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Boat #8 Technical Report 5/6/2019 2019 Tech Report - Google Docs University of Rochester Solar Splash Boat #8 Technical Report May 6th, 2019 Team Members Chris Dalke · Andrew Gutierrez · Seth Schaffer · Martin Barocas · Nick Davis Ivan Frantz · Leo Orsini · Owen Goettler · Daniel Wong · Heriniaina Rajaoberison Melanie Armenas · Mark Westman · Daniel Allara Advisors Dr. Ethan Burnham-Fay · Kyle DeManincor · Jim Alkins https://docs.google.com/document/d/1O9zWnMsXp2kttvCnGx9Cloe6BIANx8N5uxl2V2ImnuY/edit# 1/81 5/6/2019 2019 Tech Report - Google Docs University of Rochester, Tech Report ·Page 2 Executive Summary This year, the University of Rochester Solar Splash team focused on improving our boat in two areas. We built a robust, modular telemetry system which records sensor data about the boat’s performance. Data points are displayed live in the boat, transmitted over radio to a shore computer, and stored in a database for later analysis. This system is used to transmit the throttle and controls for the boat, allowing our team to use control algorithms to follow a power budget. On the mechanical systems side, we improved our outboard motor to use a simplified direct drive and interchangeable motor system. Our outboard motor has been modified to accommodate propellers up to 14”. The ability to change motor and propeller on the same outboard assembly gives our team a large amount of flexibility. Each of these changes was implemented in response to events of the previous year. At the end of last year, our team suffered a setback that prevented us from attending competition. During testing, we overheated our motor and were not able to secure a replacement in time for competition. This incident, while unfortunate, was incredibly valuable in directing our team’s future. First, this was an indication that our drivetrain, propeller, and motor were mismatched as our system was overloading the motor even at low speeds. Second, this reinforced the importance of a telemetry system which can provide feedback early in the testing phase to identify problems. With these changes in mind, our team set goals for expanding our telemetry system and modifying the drivetrain. Our efforts this year are also a continuation of our goal for last year of building a modular system which can be iterated on yearly by our team. Although our focus this year was on two subsystems, we expanded the modular nature of our boat in both the telemetry and drivetrain systems. The end result of these efforts is a boat which can be reconfigured quickly, is easy to setup and run in testing, and is robust to the failure of an individual component. The development of a telemetry system is a huge step forwards for our team as it allows us to quantitatively measure the results of our system improvements. Previously, we had no system of measuring the performance of our boat, meaning we could only guess at where problems in our system existed. The telemetry system allows us to accurately measure and compare the performance of our boat, as well as diagnose problems in a more efficient manner. Outside of engineering work, our team has spent time recruiting members, participating in on-campus and off-campus events, and other matters which will ensure the longevity of the group. We implemented training programs in electronics, programming, and mechanical design, with the intention of helping members build engineering skills. Overall, we are very proud of the work that the University of Rochester Solar Splash team has done this year. We’ve made significant progress in our engineering work, involvement in our campus community, and overall mission of racing a successful boat at the Solar Splash competition. We look forward to competition! https://docs.google.com/document/d/1O9zWnMsXp2kttvCnGx9Cloe6BIANx8N5uxl2V2ImnuY/edit# 2/81 5/6/2019 2019 Tech Report - Google Docs University of Rochester, Tech Report ·Page 3 Table of Contents Executive Summary 2 Table of Contents 3 I. Overall Project Objectives 6 II. Data Acquisition and/or Communication 7 A. Current Design 7 B. Analysis of Design Concepts 7 C. Design Testing and Evaluation 8 III. Electrical System 9 A. Current Design 9 B. Analysis of Design Concepts 9 C. Design Testing and Evaluation 11 IV. Power Electronics System 11 A. Sprint Configuration 11 B. Endurance Configuration 12 C. Power Budget 13 V. Drivetrain and Steering 14 A. Drivetrain 14 B. Propellers 16 C. Steering System 17 VI. Solar Energy System 19 A. Solar Panels 19 B. Solar Chargers 19 C. Solar Tracking System 21 VII. Hull Design 22 A. Current Design 22 B. Analysis of Design Concepts 22 C. Design Testing and Evaluation 23 VIII. Project Management 23 A. Team Members and Leadership Roles 23 B. Project Planning and Schedule 24 C. Financing and Fundraising 24 https://docs.google.com/document/d/1O9zWnMsXp2kttvCnGx9Cloe6BIANx8N5uxl2V2ImnuY/edit# 3/81 5/6/2019 2019 Tech Report - Google Docs University of Rochester, Tech Report ·Page 4 D. Strategy for Team Continuity and Sustainability 25 