Electrical System Electrical System Overview Main Components Batteries

Electrical System

Electrical System Overview � Main Components › Batteries �Primary (72 VDC) �Secondary (12 VDC) › Motor �Brushed DC › › Motor Controller DC-to-DC Converters Microcontroller Ignition Switch › Peripherals (5 VDC) �Potentiometers �Hall Effect Sensors �Switches › Circuit Protection �Fuses �Diodes �Circuit Breakers �Optoisolators › Safety �Emergency Stop �Kill Switch

Electrical System Functional Overview � System Functions › Store High Voltage (HV) and route current to electric motor to propel motorcycle › Maintain OEM-type motorcycle battery voltage used to power microcontroller and motor controller › Control rear wheel spin and front wheel lift by modifying the throttle input signal to the motor controller › Isolate HV battery from all HV components for safer operability and serviceability

Electrical System Wiring Diagram

Electrical System Specifications Input Peripherals Spec # Voltage Range Component Description Part Number(s) Ref. Spec(s) 21176 -0706 (FR WSS) 21176 -0134 (RR WSS) 21007 -0166 (FR RLR) 21007 -0167 (RR RLR) S 2, S 11 2 0. 4 VDC = air gap, 5 VDC = blocked by ferro-magnetic material, 50 pulses per rotation Accelerator Sensor Assembly Potentiometer Analog 3 0 1 0 VDC = closed throttle, 5 VDC = wide open throttle (WOT) 13 S-85884 -00 -00 S 11 Gear Position Sensor (OEM-type) Potentiometer Analog 3 1 1 Tiered levels of voltage designated for each gear position (i. e. 0. 5 VDC = 1 st, 1. 0 VDC = 2 nd, 1. 5 VDC = 3 rd, etc. ) 13151 -0045 S 11 Gear Position Sensor (Magnet type) Hall Effect Digital 2 2 2 Upper sensor trigger = upshift, lower sensor trigger = downshift, triggered by rising-edge HP 620 -300 S 11 Potentiometer Analog 3 1 1 0 VDC = suspension fully extended, 5 VDC = fully retracted CLP-250 S 1, S 11 Switch Digital 2 2 2 Button 1) adjusts traction control levels (i. e. 1 st push = 10% allowable slip, 2 nd push = 5% allowable slip, 3 rd push = OFF) Button 2) starts/stops Data Acquisition; Both triggered by rising-edge 3 -1437565 -0 S 11 # of Microcontroller Outputs Needed # of Components Needed Description Part Number(s) Ref. Spec(s) 0 1 4 N 25 -000 E S 10 Part Number(s) Ref. Spec(s) ds. PIC 33 FJ 12 GP 202 S 10 S 21 S 22(b) # of Components Needed Digital Wheel Speed Sensor 0 - 5 VDC Input Type Wire Count Hall Effect S 20 S 22(a) Type # of Microcontroller Inputs Needed S 23 Front Suspension Travel Sensor S 24 Push-Button Output Peripherals Spec # Voltage Range S 25 0 - 3. 3 VDC Component Optoisolator Type NPN Output Type Wire Count Digital 3 Optoisolator reduces interference from motor controller to microcontroller. Microcontroller Spec # Requirement Quantity Description S 26 USB Port 1 Required for data acquisition and programming by a PC. S 27 External Interrupts 4 Allow specific digital peripherals (i. e. WSS, to input external trigger for program interrupts. S 28 Throttle Control PWM Output 1 Output PWM for throttle control at fixed frequency of 1000 - 2000 Hz. S 29 Voltage Sample PWM Output 1 Output PWM to sample 12 VDC battery voltage every 1 - 2 seconds. S 30 10 -bit ADC 1 Required to interpret analog voltages into 1024 unique binary values for the microcontroller to analyze. Legend FR = Front VFA = Very Fast Acting RLR = Reluctor Ring RR = Rear WSS = Wheel Speed Sensor LPF = Low Pass Filter

