EEL4914SeniorDesign

FinalDesignReport

ElectricSuperBike
TheBestTeamintheWorld

MattFisher

RichardOrr

madfish@ufl.edugautama@ufl.edu

21April2008
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Contents
Contents........................................................................................................................................................................................2
Abstract ........................................................................................................................................................................................3
ProjectFeatures ........................................................................................................................................................................3
ConceptsandTechnology .....................................................................................................................................................4
ControlBoxandSensors...................................................................................................................................................4
MotorControl........................................................................................................................................................................4
RechargingCapability........................................................................................................................................................5
Wireless ...................................................................................................................................................................................6
ProjectArchitecture: ...............................................................................................................................................................7
GanttChart ............................................................................................................................................................................... 10
Competition ............................................................................................................................................................................. 11

Figures:
Figure1Page3:ForceandPWMdutycycle:saturationpoint
Figure2Page4:FlexiforceSensor
Figure3Page5:Motorcontrolcircuitwithovercurrentprotection
Figure4Page6:Batteryrechargecircuit
Figure5Page7:Systemblockdiagram
Figure6Page7:Controlboxschematic
Figure7Page8:ControlboxPCBlayout
Figure8Page8:Sensorcircuits
Figure9Page9:Softwareflowchart
Figure10Page10:Ganttchart
Figure11Page11:Chargercompetitorbicycle
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Abstract
Ourprojectisanelectricbicyclethatautomaticallyvariesmotortorqueaccordingtotheamountof
forcetheriderappliestothepedals.Theamountofassistanceprovidedcanbeadjusted
continuouslybetween0(themotorneverturnson)and100percent(fullpoweratsaturation
pedalforce).
Themotorispoweredbythree13Vleadacidbatteries,whichcanberechargedbythemotorwhen
brakingorcoasting.AnLCDdisplaysspeed,distancetraveled,motorpowerandassistsetting,and
thecurrentoperationmode.

ProjectFeatures
LCDscreen:Themaincontrolboxincludesa128x64pixelgraphicLCDthatshowsthecurrentspeed
numericallyandgraphically,thedistancetraveled,theselectedlevelofmotorassist,thecurrent
dutycycleofthemotor,andtheoperatingmode(runningorcharging).
WheelRotationSensor:AbipolarHalleffectsensormountednearthefrontwheelisusedto
determinespeedanddistance.
VariableMotorAssistance:Aknobmountedonthecontrolboxallowstheridertovarythelevelof
motorassistance.At0,themotorwillneverturnon.At100%themotorrunsatfullpowerwhen
thesaturationforce,approximately500N,isappliedtoeitherpedal(seefigure1).Atanysetting,
thedutycycleofthemotorvarieslinearlywiththeforceapplied.

Figure1:ForceandPWMdutycycle:saturationpoint

RegenerativeBraking:Whenthebrakeisapplied,thesystemswitchestochargingmode.Inthis
mode,thebatteriesareconnectedinparallel,thedutycycleissettozero,andthecurrentproduced
bythespinningmotorisusedtochargethebattery.

WirelessLCD:shortrangeXbeemodules,CompacttwolineLCD.Willdisplaycurrentspeed,
distancetraveled,andmotordutycycle.DrivenbyaPICprocessor.

ConceptsandTechnology
ControlBoxandSensors
AtmelATMega32microcontroller:TheATmega32offeredplentyofdigitalandanalogI/Opins,
moderatepoweruse,highspeed,andanexcellentfreeIDEinAVRStudio.
GraphicLCD:Whilequitedifficultforthebeginner,(themodelweusedlacksacharactergenerator
andcomeswithaninaccuratedatasheet)ithashighresolutionandalargescreenarea,soitcan
displayalotofinformationinaneasytoreadlayout.
HallEffectSensor:AbipolarlatchedHalleffectsensorismountednearthefrontwheelanddetects
thepassageoftwomagnetsfixedtothewheel.Thebipolarsensormakesiteasytodetecta
completewheelrotation.Aunipolarsensorwouldbeveryinaccurate,asthemagnetcouldbe
parkednearthesensorandsmallmovementswouldproducefrequentrotations,leadingtoa
uselessspeedcalculation.Theswitchingtimeofoursensorisadequateforspeedsupto
73,863MPH,whichwedonotanticipate.
ForceSensors:FlexiForcesensors(seeFigure2)aremountedonthepedalstomeasuretheamount
offorceapplied.Thesensorisavariableresistorandvariesbetween~10Mand~1Kasforceis
applied.

