FSAE Mobile Workstation Electrical Power Preliminary Design Review

FSAE Mobile Workstation Electrical Power Preliminary Design Review Tyler Tallo 11/09/2018 P 19223 FSAE Mobile Workstation

GOALS AND IMPROVEMENTS • Provide a Robust, Simple System to Power the Workstation • Make the system as safe and easy to use as possible • Ensure the system can operate for years with minimal maintenance • Reduce Cost • Cut cost where possible with sacrificing safety, reliability, functionality or ease or use • Weatherproof • System should be designed to be weatherproof and safe to operate in wet conditions P 19223 FSAE Mobile Workstation

ALTERNATIVE DESIGNS • Generator • Considered using generator to supplement battery power • Generator was removed for various reasons after consulting costumer • Heavy • Large Footprint • Expensive P 19223 FSAE Mobile Workstation

GEOMETRY Inverter Batteries P 19223 FSAE Mobile Workstation

SCHEMATIC P 19223 FSAE Mobile Workstation

INTERFACES/CLEARANCES • Frame • Work with Jason to ensure there is enough room for wire routing • Cabinets • Work with Jason to ensure there is enough space for inverter and batteries • Ensure inverter has sufficient cooling • Weatherproofing • Make sure external connectors are either covered or are >IP 67 rated • Ensure cooling inlets are properly protected from spray and rain P 19223 FSAE Mobile Workstation

LOAD CASES/CONSTRAINTS • Laptop Chargers • Average 135 W laptop draws 2. 5 A continuously • 2 laptops charging at one time • Cell Phone Chargers • Average 120 V charging adapter draws. 3 A continuously • 4 phones charging at one time • Jump Starting Combustion Car • ~80 A peak • From F 26 starting testing • Inverter Max Output • 10 A @ 120 VAC continuously P 19223 FSAE Mobile Workstation

DATA • All Data for System Loads from Manufacturers Datasheets P 19223 FSAE Mobile Workstation

POWER SOURCE • 2, 100 Ah, Sealed Lead Acid (SLA) RV Batteries • 12 VDC • Wired in 2 P 1 S configuration • 2400 Wh of capacity • Chosen for cost and robustness when compared to a lithium battery P 19223 FSAE Mobile Workstation

INVERTER/CHARGER SPECS • AIMS 1000 W Inverter Charger • Model: PICOGLF 10 W 12 V 120 VR • Optional Remote Control Panel • 10 A @ 120 VAC output • 20 A Charging Current • 10 Hour Charge Time • Functions as: • 12 VDC to 120 VAC Inverter • Battery Charger • GFCI Built-in • Overcurrent protection • Battery under voltage protection P 19223 FSAE Mobile Workstation

CHARGING PORT • Hubbell Sealed Twist-Lock Port • Watertight • Specialized connector • Will make a separate small charging lead • Connector unique enough to keep it from being used for other things, however parts available at any hardware store • Charge port mounted to outside of cart P 19223 FSAE Mobile Workstation

JUMP STARTING • Circuit Fused to 100 A • Using Gigavac Automatic Low Voltage Disconnect • Keeps 12 V battery voltage from dropping to low during jump starting • Cutoff voltage programable • Rated to 400 A continuously • LED driver to indicate when battery is too low • Anderson SB 50 Connector • Cheap and Robust • Rated to 120 A continuously • Have large quantity in stock • Will Require a hood to shield it from rain P 19223 FSAE Mobile Workstation

POWER OUTLETS • 2 Outlets • All outlets will have USB ports for easy charging of electronics • 1 inside workstation, in watertight electronics charging cabinet • 1 outside, mounted to side or top worksurface • Outside outlet will have waterproof cover to protect from rain P 19223 FSAE Mobile Workstation

ANALYSIS • P 19223 FSAE Mobile Workstation

TESTING PLANNED • Full Discharge Test • Ensure capacity is as stated • Jump Start Test • Ensure cut off relay is functioning as intended P 19223 FSAE Mobile Workstation

MANUFACTURING AND SERVICEABILITY CONCERNS • Wiring in Small Areas • Ensure proper use of grommets to keep wires from chaffing • Ensure proper wire bend radius to avoid stressing cable • Large Amount of Panel Cutouts • Will need to work with Jason to ensure all external connectors and panels have proper cutouts and waterproofing P 19223 FSAE Mobile Workstation

FMEA Item and Function Electrical Wiring Inverter Potential Failure Potential Effects modes of Failure Wires Chaffing External Short Circuit Arc Flash, Electrocution Severity (5=severe) Potential Causes of Failure Occurance (5=very likely) Detectability (5=difficult) RPN Recommend Actions 5 Improper Design or Assembly 3 1 15 Proper Assembly Charger Fails Battery Isnt Charged 2 Bad Component 1 1 2 Inspect Frequently Outlets Water Ingress Into Outlet Electrocution 5 Improper Design or Assembly 2 2 20 Proper Assembly P 19223 FSAE Mobile Workstation

MATERIAL NEEDS • None P 19223 FSAE Mobile Workstation

PARTS/MATERIAL TO ACQUIRE Subsystem Item Description MFG Part Number Vendor Part Number QTY Electrical 1000 W Inverter/Charger PICOGLF 10 W 12 V 120 VR 1 $426. 00 Inverter. RUS Automatic Battery Cutoff MXSL 15 BE 1 $272. 38 Waytek Wire HOM 120 GFICP 100002959 1 $39. 95 Home Depot B 00 S 1 RT 58 C 2 $169. 99 R 05 -T 5632 -0 BE 205430287 4 $22. 97 $91. 88 Home Depot PSB 37550 GY 202284546 4 $5. 83 $23. 32 Home Depot MX 1050 S 202266482 2 $3. 67 $7. 34 Home Depot Am-CBS 01 B 07413 JWLD 1 $19. 97 2105 S 30 -AFC 205015280 50 $0. 89 $44. 50 Home Depot E 987 NR 202205916 1 $28. 14 Home Depot GFCI 1 Pole 20 A Circuit Breaker RV Battery 15 A USB Power Outlets Outlet Junction Boxes Junction Box Weatherproof Covers Battery Cutoff Switch 12 AWG 3 Conductor BX Shielded Cable Breaker Junction Box P 19223 FSAE Mobile Workstation Price/Each Extended Price Vendor $339. 98 Amazon $19. 97 Amazon

WHAT I LEARNED? • How to integrate off the shelf components • How to choose the right battery for an application P 19223 FSAE Mobile Workstation

THANK YOU! QUESTIONS? P 19223 FSAE Mobile Workstation