors
- 68. ESS Integration Design vs. Integration Bottom of trunk Aluminum ESS enclosure Interior connection
- 69. ESS Integration 6mm clearance NYSR: 12.7 mm (>300V)
- 70. ESS Integration Design vs. Integration Bottom of trunk ESS enclosure (conductive) Lug connection Acrylic Spacer
- 71. ESS Integration Design vs. Integration Acrylic Spacer
- 72. ESS Integration
- 73. ESS Integration
- 74. ESS Integration Design vs. Integration: Moving lugs to maintain clearance from lid
- 75. ESS Integration Design vs. Integration: Moving lugs to maintain clearance from lid
- 76. ESS Integration Design vs. Integration: Moving lugs to maintain clearance from lid
- 77. ESS Integration Design vs. Integration: Moving lugs to maintain clearance from lid
- 79. Questions?