关 键 词：

纯电动车电力驱动系统设计CAD图纸 说明书 电动车 电力 驱动 系统 设计 cad 图纸 仿单

资源描述：

纯电动车电力驱动系统设计CAD图纸 说明书,纯电动车电力驱动系统设计CAD图纸,说明书,电动车,电力,驱动,系统,设计,cad,图纸,仿单

内容简介：

任务书 院(系) 专业班级 学生姓名 一、毕业设计题目 纯电动汽车电力驱动系统设计 二、毕业设计工作自 年 月_ _日 起至 年 月 日止三、毕业设计进行地点: 四、毕业设计内容要求：要求运用所学知识，分析电动汽车的结构和参数以及传动机理，选择适当的驱动电动机、储能装置，选取适当的变速装置设计纯电动汽车的电力驱动系统。最终上交的毕业设计内容包括：1、开题报告一份；2、系统原理图、系统结构总图、部件图及明细表；3、完整的毕业论文一份；4、外文翻译。指 导 教 师 系(教 研 室) 系(教研室)主任签名 批准日期 接受设计任务开始执行日期 学生签名 Journal of Environmental Sciences 21(2009) 745749Research and development of electric vehicles for clean transportation WADA MasayoshiDepartment of Human-Robotics, Faculty of Development, Saitama Institute of Technology, Saitama 369-0293, Japan. E-mail: mwadasit.ac.jpAbstractThis article presents the research and development of an electric vehicle (EV) in Department of Human-Robotics Saitama Instituteof Technology, Japan. Electric mobile systems developed in our laboratory include a converted electric automobile, electric wheelchairand personal mobile robot. These mobile systems contribute to realize clean transportation since energy sources and devices fromall vehicles, i.e., batteries and electric motors, does not deteriorate the environment. To drive motors for vehicle traveling, robotictechnologies were applied.Key words: electric vehicle; robot technology; converted electric vehicle; clean transportationDOI: 10.1016/S1001-0742(08)62335-9IntroductionThe influences of internal combustion systems such ascars with gas engines become a serious social problembecause of the environment pollution. To alleviate theproblems, automobile manufacturers forced to shift theirpart of productions from pure internal combustion systemsto hybrid systems or electric systems. An electric systemprovides the best solution to the problem, however, weightandenergycapacityofelectricbatteriesarestillnotenoughfor the substitution of the internal combustion system withgasoline. Therefore, a hybrid system might be a reasonablesolution for the substitute of pure internal combustionsystem so far. Toyota Motor Corp. provided their firsthybrid car “PRIUS” (Toyota Motor Corporation, 1997),and the hybrid technology has been extended to large classof cars, such as “Estima hybrid” and “Harrier hybrid”.It is estimated that electric systems will be widely usedin the near future. To get initiative in this direction ofdevelopment, Mitsubishi Motors developed a pure electricvehicle, “i-MiEV” and Fuji Heavy Industry also developed“R1e”, both of which will be commercially available soon.Electric drive systems are relatively simple comparedwith an engine. It needs no cooling system, lubricantsystem, timing control between electric and gas responses.In our electric vehicle (EV) project, the first stage of theresearch has been started in which we study the fundamen-tal capabilities of EV. For the objective, we developed aconverted EV (electric mini, E-MINI) in our laboratary. Inthisarticle, the procedure of conversionand results of basictests including road tests are reported.* Corresponding author. E-mail: mwadasit.ac.jp1 Electric vehicle development1.1 Developments of electric vehicle in laboratory or aspersonal projectGood features of EVs are clean and easy to handle notonly in driving but also in the development in universitylaboratory or as personal project. To develop a gas engine,a large space with expensive facilities is needed for testingengine, such as an isolated room with a noise reductionsystem, an air ventilations, a safety system for eliminatingthe damages of engine explosion, etc.Unlike the development of engine, a drive system withan electric motor is quite simple and easy to handle.No special facility for noise reduction is needed, becauseelectric motor is very quiet compared with engine. No airventilation system is needed since electric system doesnot contaminate the environments, and smelly or volatilechemistry such as gasoline is not used.1.2 Base carAs a base car for converted EV, a class of light-car(less than 660 cc of gas engine) or a small-car around10001300 cc might be suitable. Since the light-car showsa better performance in traveling range and acceleration.After the conversion, it would gain 100 kg and sometimesadditional weight could reach 300 kg.We chose a Rover Mini (known as a Mini Cooper) asa base car to develope the converted EV because of itsrelatively small size, rigid monocoque chassis construc-tion, and easily obtainable of parts. The car has beensold for about 40 years without major design change.Additionally, its electric systems are quite simple whichhas no computers, nor brake-servo system.Figure 1 shows a snap shot of a base car before746WADA MasayoshiVol. 