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CONTROL SYSTEM DESIGN FOR ELECTRICAL VEHICLE
5
CONTROL SYSTEM DESIGN FOR ELECTRICAL VEHICLE
CONTROL SYSTEM DESIGN
FOR
ELECTRICAL VEHICLE
GRADUATION/DESIGN PROJECT
in partial fulfilment of the requirements for the degree of
BACHELOR OF SCIENCE
SUPERVISOR: ASSOC. PROF. LEVENT ÇETİN
CO-SUPERVISOR: ASST. PROF. HÜSEYİN YEŞİLYURT
JANURARY 2021
WEEKLY WORK PLAN
VEHICLE CONTROL SYSTEM
Vehicle Control System
Cemre Bağbozan 170412035
Hakan İlhan Çıvgın 170412072
VEHICLE CONTROL SYSTEM CONNECTION PLAN
Connection Plan
IN-VEHICLE ELECTRIC PLAN
Electric Diagram
ATMEGA2560-16AU SMD
8-Bit 16MHz Microcontroller
We want to add new features to our vehicle to get closer to a real driving experience and to improve everyday city vehicles. In this regard, Atmega-based microcontrollers, which can work in harmony with sensors and modules available in the market, were preferred.
Microcontroller
COMPUTER
IN-VEHICLE COMMUNICATION (CANBus)
ATMEGA2560-16AU
CANBus
CAN TRANSCIEVER MCP2515
CAN_H
CAN_L
BATTERY MANAGEMENT SYSTEM
MOTOR DRIVER
MOTOR DESIGN
BRUSHLESS DC
HUB MOTOR
Motor Design
Ramazan Çoban 160412047
BRUSHLESS DC HUB MOTOR
2.1 HUB Motor
The HUB motor is a type of in-wheel electric motor. One of the biggest contributions of being in the wheel is not using a transmission element.
2.1.1 What is the Difference of HUB Motor from Other Motors?
It is more suitable than the other motors researched in terms of weight and use. High efficiency, less mechanical complexity, reversing the electric current to determine the direction of rotation, rather than making detailed gear arrangements.
2.1.2 Advantages of HUB Motor
The most important advantage of the HUB motor for us is that it can be designed easily. It has a system that can be used more efficiently for our team and our vehicle, it is an easy system to control, there is no power train for vehicle driving, low mechanical parts and low weight as a result of calculations are also important factors for us.
2.1.3 Disadvantages of HUB Motor
Limited design space, if more than one hub motor will be used, proper management is required, an efficient cooling system design is required.
2.2 Brushless DC Motors
Brushless direct current motors are synchronous motors powered by direct current electricity through an inverter or switching power supply, which generates electricity in the form of alternating current to drive each phase of the motor through a closed loop controller.
BRUSHLESS DC HUB MOTOR
2.3 DESIGN REQUIREMENTS
DESIGN REQUIREMENTS
2.4 MOTOR DESIGN CYCLE
MOTOR DESIGN CYCLE
There are necessary cycles when designing a motor. These cycles are as stated above.
2.5 MOTOR CALCULATIONS
MOTOR CALCULATIONS
2.6 ANALYZE RESULTS
ANALYZE RESULTS
BATTERY MANAGEMENT SYSTEM
Battery Management System
1- Cell voltage measurement and balancing
2- Temperature measurement
3- Battery pack charge/discharge current measurement
4- State of charge ( SoC estimation
5- Electrical protections
Ebubekir Polat 160412016
General Properties of Designed BMS
Modular design: Slave BMS’s can be connected in series.
Each slave can control four cells.
BMS Design
Temperature measurement.
Over temperature, Overcharge, Overdischarge and short circuit protection
BMS Design
Modular Design
Single Board Design
-Multiple masters on same PCB
-Whole PCB needs to be replaced if required,
-Expensive for reproducing
-Higher work load for each microcontroller unit
-BMS must be designed for predetermined series of cells
-Multiple slaves, one master on different PCBs
-More than one Microcontroller unit
-Easy to redesign and reproduce a circuit
-Less work load for each microcontroller unit
-Flexibility for different series of cells
Microcontroller Unit
Slave MCU, Attiny1616
Master MCU, STM32F103C8T6
Microcontroller Unit
-Enough pins for master task
Its purpose is send balance commands to slaves, control charge and discharge and compute State of Charge
-Enough pins for slave task
-User friendy programming libraries
-Can be programmed using C and Wiring
-Internal Clock and ADC
Its purpose is measure voltage of batteries and balance
Cell Voltage Measurement
Resistor Voltage Divider
Differential Voltage Sensing
Cell
-Less precise measurements
-Low resolution
-Low cost
-More precise measurements
-High resolution
-High cost
Active Balancing
Cell Balancing
Inductive Converter (Buckboost Method)
-Efficient charging
-Excessive charge is transferred into lower cell
-Hard to implement
Cell Balancing
Passive Balancing
Charge Shunting
-Energy loss
-Excessive charge is dissipated on bleeding resistor
-Easy to implement
-Most common method
Temperature Measurement
Negative Temperature Coefficient Thermistors (NTC)
Resistance Temperature Detector
Temperature Measurement
100k NTC
-Cheap
-Nonlinear characteristics
PT100
-Expensive
-Linear characteristics
Communication
I2C
-Requires only two wires
-Provides Acknowledgment bits
-Up to 1 Mbps communication speed
-Half duplex
-Communication circuit is easy
Communication & Isolation
SPI
-Requires four wires
-Does not provide Acknowledgment
-Twice as fast than I2C
-Full duplex
-Circuit becomes comples for more than one slaves.
Isolation
Every slave will be powered by cells across it.
Slaves are isolated from each other in terms of power.
Isolation
ADuM1250
Hot swappable I2C Isolator
-1000kHz operation
-It is used in electric vehicle battery management
State of Charge
State of Charge
It is important to estimate the state of charge (SoC) of the battery pack, which is defined as the available capacity in Ampere-Hours and expressed as a percentage of its rated capacity. It can be used to estimate fuel guage algorithms.
Coulomb Counting Method
Kalman Filter Method
-Is an algorithm to estimate the inner states of any dynamic system.
- Model based state estimation technique
- Battery models are nonlinear and linearization is required
- Needs a suitable model and precise identification of its parameters.
- It needs a large computing capacity
-Most common technique
-Calculates the remaining capacity by accumulating the charge transferred in or out of the battery.
BATTERY PACKAGE DESIGN
Battery Package Design
Hüseyin Bağhan 170412014
LI-ION BATTERY & BATTERY PACK
Why Li-Ion battery was choosen;
Generally used in electrical vehicle.
Long Shell life
Quick Charge Capability
Li-Ion Battery & Battery Pack
High Energy Efficiency
Price
Degradation at high temperatures
Loss of capacity or thermal degradation as a result of overcharging.
LITHIUM-ION BATTERY TYPES
Cyclindrical Type
Pouch Type
Prismatic Type
Lithium-Ion Battery Types
Rounded structure causes significant loss of space.
Geometry is almost freely selectable and easy to size is scalable.
Prismatic cell body fabrication is more complex, but offers a high level of safety and energy density at the module level.
BATTERY SELECTION
Battery Selection
BATTERY PACK
Battery Pack
Cooling with Air
BATTERY PACK COOLING SYSTEM
The system of air-cooling can be classified as natural convection cooling and forced (artificial) convection cooling dependent on cooling system which can use a fan.