“battery ev scalex” scalextric slot-cars for student led ... allen_0… · hea stem conference...

HEA STEM Conference 2018:Creativity in Teaching, Learning and Student Engagement

Antony Allen & Andrew MooreWMG, University of Warwick

HEA STEM Conference, Feb 2018

“Battery EV ScaleX”Scalextric slot-cars for student led exploration of

battery electric vehicle phenomena

Introductions

Dr Antony Allen CEng FIMechE FIET SFHEA

14 years automotive research and development

8 years working directly in automotive companies

4 years as Senior Teaching Fellow at WMG, University of Warwick

Mr Andrew Moore

Electronics designer since 1983

Robotics, Power Lasers, Radar, Microbiology, Aerospace, Rail

5 years as Lead Engineer at WMG, University of Warwick

Workshop overview

1. Introductions 2. Context of application

Course formatsSkills for industry

3. Experiment design: Exercise 14. Overview of the equipment5. Experiment design: Exercise 26. Further experiments7. What next?8. Summary and discussion

2. Context of application





Technical Accreditation SchemeDelivered exclusively for employees at Jaguar Land-RoverLevel-7 provision within the JLR Academy for Life-Long LearningAll modules are co-owned by a company subject expertMulti-institution degree scheme with mutual recognition andtransfer of credits80+ modules from 8+ providersWMG modules are 15 CATS

40hr “Tutor led content” over one week110hr independent study assessed by post-module assignment

CATS Credits

MSc in Sustainable Automotive EngineeringFull-time over 1 year or Part-time over 3 years

Launched in October 2015

Sustained student base, 50%+ international

Nine x 10 CAT modules delivered in one-week format:Automotive Hybridisation and Electrification

Energy Storage and High Voltage Systems

Propulsion Technology – Machines, and Control

Lightweight Structures and Materials

Systems Modelling and Simulation

Four elective modules such as

Technology management, Innovation, Management of Change, Supply Chain Management etc.

900 hour (90 CATS) dissertation project

The SAE course grew out of a suite of modules on the TAS professional programme

Further details and course video available: Type “WMG SAE” into Google

SAE: Core modules

Research lead

Industry relevance

Automotive Council roadmap forlow-carbon propulsion technology

Automotive CouncilStrategic Technologies

Some of the challenges

Teaching an MSc module in one week

Pre-module work is rarely undertaken

Maintaining engagement

Practical experience

Problem based learning

Upskilling and “wicked competences”*

Maintaining academic standards*[Knight 2007 Fostering and assessing wicked competencies]

It’s not atraining course!

Energy Storage and High Voltage SystemsOn-vehicle energy storage technologiesSpecification, battery design and constructionHigh voltage integration for automotive platformsThree days of lectures and case study sessionsTwo full days of rotating small-group practicalsHands-on experience in WMG’s battery pilot lineand battery characterization laboratory

Make a battery Test a battery

Design problemclass

Vehicle chargingevaluation

3. Experiment design: Exercise 1





Experiment design: Exercise 1Working in in small groups,

Design an experiment

to determine the speed of the vehicle.

Useful information:

A flexible tape-measure, stopwatch and smartphone are available along withpen, paper etc.

The control system connects the car’s motor directly to the battery via a relay.

The control system can be preconfigured to open the relay after a set periodof time has elapsed (1ms resolution).

The car takes time to accelerate / decelerate

Experiment design: Exercise 1

This is a fairly simple example of a

partially defined problem:

Many approaches, most correct.

Some approaches more sensible than others!

Unspecified requirements.

Compromises between time feasibility and accuracyof result.

Could easily spend far too long on it!


Key aspects of experiment design:

What is controlled?

What is measured?

How long will it take?

How long have we got?

How accurate will the answer be?

How accurate does the answer need to be?

4. Overview of equipment





What is the Battery EV ScaleX?

What is the Battery EV ScaleX?Functions of the control system:

1ms execution rateMeasures battery voltage and currentCalculates power and accumulates time, charge, and energyCloses charge or discharge relay at start of experimentOpen the relay when any of the above parameters reach a pre-configured threshold

E.g. open after x seconds, open after y joules, etc.

Plots real-time graphs and UI displaysLogs time, voltage, current and relay state to csv files (at 1ms)

NB Charging is at the voltage / current limit controlled by the PSU

5. Experiment design: Exercise 2






Working in in small groups,Design an experiment

to determine the battery efficiency.

The control system can:Use relays to connect the battery to either the power supply or the car.Monitors time, current and voltage, taking 1ms samples.Calculate power and accumulate time, charge, and energy.Open the relay when any of the above parameters reach a pre-configuredthreshold (E.g. open after x seconds, open after y joules, etc.)

The power supply can:Maintain its output according to preconfigured fixed voltage and current limits


Success evidences key learning about batterytechnology:

What does the battery actually store?How can we ensure consistency over the test?What is measured, what is controlled?Time duration? Accuracy?Electrical fundamentals:

Current, charge, amps, coulombs, As, AhPower and energy, W, J, Wh, kW, kWh, MJ

6. Further experiments





Further experiments aligned with module ILOsVehicle energy requirement

In Wh/mile or miles/kWh

Boundary of charging constraintsConstant currentConstant voltage

Representation of overnight vs rapid chargingEffect of charging rate on

Battery efficiencyWhole vehicle energy requirement

Populate and apply zero order modelsPredict outcomes and verify experimentally

Populate and apply first order models

7. What next?





Future developments1. Lower cost implementation

Arduino rather than dSpace MicroAutoBoxMultiple systems for parallel working

2. Variable vehicle speedPWM the battery to car connection with variable duty

3. Speed measurement and controlDC motor commutation frequency indicates vehicle speed

4. Positional measurementUse inductance of track / car circuit to measure distanceVary speed according to position on the track

5. Efficient driving challengeOne lane is computer controlledUser controls the otherChallenge is to use least energy for a set distance

Teachingapplications

Outreach andEngagement

Questions and discussion

We hope you’ve enjoyed this workshop

We’re happy to share the resources

Contact:

[email protected]

[email protected]

Appreciate your questions and thoughts

@DrAntAllen

@AndrwADM

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