BRAKE SYSTEM PLAUSIBILITY DEVICE (BSPD)

The brake system plausibility device (BSPD) is directly supplied from LVMS which is a 12V DC
supply, complying with T11.6.3. It opens the shutdown circuit when hard breaking occurs while ≥ 5kw
power is being delivered to the motor, according to T11.6.1. BSPD is a part of shutdown circuit,
according to EV 6.1.2.

BSPD takes two inputs, one from current sensor for measuring electric power delivered to the motor, and
one from brake pressure sensor to detect hard braking. A potentiometer is used as brake pressure sensor.
The potentiometer produces an electric signal when brakes are applied, which is fed to comparator to
detect hard breaking. An HTFS 200P/SP2 (hall-effect) current sensor is used to measure the current from
accumulator to motor controller. The current sensor signal is also fed to a Comparator for confirmation of
5kw power being delivered to the motor. The output of both the comparators is fed to another comparator
to detect the fault. If the fault exists for more than 500 milliseconds, the LED is turned on indicating fault
to shutdown circuit, complying with rule T11.6.2.

When a fault is detected by BSPD the cockpit reset button must be pressed to restore the supply to rest of
the system after removing the implausibility.

When fault is detected by BSPD, led D3 is turned on. Led D4 is turned on when no fault is detected,
indicating power supply to shutdown circuit. As shown on PCB.

Components used:

capacitor 470u
resistors
Operational amplifiers LM358
Thyristor
Transistors 2N2222
LEDs
Brake sensor used Potentiometer
Torque encoder used Potentiometer
Dc current measurement used HTFS 200-P/SP2
Supply voltage 12V

COMPONENT DESCRIPTION:

LM358:

LM358 IC is a great, low power and easy to use dual channel op-amp IC. It consists of two
internally frequency compensated, high gain, independent op-amps. This IC is designed specially to
operate from a single power supply over a wide range of voltages. Supply voltage ranges from 3V to
32V.
 HTFS 200-P/SP2:

HTFS 200-P/SP2 hall-effect sensor is designed to measure wide current ratings and has high
immunity to external interference. It is used in BSPD to measure current from accumulator to motor.

2N2222:

The 2N2222 is a common NPN bipolar junction transistor (BJT) used for general purpose low-
power amplifying or switching applications. It is designed for low to medium current, low power,
medium voltage, and can operate at moderately high speeds.

PCB Design:
REFERENCES:

EV6.1.2
The shutdown circuit is defined as a series connection of at least two master switches, three
shutdown buttons, the BOTS, see T6.2, the IMD, the inertia switch, see T11.5, the BSPD,
see T11.6, all required interlocks and the AMS.

T11.6.1
A standalone non-programmable circuit, the BSPD, must open the shutdown circuit, see
EV6.1 and CV4.1, when hard braking occurs, whilst
• [EV ONLY] _5kW power is delivered to the motors.
• [CV ONLY] the throttle position is more than 25% over idle position.
The shutdown circuit must remain open until power cycling the LVMS or the BSPD may
reset itself if the opening condition is no longer present for more than 10 s.

T11.6.2
The action of opening the shutdown circuit must occur if the implausibility is persistent for
more than 500 ms.

T11.6.3
The BSPD must be directly supplied from the LVMS.

T11.6.5
To detect hard braking, a brake system pressure sensor must be used. The threshold must be
chosen such that there are no locked wheels and the brake pressure is _ 30bar.

T11.6.6
[EV ONLY] To measure power delivery, a DC circuit current sensor only must be used. The
threshold must be chosen to an equivalent of _5kW for maximum TS voltage.

Ordering the PCBs

Now we have got the PCB design and it’s time to order the PCB’s. For that, you just have to
go to JLCPCB.com, and click on “QUOTE NOW” button.

JLCPCB are also sponsor of this project. JLCPCB (ShenzhenJLC Electronics Co., Ltd.), is
the largest PCB prototype enterprise in Chinaand a high-tech manufacturer specializing in
quick PCB prototype and small-batch PCB production. You can order a minimum of 5 PCBs
for just
$2.

To get the PCB manufactured, upload the gerber file you downloaded in the last step. Upload
the.zip file or you can also drag and drop the gerber files.
After uploading the zip file, you’ll see a success message at the bottom if the file is
successfully uploaded.
You can review the PCB in the Gerber viewer to make sure everything is good. You can view
both top and bottom of the PCB.
After making sure our PCB looks good, we can now place the order at a reasonable
price. You can order 5 PCBs for just $2 but if it’s your first order then you can get 10
PCBs for $2.
To place the order, click on “SAVE TO CART” button.
My PCBs took 2 days to get manufactured and arrived within a week using DHL
delivery option. PCBs were well packed and the quality was really good.