E. Discussion and Self-Evaluation 25 IX. Conclusions and Recommendations 25 A. Strengths 25 B. Weaknesses 26 C. Lessons Learned 26 D. Achievement of Objectives 26 E. Future Objectives 26 References 27 Appendix A: Battery Documentation 28 A. Material Safety Data Sheets 28 B. Battery Datasheets 34 Appendix B: Flotation Calculations 36 Appendix C: Proof of Insurance 38 Appendix D: Team Roster 39 A. Undergraduate Roster 39 B. Advisor Roster 39 Appendix E: Telemetry Data 40 A. Description of Telemetry Protocol 40 B. Telemetry Node Implementation 42 B. Telemetry Node Data 43 Appendix F: Electrical System Data 44 Appendix G: Power Electronics Data 47 A. Motor Specs 47 B. Motor Controllers 47 C. Motor Datasheets 48 D. Notes on Alltrax Throttle Control 51 Appendix H: Drivetrain and Steering Data 52 A. Torqeedo Propeller Datasheets 52 B. Drivetrain CAD Drawings 53 C. Lower Unit Modifications 58 Appendix I: Solar Energy System Data 59 https://docs.google.com/document/d/1O9zWnMsXp2kttvCnGx9Cloe6BIANx8N5uxl2V2ImnuY/edit# 4/81 5/6/2019 2019 Tech Report - Google Docs University of Rochester, Tech Report ·Page 5 A. Solar Charger Datasheets 59 B. Solar Panel Datasheets 60 C. Explanation of Step-Down vs. Boost MPPT Chargers 61 Appendix J: Hull Design Data 63 A. Hull Modification Process 63 B. Hull Design History 67 C. Hydrostatics Testing Program 69 Appendix K: Project Management Data 71 A. Executive Board Roles 71 B. Budgeting Documentation 71 Appendix L: Sponsorship Packet 73 Appendix M: Power Budget 78 Appendix N: Solar Tracker 80 https://docs.google.com/document/d/1O9zWnMsXp2kttvCnGx9Cloe6BIANx8N5uxl2V2ImnuY/edit# 5/81 5/6/2019 2019 Tech Report - Google Docs University of Rochester, Tech Report ·Page 6 I. Overall Project Objectives Our objectives for this year focused on two areas: Our drivetrain and telemetry systems. We identified several objectives in each area, which we worked on throughout the year. In the drivetrain area, we had the following goals: ● Move to a direct drive system: Previously, we were gearing up our outboard motor to attempt to raise the propeller RPM, but this overloaded the motor since it was not able to provide the torque requirement. Instead of using the mechanical system to force the desired output RPM, we planned to use a direct drive and a motor which would better fit for our application without gearing. ● Build a system for switching motors on the assembly: The motor we use for Sprint is not efficient for Endurance. In order to pair a motor to each event, we need a system which allows us to easily interchange motors on the same assembly. ● Adapt the lower unit to allow for larger propellers: The outboard motor unit that we use previously only allowed for 8” propellers due to a ventilation plate. By removing this plate, we can accommodate propellers up to 14”. This allows our team to use a wider range of propellers, particularly larger diameter propellers which operate at lower speeds that better match our electric motors compared to the original boat propellers. In the telemetry area, we built on the work we started last year: ● Instrument all pieces of our electrical & drivetrain system: We set a goal to complete the work started in previous years, and build telemetry sensors for all components of our system. This involved the creation of several telemetry sensor PCBs. ● Complete the Telemetry functionality: The telemetry system needed a completed monitoring UI, database storage, and a more robust communication protocol which could handle the increased sensor input. ● Shift throttle and control signals to use the Telemetry system: Previously, our throttle used an analog voltage connected directly to the motor controller. We are switching to a throttle value within the telemetry system, which is interfaced with the motor controllers via a specialized telemetry device. This consolidates our signals to use a common system, and allows us to control throttle more accurately. ● Use sensor data to aid driver decisions in endurance mode: In the endurance race, the goal is to target a set power consumption as governed by our power budget. Once we have moved to a drive-by-wire system, we can use a PID loop in the telemetry system to drive the boat at a fixed power consumption. In summary, our team has objectives in two areas: Improvement of our drivetrain system, and the completion of our telemetry system. The pursuit of these goals has allowed our team to develop a system which can be modified in response to testing and provides extensive data about performance, setting our team up for success at competition and in future years. https://docs.google.com/document/d/1O9zWnMsXp2kttvCnGx9Cloe6BIANx8N5uxl2V2ImnuY/edit# 6/81 5/6/2019 2019 Tech Report - Google Docs University of Rochester, Tech Report ·Page 7 II. Data Acquisition and/or Communication A. Current Design Our previous data collection system used a Raspberry Pi, which connected to a battery monitor to collect voltage and current readings using a JSON-based protocol.
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