Hydraulic Hybrid VehiclesTeam Dumpster Divers - Design Review Snapshot

March 8, 2005

Team Members:Michael Shurtliff - EESeneca Bertovich - CompEMichael Amato - MEJoel Stobie - MEAndi Morey - EEEric Hake - EE

Controls

W eight FactorPrice 0.2 2 0.4 5 1 10 2 10 2# of I/O 0.2 2 0.4 2 0.4 8 1.6 8 1.6Speed 0.2 8 1.6 8 1.6 8 1.6 8 1.6Programming Ease 0.2 2 0.4 2 0.4 10 2 10 2Data Acquisition 0.1 0 0 0 0 10 1 10 1Space 0.05 10 0.5 10 0.5 4 0.2 6 0.3Pow er Absorbtion 0.05 10 0.5 10 0.5 2 0.1 2 0.1

1.0 34.0 3.8 37.0 4.4 52.0 8.5 54.0 8.6

Rabit Microcontroller Pic Controller Fie ldpoint Compact Fie ldpoint

Design Matrix

Rabit Microcontroller

15%

Pic Controller17%

Fieldpoint34%

Compact Fieldpoint

34%

FieldPoint Modules

Frame Assembly

Detail Design PhaseTarget Completion Date: Jan. 31st

Excel Models Preliminary DesignSize Components Design Components Solid Works Models Order Parts

FabricationTarget Completion Date: March 11th

System ComponentsTake Apart F350 (Feb 7th)

Complete Valve Logic (Feb 11th)

Machine Components (Feb 25st)

Have Reservoir Built (Mar 4th)

Size Hoses (Mar 4th)

Model Hydraulic Schematic in AMESim (Mar 5th) Assemble Components (Mar 11th)

Tune System (Ready by March 21st)

Develop ControlsInstall Computer (Feb 11th)

Rough Code Development (Feb 18th)

Defined Code Development (Mar. 11th)

Wiring Diagram (Mar. 11th)

Tested Program Ready to Run (by March 21st)

TestingTarget Completion Date: April 8th

Jack Stand Testing (March 30th)Road Tests (April 8th)Gather necessary info for analysis

Evaluation & EXPO!Target Completion Date: April 29th

Data Analysis (April 22nd)Evaluate Results (April 22nd)Present at Engineering EXPO (April 29th)

DDR – DeliverableDUE DATE: May 7th

Design Process for Spring Semester

Frame AssemblyBuffBuff

Which Mode?

Which Mode?

System ON

Assist ModeAssist Mode Regen ModeRegen Mode

Inputs Correct?

Inputs Correct?

Inputs Correct?

Inputs Correct?

Break Pressure

Accumulator Pressures,Transmission, Engine RPMs.Brake Pressure

Accumulator Pressures,

Transmission, Velocity,

Throttle Pressure

NO NO

Throttle Pressure

Open ValveOpen Valve

YES

Open ValveOpen Valve

YES

Swash Angle?

Swash Angle?

Swash Angle?

Swash Angle?

Done?

Done? Done

?

Done?

NONO

Close ValveClose ValveYES YES

Accumulator Pressures,Velocity,Throttle Pressure

Accumulator Pressures,

Velocity,Brake Pressure

Controls Flow Diagram AMESim ModelRegen ModeRegen Mode

Functional Requirements

Importance Goals and Need Ways to Model 1 Safety Improvement DFMEA 2 Achievability Gaunt Chart/Schedule 3 Improve Gas Mileage and

Acceleration Using Excel and energy use, calculate over driving cycle

4 Cost effective Economic Analysis 5 Increase Reliability DFMEA 6 Maintainability Access to components, access panel

in resovoir, user manuals with specs for all components

7 Smoothness Existance of Control system, accelerometer readings

8 Reduce Weight Drawings, component specs 9 Noise Reduction Reference from noise book according

to bushings and shock supressors

10 Increase Brake Life Using Excel, calculate over driving cycle

Importance Goals and Need Ways to Model 1 Safety Improvement DFMEA 2 Achievability Gaunt Chart/Schedule 3 Improve Gas Mileage and

Acceleration Using Excel and energy use, calculate over driving cycle

4 Cost effective Economic Analysis 5 Increase Reliability DFMEA 6 Maintainability Access to components, access panel

in resovoir, user manuals with specs for all components

7 Smoothness Existance of Control system, accelerometer readings

8 Reduce Weight Drawings, component specs 9 Noise Reduction Reference from noise book according

to bushings and shock supressors

10 Increase Brake Life Using Excel, calculate over driving cycle

LabVIEW Simulation

DFMEA of Current SystemTeam Dumpster Divers - Design Review Snapshot

March 8, 20045

Drive Cycle ResearchTeam Dumpster Divers - Design Review Snapshot

March 8, 2005

Hydraulic Assist Cycle (ASSIST)

• Best efficiency range for hydrostat as a motor is 500 – 2000rpm (about 10 – 40 mph)

• For safety – we want to assist engine at lowest speed possible at higher speed, system must react more slowly due to high fluid flow, which could be dangerous in case of emergency

Regenerative Cycle(REGEN)

• Best efficiency range for hydrostat as a pump is about 2000psi – 4500psi

• Goal is to fill accumulator–Approx. 370kJ to fill from 2000psi to 4500psi

–Requires an initial regen speed of about 38 mph to obtain 370kJ in accumulator

Electric Charge PumpTeam Dumpster Divers - Design Review Snapshot

March 8, 2005

• (Point 1 on figure) Diesel engine efficiency very low when at idle

• (Point 2) Add 10 N-m of torque from pump through alternator

• Efficiency increases due to that engine uses less fuel to do added operation

• Conclusion: Run e-pump whenever diesel engine is at idle

New Hydrostat MountsTeam Dumpster Divers - Design Review Snapshot

March 8, 2005

After testing, we found the regenerative braking system was very noisy. Most of the system noise is machine borne noise. In an effort to reduce the noise of the system, we had to come up with a dampening scheme. Since the hydrostat acts as both a pump, and a motor, we had to design a mount that would have dampening ability in both directions. The hydrostat’s internal layout also puts forces in the axial direction; we needed to dampen vibrations in that direction as well. The solution was to use an omni-directional vibration dampener. We found the necessary spring rate, and matched it as closely as possible to production vibration dampeners, and came up with a dampener that could isolate the noise up to 77% when the hydrostat was operating at 2500 RPMs.

Scheduled ConferencesTeam Dumpster Divers - Design Review Snapshot

March 8, 2005

Conference When Where What

ASME Conference

April 1, 2

Tacoma, Washington

Presentation

SAE International

Congress

April 11-14

Detroit, Michigan

Poster, Fliers,

Interaction

Mathworks International Automotive Conference

June 22, 23

Dearborn, Michigan

Display Truck,

Posters, Presentation

Thanks to Our SponsorsTeam Dumpster Divers - Design Review Snapshot

March 8, 2005