ELECTRICAL SYSTEMS

OF THE ELECTRIC
MOTORCYCLE
Matthew Bergey
Overview
• Project History/Background
• Motorcycle Electrical Systems Description
• This Year’s Project Designs
• Proposed Implementation/Future Work
SCV Project History
• Began in 2006 as the Solar Commuter Vehicle Project
• Research project to explore feasibility of electric
motorcycles
• Assembled from a Kawasaki Ninja motorcycle
Brushed DC Motor Conversion
• Gasoline engine to brushed DC motor with lead acid
batteries.
Motor Upgrade
Brushed Brushless
Rotor Movement Mechanism Physical Contacts Induced Magnetic
(Causing Fields from Control
Mechanical Wear) Circuitry
Efficiency Decent Better

More
complicated but
higher quality
and more
efficient
Brushed Motor Brushless Motor
Battery Upgrade
Lead-Acid Lithium-Ion
Construction Lead Dioxide (PbO2) Lithium Metal Ions
Performance/Maintenance Undesirable Desirable
Energy/Weight Ratio Low High
Applications Non-weight, space Low weight, low
critical applications space consumption
(Car Starters)

Better
Performance,
High Energy
Density
Lithium-Ion
Lead-Acid
 Current Power Systems Overview

Battery Pack Motor Controller Motor

Stores and Delivers

Provides regulated
Charge
battery pack energy
to the motor
Our Batteries
• Operating Cell Voltage Range 2.5V-3.6V
Our Battery Pack

Battery Module Battery Pack

86.4 V
x10
x10

Mod 3
x10
x10
x10
x10
x10
x10

x10
57.6 V
x10

Mod 2
x10
x10
x10
x10
x10
x10

x10 28.8 V
x10
x10
Mod 1
x10
x10
x10
x10
x10

0V
20-28.8V
Tasks
• To-Be-Designed (TBD) Projects for this year

Accessory Power
Battery Balancing Systems
Accessory Power
Systems

TBD TBD TBD

Power for Lights
Battery Cell Battery Cell
and Horn
Protection Readings
 Accessory Power Outline
Battery Pack Motor Controller

For High
60-86.4 V Voltage
Motor

Motorcycle
Accessory Power 12 V Headlights, Tail
Systems @10A Light, Horn
TBD
For Other Low 5V Microprocessors
Voltage Components
Accessory Power System Design

• Produces 12V and 5V from pack range: 60-86.4V and can

deliver high current.
• Implemented Linear Technology LT3810 chip.
• Unresolved problems led us to seek commercial options.
Battery Balancing
• Circuitry needed to keep cell string voltages between
2.5V-3.6V while charging the pack to 86.4V
x10
x10

x10

+
Mod 3

x10

x10
x10
2.5V-3.6V
x10 -
x10

x10
x10

x10
Mod 2

x10

x10
x10

x10
x10

x10
x10

x10
x10
Mod 1

x10
x10

x10
x10
Battery Balancing Structure

Charging System Balancing System

Battery Pack

TBD

Charges pack to 86.4V Regulates charge

distribution to cells Charged Pack: 86.4V
Charged Cells: 3.6V
Battery Balancing
• Circuitry needed to keep cell string voltages between
2.5V-3.6V during charging.
• Texas Instruments Battery Balancing Chip selected
• Support circuitry designed.
• One chip per module
• Programming Functionality
Battery Monitoring Structure

Microprocessor
Battery Pack Battery Monitoring
System

TBD

Retrieves Individual
Cell Voltages Reads and stores
60-86.4 V cell voltages
User Interface Display
5V max

Displays Cell 000MPH 100% 3.1V

Voltages 24.0A FULL 3.2V
 Battery Balancing Cell Selection
86.4 V

Cell
Battery Pack Analog Switch Readings

82.8 V
Microprocessor
86.4 V
+ Decoder
3.6V
- 5V

82.8 V Turns on two switches

+ to read cell voltage
3.6V
-
 Battery Balancing Cell Selection
Other Switches 57.6 V

Cell
Analog Switch Readings
Battery Pack

54 V
Microprocessor
86.4 V
+ Decoder
3.6V
- 5V

82.8 V Turns on two switches

+ to read cell voltage
3.6V
-
Battery Balancing Cell Readings
86.4 V
Analog Switch

Cell Selector

82.8 V
Microprocessor

Decoder

Turns on two switches

to read cell voltage
Battery Balancing Cell Readings
3.6 V
Analog Switch

Cell Selector

0V
Microprocessor

5V

Decoder

3.6 V
Turns on two switches
to read cell voltage
Electrical Systems Structure
User Interface Display
Charging System Battery Monitoring
Selection and 000MPH 100% 3.1V
Sampling 24.0A FULL 3.2V
Circuitry

Battery Pack Motor Controller

Balancing System

Motor
Accessory Power Systems

Commercial
Selection
Thanks
• Dr. Pratt
• Paul Myers
• Predecessors:
• Sara Finn
• Eric Hornberger
• Jon Wolgemuth