Multidisciplinary Senior Design s3

Multidisciplinary Senior Design Project Readiness Package

Project Title: Active Cooled Battery Packs for Electric Motorcycle Applications Project Number: P18xxx (P/ending year/project #, e.g. P15001 finishes in 2015 and is (assigned by MSD) project number 001) Primary Customer: (provide name, phone RIT Electric Vehicle Team/Alexander Young ([email protected]) number, and email) Sponsor(s): (provide name, phone Who is providing financial support? number, email, and amount of support) Preferred Start Term: Fall 2018 Faculty Champion: (provide name and email) Other Support: As applicable Project Guide: George Slack (assigned by MSD)

Jeffrey Botticello, Sydney Lizarazo 5/22/17 Prepared By Date

Received By Date

Items marked with a * are required, and items marked with a † are preferred if available, but we can work with the proposer on these.

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 Project Information

* Overview: The RIT Electric Vehicle Team is a student run organization dedicated to promoting the viability of electric vehicles through real world demonstrations of electric drivetrains in action. The team has successfully raced an electric motorcycle in the eMoto Racing Series at New Jersey Motorsports Park, winning 1st and 2nd in 2015 and 2016, respectively. The next goal of EVT is to build a new revision of the motorcycle, REV2, and compete at Pikes Peak International Hill Climb in Colorado.

Currently, the battery packs on REV1 utilize passive cooling through AllCell, a wax- impregnated graphite matrix that regulates battery cell temperature through phase change. While this technology has proven successful so far, the AllCell is limited to certain temperature ranges, and after a certain point will not effectively cool the batteries. In order for this technology to be effective, it would require a greater volume of the AllCell material, which, for the limited constraints of a motorcycle frame, is not feasible.

For REV2, the battery packs will need to be actively cooled in order to increase performance and continue to be competitive with other teams during races. Active cooling will allow EVT to compete at much higher levels of performance than currently possible, The senior design team working on this project will need to design and build active cooled battery packs that can be fully integrated with REV2’s frame and drivetrain.

* Preliminary Customer Requirements (CR): 1. Hold enough energy to successfully complete the Pikes Peak International Hill Climb with the selected powertrain of REV2. 2. Output a high enough power to not limit the capabilities of the selected powertrain of REV2. 3. Maintain the temperature of the cells in the pack below the upper limit of their operating range. 4. Be sealed to intrusion of rain water, dirt, or debris as would be experienced under typical operating conditions. 5. Fit within the frame of REV2 and mount easily with well located mounting points. 6. Minimize weight so as not to limit the performance of REV2. 7. Include sensors throughout the pack for measurement of cell temperature. 8. Hold and integrate an EVT designed battery management system for maintaining voltage balance in the cells of the pack, as well as collecting data from pack sensors. 9. Conform to all PPIHC rules and regulations for battery pack design.

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 † Functional Decomposition (will not be given to the students, but will be provided to the team’s guide for reference): What functionality will be delivered in order to satisfy the customer requirements? This may be in the form of a list of functions, a function tree or a FAST diagram.

* Preliminary Engineering Requirements (ER): Include both metrics and specifications. Each ER should map to one or more CRs (see above). Metrics: what quantities will be measured in order to verify success? Specifications: what is the target value of the metric that the team should design to?

ER CR Metric Target Spec 1 1 Total System Battery Capacity Minimum 8 kWh 2 2 Total System Battery Voltage Maximum Operating Voltage of REV2’s Drivetrain Components 3 3,7 Max Cell Temperature Under Typical Race Specified Operating Conditions Temperature of Cells Chosen 4 5 Max Volume of Packs Internal Volume of REV2’s Mainframe 5 4,9 Ingress Protection during Typical Race Conditions IP-64 6 4,9 PPIHC Rule 1: Battery System - Batteries must be Meets Criteria fully contained in enclosures that can be sealed by PPIHC Officials. Enclosures must be equipped with a forced ventilation system rated at least 10cfm. It must operate whenever the battery