Electrical System Specifications (cont. ) Power Distribution, Wire Ratings, & Circuit Protection Spec # Voltage Level S 31 Component Wire Count Rating(s) # of Components Needed 3 5 A, 12 VDC 1 Ignition Switch S 32 Kill Switch S 33 2 Emergency Stop 1 A, 12 VDC 2 4 A, 230 VDC Part Number(s) Ref. Spec(s) Three positions: OFF (0 VDC, HV OFF), ACC (12 VDC, HV OFF), RUN (12 VDC, HV ON) 27005 -5137 S 10 1 MUST be operated without removing either hand from the handlebars, be identifiable by rider and person not sitting on machine, disable the machine's controller, not be a software input, does not act as a General Circuit Breaker. MUST be Normally Closed. 0616 -0159 S 10 4 MUST be located behind rider, be operated if machine is on its side, be a red button with a yellow disc of at least 8 cm in diameter reading "Emergency" in red or black letters, latch down mechanically once it has been operated, require manual operation to reset it, act as a General Circuit Breaker that interrupts ALL electrical transmission between the batteries by means of a spark-proof circuit breaker, include isolation of pre-charge (ground) circuits. MUST be Normally Closed. Four switches will be used for test bench. C 22 -PVT 60 P-K 11 S 10 12 VDC (Low Voltage) Description S 34 Wire Diameter - 22 AWG - Follow the 10 x normal current rule for microcontroller inputs and outputs, multi-strand. - S 10 S 35 Fuse 2 10 A 1 Protect the microcontroller, motor controller, and relays from overcurrent. - S 10 S 36 Circuit Routing - - - Twist all pairs of wires, if feasible, to reduce EMI. - S 10 - S 5 1 N 5349 BG S 10 1 N 4001 S 5 1 N 4004 S 5 S 37 Microcontroller Undervoltage Protection 1 - 1 Automatically shut down when the microprocessor input voltage falls below 9 VDC. This prevents inaccurate microcontroller outputs from out-of-range supply voltages. S 38 Microcontroller Overvoltage Protection 2 5 W, 12 VDC 1 Install a Zener diode at the VDD input of the microcontroller to prevent overvoltage damage if improper voltage levels are applied. S 39 Contactor Coil Suppresion Diode 2 1 A, 50 VDC 1 S 40 Contactor Coil Suppresion Diode 2 1 A, 400 VDC 2 S 41 Wire Diameter - 4 AWG - 6 AWG for Current < 300 A, 4 AWG for 300 A < Current < 450 A, 4 AWG-2 AWG for 450 A < Current < 500 A, 2 AWG-1/0 for 500 A < Current < 650 A - S 10 S 42 Wire Insulation Resistance - 250 kΩ for < 300 Volts to earth, 500 kΩ for > 300 Volts, test insulation resistance using at least 100 VDC - S 10 S 43 General Circuit Breaker 2 400 A, 72 VDC 2 MUST open circuit when control voltage is switched OFF (relay, solenoid switch). MUST not be substituted with over-current trip switches but be controlled by Emergency Stop switch (i. e. relay, solenoid contactor) SOL-72 V-400 A S 10 S 44 Fuses 2 400 A (VFA), 80 VDC 1 MUST be easily accessible, be as close as possible to battery, be used for ALL electrical cables, be rated according to the diameter of the individual conductors, be fast burn type. ANN 400 S 10 S 45 Pre-charge Resistor 2 1 kΩ, 10 W, 72 VDC 2 Due to the large amount of internal DC capacitance of the motor controller, the pre-charge resistor helps to prevent arcing at each contactor. MIS-PRE-1 KT S 5 S 46 Motor Controller 4 450 A, 72 VDC 1 Throttle input Pins 2 and 3 are reprogrammable using the serial port and a PC. Set up this controller to accept a 0 - 5 VDC input from the Accelerator potentiometer. Actual allowable input voltage range for Pins 2 or 3 is 0. 15 - 4. 90 VDC. AXE 7245 S 10 S 47 72 VDC-to-12 VDC Converter 4 124 W, 9 A (continuous) 10 A (peak) 1 Converter MUST isolate both 72 VDC and 12 VDC power and ground circuits. PST-DC/7212 -9 72/12 S 5 72 VDC (High Voltage) Legend FR = Front VFA = Very Fast Acting RLR = Reluctor Ring RR = Rear WSS = Wheel Speed Sensor LPF = Low Pass Filter Due to large amounts of energy stored in the motor coils during operation, a voltage spike of several hundred volts is generated when the breaker is turned OFF. This diode surpresses this spike which protects the connected motor controller and DC-DC converters. Cathode (i. e. banded end) MUST face positive voltage!

Electrical System Bill of Materials (BOM*) Bill of Materials Item Component # of Components Needed Part Number 1 72 VDC Battery 1 (supplied) 2 DC Motor 1 (supplied) 3 Motor Controller 1 (supplied) 4 LPF (PWM adjustment) 1 - 5 25 Hz LPF (1 resistor, 1 capacitor) 1 - 6 Normal Diode 2 6 A 06 7 Zener Diode 1 1 N 4742 8 Relay 1 275 -001 9 12 VDC-to-5 VDC Converter 1 LM 317 10 10 A 12 VDC Fuse 1 270 -1093 11 12 VDC Battery 1 UPG 42511 12 ds. PIC 33 FJ 12 GP 202 1 - 13 100 k Resistor 2 - 14 10 k Resistor 1 - 15 3. 3 k Resistor 1 - 16 1 k Resistor 1 - 17 PMOS MOSFET 1 IRF 9530 -ENP 18 NMOS MOSFET 1 IRF 9530 -ENN *Only includes parts not listed in the System Specifications to prevent redundancy.