21Fig. 1Rover Mini (before conversion to EV).conversion to EV. The base car used was manufactured in1986 and its specifications are shown in Table 1.1.3 Motor typeSome types of motors which can be used for electricvehicle propulsions are now commercially available suchas direct current (DC) brash motors, DC brash-less motors,induction motors, etc. However, if a base car with a backgear was chosen, a DC brash motor is a solution withthe highest priority when consider the cost, weight, andperformances.Currently, digital control technology is applied to drivea such high power motor in which power switching devicessuch as FETs, IGBTs are used. The full voltage power lineis switched on and offin high frequency higher than 10kHz by the switching devices and the pulse shaped voltageis applied to motor windings. The switching frequency isconstant while a ratio between on-time and off-time in onecycle is varied based on the operation value. This drivemethod is called as a pulse width modulation (PWM).For rotate a DC brash motor in specific direction, itneeds just one switching device which chops a power lineconnected to a motor. However, if rotating a motor to drivein multiple directions is needed, namely clockwise (CW)and counterclockwise (CCW), four switching devices areneeded to be installed. Compared to DC brash motor, a DCbrash-less motor or an alternate current (AC) motor needat least six switching devices which have to be controlledindependently. Also, a sensor for detecting rotor angleis essential and can make a motor and a driver to becomplicated, heavy and bulky.Table 1Specifications of Rover Mini (1986)ParameterEngineSize 998 cc; max. power: 31 HP;max. torque: 7.1 (kgfm)DimensionLength 3054 mm; width 1440 mm;height 1330 mm; wheelbase 2036 mmWeight680 kgNumber of persons4DriveFront-engine and Front-drive (FF)Transmission4-Speed manual transmissionFrom the discussion, it is clarified that a DC brash motorrotating only in one direction is the simplest configurationcompared with others. The configuration can be availableby installing or remaining a back gear on the vehicle. Thisis not a difficult requirement because a normal gas enginecan rotate in one direction as well. It could be an anothersolution to alter the connection between batteries and amotor using circuit contactors to provide a current flowin negative direction. In this case, the moving direction,forward or back, is controlled by an electric switch, unlikea usual automobile which moving direction is controlledby a mechanical gear transmission. However, this is aunique solution only applicable for EVs.1.4 Battery typeWe have to consider the type of drive batteries forpropelling EV. A Li-ion battery may present the best per-formance among the existing batteries in its energy/weightratio. However, the strict current control in charging anddischarging situations is required and a special orderedbattery charger has to be used in many cases. If thebattery configuration has been fixed, it would be difficult tochange it for a new specification, such as changing voltage,increasing the number of batteries to enlarge maximumcurrent, etc. Beside the inconveniences, Li-ion batterysystems are extremely expensive which are 10100 timesof lead type battery in cost. In addition, it has not beenaccepted by the public that the safety of the Li-ion batterieshas been established.Due to above reasons, lead based batteries was chosenfor drive EV. Optima yellow top, the deep cycle batteryfrom Optima batteries, Inc., provides quite high perfor-mances compared with standard lead batteries.2 Electric vehicle design2.1 Components for electric vehiclesMost important components for EV are a drive motorand a motor controller as discussed in the previous section.A motor used for converted EV is a series-wound DCbrash motor which is available on 72120 VDC and 400 Acurrent at most. A motor controller with power switchingdevices can turn on and off120 VDC power at most in 15kHz frequency. Some of the important components used inEV are shown in Table 2 together with photos of a motorand a controller in Fig. 2.2.2 Design of drive unitThe major subjects of the conversion are a design andTable 2EV components (important components only)MotorL91-4003Advanced DC motorsController1221C7401CURTISThrottlePB-6CURTISBreakerTQD-200General electricElectric contactorEV-200-AAANAKILOVACE-meterLink10 model900092ZantrexBatteryYT-4.2LSOptima batteriesBattery chargerBL-20K&WDC-DC converter1400E72/96-1201CURTISNo. 