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 system is electrically connected to the motorcycle. All electric cables must be properly sized to expected system currents. All electric vehicle entries must be accompanied by the MSDS information on all batteries that are considered hazardous or toxic. Failure to provide proper documentation will result in disqualification. 7 9 PPIHC Rule 2: Battery Disconnect - The battery Meets Criteria system will be equipped with a manually operated, high-current switch to quickly disconnect the battery from the electrical system. This switch must be capable of interrupting the full load current. The switch must physically be located as near to the battery as practical and be operable by the rider. This switch must be clearly marked in day glow orange letters as the "Battery Switch" and be plainly marked with "ON" and "OFF" positions. 8 9 PPIHC Rule 3: Main Fuse - A separate fuse (not a Meets Criteria circuit breaker) will be placed in series with the main battery and the rating will not exceed 200% of the maximum expected current draw. All low voltage taps from the main battery will be separately fused. All fuses must be placed first in series with the battery starting at the positive connection. 9 9 PPIHC Rule 4: Electrical Shock Hazards - All Meets Criteria exposed conductors operating at greater than thirty-six (36) volts must be properly insulated and marked with "High Voltage" warning signs. 10 8 EVT BMS Integrated with Pack? Yes 11 6 Weight of Pack Minimized? Yes

* Constraints: 1. Design must be entirely modeled using Solidworks in order to be compatible with all other EVT models. 2. Must not have any exposed electrical connections outside of the main pack connectors. 3. Must fit within the frame of EVT’s REV2.

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 † Potential Concepts: (will not be given to the students, but will be provided to the team’s guide for reference):

1. Tesla’s liquid cooled Li-ion batteries: Coolant flows through a ribbon that is interweaved between the 18650 cells. Required disciplines: thermal analysis, volume optimization, fluid flow knowledge - all required.

2. Thin cooling plates between individual cells - this kind of technology is used in the Chevy Volt and BMW i3. Required disciplines: thermal analysis, volume optimization, fluid flow knowledge - all required.

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 * Project Deliverables: Minimum requirements: ● All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test results) ● working prototype ● technical paper ● poster ● All teams finishing during the spring term are expected to participate in ImagineRIT

Additional required deliverables: ● Documentation on EVT’s wiki of the entire project.

† Budget Information: Include total budget, any major cost items anticipated, and any special purchasing requirements from the sponsor(s).

Battery Cells: ~$6000 Copper Stock: ~$600 Aluminum Stock: ~$500 Insulation Material: ~$500 Connectors: ~$200 Miscellaneous Materials: ~$1000

EVT will provide any additional funding necessary outside of our MSD budget.

* Intellectual Property: Describe any IP concerns or limitations. According to RIT policy, students have the right to retain any IP they generate during a course, but some students voluntarily agree to be placed on projects where they will be asked to assign their IP. If a sponsor wishes to have a team assign their IP, we need to know ahead of time so that we can place appropriate students on the team.

In order to ensure that students can discuss their projects openly during presentations and job interviews, we ask that no more than ~20% of the project be considered confidential.

This project is owned by RIT.

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 Project Resources

† Required Resources (besides student staffing): Describe the resources necessary for successful project completion. When the resource is secured, the responsible person should initial and date to acknowledge that they have agreed to provide this support. We assume that all teams with ME/ISE students will have access to the ME Machine Shop and all teams with EE students will have access to the EE Senior Design Lab, so it is not necessary to list these. Limit this list to specialized expertise, space, equipment, and materials.

Faculty list individuals and their area of expertise (people who can provide specialized knowledge unique to your project, e.g., faculty you will need to consult for Initial/ more than a basic technical question during office hours) date Rob Stevens - Heat Transfer Michael Schralu - Heat Transfer and Fluid Mechanics Tim Landschoot - Structures Marca Lam - Materials Environment (e.g., a specific lab with specialized equipment/facilities, space for very large or oily/greasy projects, space for projects that generate airborne debris or Initial/ hazardous gases, specific electrical requirements such as 3-phase power) date Electric Vehicle Team Room Equipment (specific computing, test, measurement, or construction equipment that Initial/ the team will need to borrow, e.g., CMM, SEM, ) date Spot Welder - Supplied by EVT Thermal Camera - Supplied by EVT Materials (materials that will be consumed during the course of the project, e.g., test samples from customer, specialized raw material for construction, chemicals that must Initial/ be purchased and stored) date Battery Cells - Lithium Ion Chemistry Construction Materials - Largely Metals Battery Coolant - Water/Glycol Based Initial/ Other date

† Anticipated Staffing By Discipline: Indicate the requested staffing for each discipline, along with a brief explanation of the associated activities. “Other” includes students from any department on campus besides those explicitly listed. For example, we have done projects with students from Industrial Design, Business, Software Engineering, Civil Engineering Technology, and Information Technology. If you have recruited students to work on this project (including student-initiated projects),

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 include their names here.

