Midway Design Review Team 22 Driver Assist Electrical

Midway Design Review Team 22: Driver Assist Electrical and Computer Engineering

Primary Solution § Our solution is to create a joystick that mechanically controls the steering wheel, brakes, and throttle § The joystick will pivot horizontally allowing the driver to turn left and right. http: //img. gizmag. com/onehandeddriving. JPG? fit=max&h=670&w=77 0&s=4 af 0 a 21 ce 275 fd 7 e 9 e 9 c 78 f 8 c 92 c 344 c Electrical and Computer Engineering 2

Block Diagram Control signal Joystick signal Feedback signal Power Electrical and Computer Engineering 3

MDR Deliverables §Have motor selected with correct output torque and speed (have gearing ratio required computed) §Have a wheel jacket prototype created and mounted on steering wheel base §Have control over motors movements §Have power circuit functioning to drive controller §Have a functioning brake and throttle prototype §Have a functioning battery recharger Note: Red font was original MDR deliverable Electrical and Computer Engineering 4

Individual Assignments for MDR Steve Cook: Qingchuan Wu: §Throttle §Brakes §Power Supply §Motor Driver Design §Battery Charger Sam Burke: §Gearing §Wheel Jacket §Controller Debugging Electrical and Computer Engineering Andrew Klinkowski: §Controller §Motor Driver Implementation 5

Motor Selection Requirements • Speed: 1. 5 rps • Torque: 6 Nm Motor Specs • Speed: 4000 RPM • Torque: . 125 Nm • Brushless DC Electrical and Computer Engineering 6

Gearing § A gearing ratio of 48 will allow us to have the outputted torque required, while staying within the speed limit. §. 125 Nm * Gear. Ratio = 6 Nm § Gear. Ratio = 48 § Speed = (4000 rpm/60)/48 = 1. 38889 rps Electrical and Computer Engineering 7

Steering Wheel Jacket § In our prototype design a piece of plexiglass was used with a bike chain mounted to it using JB Weld. § The bike chain can be spun by the motor which spins the steering wheel Electrical and Computer Engineering 8

Brake Prototype § The brake stops the car and control reverse in the video game. • Includes: potentiometer, wire, and hand brake • Potentiometer sends a voltage reference between 0. 58 V to 4. 5 V depending on depression of hand brake • Higher voltage corresponds to harder braking • 10 k Potentiometer is used to reduce power and maximize voltage reference swing. Electrical and Computer Engineering 9

Throttle Prototype § Throttle allow the driver to control the gas • Includes: potentiometer, wire, and throttle • Potentiometer send a voltage reference between 3. 92 V to 0 V depending on position of the throttle • Lower the reference voltage corresponds to faster acceleration • 10 k Potentiometer is used. Electrical and Computer Engineering 10

Power – Battery Charger Requirement § Charge external 12 V Ni. MH battery from the cigarette port. 11 - 14 V input § Limit Charging current below 3 A § Limit Charging voltage below 16 V Electrical and Computer Engineering 11

Battery Charger § Used to charge external battery pack from 12 V car battery Electrical and Computer Engineering 12

Power – Battery Charger Result § SEPIC topology charger Electrical and Computer Engineering 13

Power – Battery Charger Simulation Electrical and Computer Engineering 14

Power – Battery Charger Result R load Vin I in Vout I out P in P out Efficienc y 20 12 1. 56 15. 35 0. 748 18. 72 11. 4818 61. 3 15 12 2. 18 15. 35 0. 994 26. 16 15. 2579 58. 3 10 12 3. 04 15. 35 1. 46 36. 48 22. 411 61. 4 9 12 3. 39 15. 35 1. 62 40. 68 24. 867 61. 1 8 12 3. 4 15. 35 1. 77 40. 8 27. 1695 66. 6 7 12 3. 38 14. 4 1. 86 40. 56 26. 784 66. 0 6 12 3. 39 13. 7 2. 03 40. 68 27. 811 68. 4 5 12 3. 43 11. 3 2. 31 41. 16 26. 103 63. 4 4 12 3. 49 10. 7 2. 48 41. 88 26. 536 63. 4 Electrical and Computer Engineering 15

Power Supply Electrical and Computer Engineering 16

Power – Power Supply Requirement § Requirement • Provide regulated supply voltage 7. 5 V for controller • Provide 2 isolated voltages 12 V for driving Mosfet § Implementations • Flyback converter • PI control on 7. 5 V output • Mutual inductance regulation on 12 V outputs Electrical and Computer Engineering 17

Power – Power Supply § Requirement • Provide regulated supply voltage 7. 5 V for controller • Provide 2 isolated voltages 12 V for driving Mosfet § Implementations • Flyback converter • PI control on 7. 5 V output • Mutual inductance regulation on 12 V outputs Electrical and Computer Engineering 18

Power – Power Supply Simulation Electrical and Computer Engineering 19

Power – Power Supply Simulation Electrical and Computer Engineering 20

Power – Power Supply Result § Able to provide power to the controller and Mosfet Driver § Insufficient cross regulation due to the leakage inductance of the toroid Electrical and Computer Engineering Vout 7. 5 (V) Iout 7. 5 (A) Vout 12 (V) I out 12 (A) 7. 86 0. 5 10. 9 0. 15 7. 44 0. 3 12. 6 0. 10 7. 40 0. 1 15. 8 0. 05 21

Motor Controller § An arduino is used to control the motor. § The arduino controls the frequency of the motors phases Electrical and Computer Engineering 22

Motor Driver § The driver amplifies the arduinos outputs to be used by the motor Electrical and Computer Engineering 23

Motor Gate Driver Electrical and Computer Engineering 24

Basic Motor Phase control U/V phase excitation A’ = 0 B’= 1 A=0 B=1 Flow of current Electrical and Computer Engineering 25

Cost Analysis Product Cost Brushless DC Motor $127. 00 Steering Wheel & Brakes attachment $57. 00 Bike Chain $6. 00 Plexiglass $4. 00 JB Weld $5. 00 Hand Brake $7. 00 Throttle $14. 00 Total $221. 00 Electrical and Computer Engineering 26

CDR Deliverables Steve Cook: Andrew Klinkowski: § 3 D print top half of the joystick §Install hand brake and throttle §Power supply PCB design §Full control over DC motor at required spec of 1. 5 rps § 3 D printed wheel jacket §Mount bike chain to wheel jacket Sam Burke: Qingchuan Wu: §Implementation of gear train §Mount functional motor to drive steering wheel §Controller PCB design Electrical and Computer Engineering §PCB printed charger §Charger optimization increased to 85% §Power supply rails well regulated 27

Motor Phase control- Buck (CDR) U/V phase excitation A’ = PWM B’= 1 A=0 B=1 Flow of current Normal PWM on PWM off Electrical and Computer Engineering 28

Motor Phase control- Boost (CDR) U/V phase excitation A’ = 0 B’= 1 A = PWM B = 1 Flow of current Normal PWM on PWM off Electrical and Computer Engineering 29