6Research and development of electric vehicles for clean transportation747Fig. 2Motor and a controller for E-MINI. (a) L91-4003; (b) 1221C7401.assembling of a drive unit which consists of a drive motor,a clutch, a fly wheel and a transmission. A transmissionis not always needed to an EV, however, we utilize theoriginal transmission to extend the limited motor torqueand velocity to adapt various drive situations together withfor remaining a back gear to realize back drive using DCmotor rotating only in one direction. Figure 3 shows a snapshot of removing the gas engine from the vehicle. Thecase of the transmission was partly removed by machiningprocess to locate the motor shaft to the exact location of acrank shaft of the original engine. Figures 4 and 5 showan original transmission, a machined transmission case,and the drive unit assembly with a drive motor mountedon the top of the transmission, respectively. The weight ofthe original engine was 141 kg including small peripheralFig. 3Removal an engine from Rover Mini.devices such as a generator, a starter motor, etc., whilethe drive unit with a motor weights 87 kg. The maximumtorque of developed drive unit is 6.91 kgfm and maximumpower is 22.70 kW (30.45 HP).2.3 Battery configurationVarious available combinations exist for connecting amultiple batteries to a drive motor for an EV. Most ofmotors and motor drivers are available for the power rangeDC 72144 V. The appropriate battery configuration isone of the most important subjects for developing EV. Itdepends on the size and weight of the original car, theweight of batteries, and motor performances.For generating 72 V, at least 6 batteries (12 V each) areneeded to connect them in series. However, the batteriesproviding 4.32 kWh power under the assumption requireone battery pack has 60 Ah capacity. Normally, an EVcan travel 7 to 10 km per 1 kWh energy, it is obviousthat the energy is not enough for a car in normal use. If72 V is believed the best for system, the next solution forthe system is to install 12 batteries in a car, in which apear of 6 batteries are connected in parallel. Table 3 showsthe possible connections for EV drive with lead type 12 Vbatteries.For driving E-MINI, a DC power is generated by 8batteries connected in series which rated voltage is 96 V.The capacity of a battery is 60 Ah, total energy on a carbecomes 5.76 kWh. The batteries can be charged by anon-board battery charger with plugging it in an AC 100 Vsocket which is found at every home in Japan. Since theFig. 4Transmission of E-MINI. (a) a transmission separated from an engine block; (b) a transmission case after machining.748WADA MasayoshiVol. 21Fig. 5A drive unit assembly with motor, transmission and clutch.Table 3Possible solutions of the number of batteries, voltages andtotal capacities.TotalSingle connectionDouble (parallel) connectionvoltage (V)Num. ofCapacityNum. ofCapacitybatteries(kWh)batteries(kWh)7264.32128.648475.041410.089685.761611.5210896.481812.96120107.22014.4132117.922215.84144128.642417.28maximum current for battery charge is limited at 8 A, nospecial wiring or large breaker is required.2.4 InstallationFigure 6 shows the location of components and thewiring of E-MINI. A motor, a motor controller and athrottle are located in an engine compartment. The throttleis connected to a gas pedal by wire, driver can operate thecar in an identical manner with a standard gas car.Batteries are placed in separated locations including anengine compartment, a space under the back seats and arear luggage room. A battery charger is installed also inluggage room which electric cord is pulled out from thecap of gasoline tank for battery charging. Figures 6b and6c show engine compartment and the overview of E-MINIrespectively. The total weight of the car reaches 760 kgwhich is 80 kg gained from the car before conversion.2.5 Meters and indicatorsTo manage and get information of drive batteries, an E-mater is installed on a cockpit of E-MINI which providesa total voltage, a current flow, a remained energy in kWh,and the estimated possible time for driving (Fig. 7). Tacho-meter, and ampmeter are also installed around the cockpitfor getting instantaneous information of drive motor. Aspeedo-meter works as a standard car.3 System test3.1 Road testE-MINI has been authorized to drive on public roadswith a license plate. E-MINI could travel 35 to 38 kmdistance by one charge where approx. 3.5 to 4 kWhenergy had been consumed. Therefore, efficiency is inthe range of 8.7510.85 km/kWh. Figure 8 shows theenergy consumption and the voltage drop as travel distanceincreased from 0 (start) to approximate 30 km.3.2 Battery chargeFigure 9 shows the change of the stored energy inbattery charging using on-board charger. E-MINI has anon-board battery charger which is available for 100 V ACusing home power lines, beca