Dept. # Req. Expected Activities BME 0 CE 0 EE 0 ISE 0 ME 6 Chris Ferri. Jeff Botticello. Sydney Lizarazo. Tyler Roy. Reilly Baker. Jon Bontemps. Expected activities include: ● Overall analysis and determination of pack size, voltage, and power capacity. ● Design, modeling, analysis, and testing of liquid cooled battery solution. ● Cell and module interconnection design and testing. ● Cell holding structure design and testing. ● Pack insulation design and analysis. ● Overall pack structure and frame integration. ● Waterproofing and dustproofing. ● Vibration analysis and retardation. Other

* Skills Checklist: Indicate the skills or knowledge that will be needed by students working on this project. Please use the following scale of importance: 1 = must have 2 = helpful, but not essential 3 = either a very small part of the project, or relates to a “bonus” feature blank = not applicable to this project

Biomedical Engineering BME Core Knowledge BME Elective Knowledge Matlab Medical image processing Aseptic lab techniques COMSOL software modeling Gel electrophoresis Medical visualization software Linear signal analysis and processing Biomaterial testing/evaluation Fluid mechanics Tissue culture Biomaterials Advanced microscopy Labview Microfluidic device fabrication and measurement Simulation (Simulink) Other (specify) System physiology Biosystems process analysis (mass, energy balance) Cell culture

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 Computer-based data acquisition Probability & statistics Numerical & statistical analysis Biomechanics Design of biomedical devices

Computer Engineering CE Core Knowledge CE Elective Knowledge Digital design (including HDL and FPGA) Networking & network protocols Software for microcontrollers (including Linux Wireless networks and Windows) Robotics (guidance, navigation, vision, machine Device programming (Assembly, C) learning, control) Programming: Python, Java, C++ Concurrent and embedded software Basic analog design Embedded and real-time systems Scientific computing (including C and Matlab) Digital image processing Signal processing Computer vision Interfacing transducers and actuators to Network security microcontrollers Other (specify)

Electrical Engineering EE Core Knowledge EE Elective Knowledge Circuit Design (AC/DC converters, regulators, amplifies, analog filter design, FPGA logic design, Digital filter design and implementation sensor bias/support circuitry) Power systems: selection, analysis, power budget Digital signal processing System analysis: frequency analysis (Fourier, Laplace), stability, PID controllers, modulation Microcontroller selection/application schemes, VCO’s & mixers, ADC selection Circuit build, test, debug (scope, DMM, function Wireless: communication protocol, component generator selection Board layout Antenna selection (simple design) Matlab Communication system front end design PSpice Algorithm design/simulation Programming: C, Assembly Embedded software design/implementation 3 Electromagnetics: shielding, interference Other (specify)

Industrial & Systems Engineering ISE Core Knowledge ISE Elective Knowledge Statistical analysis of data: regression 1 Design of Experiment 2 Materials science Systems design – product/process design 1 Materials processing, machining lab Data analysis, data mining Facilities planning: layout, mat’l handling Manufacturing engineering Production systems design: cycle time, throughput, DFx: manufacturing, assembly, environment, assembly line design, manufacturing process sustainability design Ergonomics: interface of people and equipment 1 Rapid prototyping

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016 (procedures, training, maintenance) Math modeling: OR (linear programming, 1 Safety engineering simulation) 1 Project management Other (specify) Engineering economy: Return on Investment Quality tools: SPC Production control: scheduling Shop floor IE: methods, time studies Computer tools: Excel, Access, AutoCAD Programming (C++)

Mechanical Engineering ME Core Knowledge ME Elective Knowledge 1 3D CAD 1 Finite element analysis 2 Matlab programming 1 Heat transfer 1 Basic machining 1 Modeling of electromechanical & fluid systems 1 2D stress analysis 1 Fatigue and static failure criteria 1 2D static/dynamic analysis Machine elements Thermodynamics Aerodynamics 2 Fluid dynamics (CV) 3 Computational fluid dynamics 3 LabView Biomaterials 3 Statistics 1 Vibrations 2 Materials selection IC Engines 2 GD&T Linear Controls Composites Robotics Other (specify)

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Spring 2016