Project Overview

APU for Hybrid HMMWVOperation Charge

Background

• ONR Requested a test bed for lead-acid batteries.

• Returned to working condition with current systems

• Designed and manufactured a thermally regulated battery pack.

Project Goals1. Engine/alternator package capable

of charging battery pack for extended range use.

2. Procedure for repeatable over-the-road performance testing model.

3. Provide economy and power mode for engine/alternator operation.

4. Enhance vehicle safety.

5. User-friendly researcher interface.

1. Engine/Alternator Package• Starting Circuit

• Grounding

• Oil Leakage

1. Engine/Alternator Package

• Control System

- Control APU and Diesel

- Regulate Battery voltage

- “power” and “econ” mode

- Warning displays, LEDs

RCM3000 RabbitCore

• Rabbit 3000, 29.4 MHz

• 10Base-T Ethernet Port, RJ-45

• 512K Flash, 512K SRAM

• 44 configurable I/O, 4 fixed inputs, 4 fixed outputs

• Vdc: 3.15-3.45 Volts

• -40C to +70C, 5-95% RH

• Language: Dynamic C

• Single Unit - $79.00, w/ Development Kit - $299.00

• Has to be mounted on a user defined mother board

• Rabbit 3000, 44.2 MHz

• 10 Base-T

• 512K Flash and SRAM

• 16 digital inputs, 4 digital outputs, 8 analog inputs, 4 analog outputs

• -40 to +70C, 5-95% RH

• Programmed using Dynamic C

• Back up Battery

• $289.00

• 16MHz microcontroller

• 128K Bytes of ISP Flash and CAN Controller

• 4096 Bytes of SRAM

• 53 I/O pins

• Vcc: 2.7-5.5 Volts

• -40 to + 85C, 5-95% RH

AT90CAN128 AutomotiveBL2600 Wolf

Contrast and Comparison

2. Road Load Testing – Power Requirements

Possible Speed for Varying Gear Ratios

0

20

40

60

80

100

120

0 2000 4000 6000 8000 10000 12000

AC Propulsion RPM

HU

MV

EE

MP

H

HUMVEE MPH 19:1

HUMVEE MPH 15:1

HUMVEE MPH 10:1

2. Road-Load Testing – Campus LoopDriving Circuit (Route A and B)Max. 25-35 mi/hr

Driving Circuit C, Max 45 mi/hr, 0.8 miles

2. Road-Load Velocity Profile

2. Road-Load Power Prediction

3. Multi-mode Operation – Efficiency Map

3. Multi-mode Operation - Power Map

3. Multi-mode Operation - Control Logic

4. Vehicle Safety

• Fire Extinguisher

• Licensing

• Maintenance/Operation Procedures

4. Vehicle Safety• Driver-Centered

Gauge Cluster− Reduce Operator

Training Time− Driver Awareness

• Proposed Gauges:− Voltage, Amp-Hrs− Engine Status

4. Vehicle Safety

• Wiring to code.

5. Researcher Interface

• Provides a more dependable display for vehicle.

• Increases amount of information that can be presented.

• Able to withstand abuse encountered in Armed Forces.

National Instruments 15” Touch Screen

• 1024x768 Resolution

• 250 cd/m2 Brightness

• 500:1 Contrast Ratio

• 32 – 122 Degree Operating Range

• 17 – 500 Hz Operating Vibration (1g Peak)

• 5 – 95 % Humidity Range (Non Condensing)

• 42 W Power Consumption

• 40,000 Hour Backlight Life

Monitor Price – $1495.00

Desk Mount Price – $65.00

Lead Time Estimate – 5-10 Days

Rockwell Automation 15”Light Industrial Touch Screen

• 1024x768 Resolution

• 350 cd/m2 Brightness

• 400:1 Contrast Ratio

• 32 – 104 Degree Operating Range

• 10 – 640 Hz Operating Vibration (1g Peak)

• 10 – 90 % Humidity Range (Non-Condensing)

• 24 W Power Consumption

• 50,000 Hour Backlight Life

Monitor Price – $1195.00

Desk Mount Price – **

Lead Time Estimate – < 7 Days

Future Work

• Order parts (Nov 10th)−Microcontroller−Gauges−Monitor

• Verify alternator integrity (Dec 8th)

• Implement control system (Dec 8th)

• Upgrade wiring (Feb 1st)

• Over-the-road testing (Feb 15th)

Questions??