Figure2FlexiforceSensor

Thesensorsareeasytouseandtheforceappliedcanbemeasuredviaasimplevoltagedividerwith
afixedresistor.Themajordrawbackisthatwearemeasuringforcewhentherealquantityof
interestistorque.Thedifferenceisapparentwhenoneconsidersariderstandingonapedal.No
torqueisappliedtothepedalshaft,butalargeforceismeasured.

MotorControl
Wheninrunningmode(defaultmode),theAtmel32weighsthedutycycleofarectangularpulse
widthmodulation(PWM)output,determinedbythefollowinginputs:assistancelevel
potentiometerandtheforcesensoronthepedals.Theassistancelevelpotentiometerprovidesa
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ceilingforthedutycycleofsignal,whereastheforcesensorsonthepedalsdeterminethefinalduty
cyclevaluesbelowthisceiling.
ThePWMsignalisthenfedintothecurrentlimitingcircuitshownbelow,andtheoutputofthatis
fedtothegateof4IRFP150NChannelMOSFETS,whichdrivethemotor:

Figure3:motorcontrolcircuitwithovercurrentprotection

Usingthisstrategy,thedutycycleofthemotorisvariedproperlywiththepressureappliedatthe
pedals,withouttheworryoffloodingthemotorwithcurrentwhenitisstalled.Thesensitivityof
thiscurrentprotectioncanbebiasedusingavoltagedivider.However,itisstillnotrecommended
tostallthemotor,astheMOSFETscouldstilloverheat.

RechargingCapability
Whenapushbuttononthebrakehandle(attachedtoamicroprocessorinputpin)ispressed,the
softwarerunsinchargemode.Themicroprocessorthensendsanactivehighsignaltoanother
IRFP150NChannelMOSFET.ThisMOSFET,whosedrainisconnectedtothe+12Vterminalofone
ofthebatteries,willdriverelayswhichconnectthebatteriesinparallel,toberechargedwiththe
followingcircuit:

Figu
re4:
Batt
ery
rech

argecircuit

Thepeakvoltagethatthemotor(nowagenerator)canreachisapproximately18V.Thisvoltageis
regulatedwithanLM317to14.5V.Valuesofvoltagelargeenoughtochargethebatteriesareonly
reachedforaveryshortburstoftime(about1second).ARCAportattheinputoftheLM317was
addedtoconnectotherchargingdevicestothecircuitifneeded(e.g.solarcell,DCpowersource,
etc)

Wireless
ThewirelessLCDmustupdatefrequentlyandbereasonablyaccurate.Thehalleffectsensorwillbe
simulatedwithapushbuttonswitchthatwillbefedtoaninterruptontheAtmega32.Thisshould
simulatethenumberoffullrotationsofthebikewheelinagiventimeinterval.Theforcesensoron
thepedalwillbesimulatedwithapotentiometerwhichwillvarythevoltagefrom0Vto2.5V,
servingasamodelforthevaryingdegreeofforceappliedtothesensor.Theplanistointegratethe
wirelessLCDwithactualsensorsonthebikeiftimepermits.

ThemainchallengeistoprogramtheUARToftheAtmega32tosendthedataseriallytotheXbee
transmitter,andthentoprogramtheUARTofthePICtoreceivethedataanddisplaythenecessary
informationontheLCD.TheXbeesthemselvesmusthaveawirelesslinkcreatedbetweenthem
throughaninterfaceboard.

ProjectArchitecture:

Figure5:Systemblockdiagram

Figure6:Controlboxschematic

Figure7:ControlboxPCBlayout

HallEffectSensor

PedalForceSensors
Figure8:Sensorcircuits

Figure9:Softwareflowchart

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BillofMaterials
600WBrushedDCMotorand36VBatteryKit

$500

AtmelATMega32microcontroller

$1.50

H9845IRFP150PowerMosfet(x8)

$24

3651036NDHalleffectSensors

$3

SLD12VDC1CAutomotiveRelays(x4)

$12

SRDS105DRelays(x8)

$2.40

ACS715LLCTR30ATCurrentSensor

$3.04

Misc.CablesandConnectors

$50

GraphicLCD

$30

FlixiforceSensors(x2)

$30

TOTAL

$655.94

GanttChart

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Figure10:Ganttchart

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Competition

TheChargerbicycle(seeFigure11),manufacturedbyElectroportal,offersaverysimilarfeature
set.ThemaindifferencesarethattheChargersassistlevelisnotcontinuouslyadjustable,andthere
isnodisplayunit.Whileaspeedometermayseemsuperfluousonabicycle,thesehybridmodelsare
capableofsustainedhighspeeds,andonecouldquiteeasilybreakthespeedlimiton,forexample,a
collegecampus.Additionally,theChargerretailsfor$1500,wellaboveeventhesingleunit
developmentcostofourproject.

Figure11:Charger
competitorbicycle

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