progress presentation 2 team hi-voltage tommy drane ajeya karajgikar will patton vanessa pogue nick...
TRANSCRIPT
Progress Presentation 2
Team Hi-VoltageTommy Drane
Ajeya Karajgikar
Will Patton
Vanessa Pogue
Nick Reagan
Min-hee Sayer
Problem Statement
• Develop an electric vehicle charging system with following requirements:– Auto connection and disconnection– 100% child/pet safe– Debris and moisture proof connection– Minimal manufacturer retooling– Minimal car owner assembly
Suggestions and Comments
• Apparatus on the bottom of the car– Protection from debris and water.– Make it concealable for aesthetics.– Clearance issues.
• Market– For home or wide spread use?– Customers without a garage?– Standardization?
• Power– Inductive charging like the electric toothbrush– Wireless electricity
• Design– Looks expensive.
Market Research
• Current standard– SAE J1772– 120V/240V AC voltage– 70A current– 16.8 kW maximum
power delivery
Market Research
Home owners Car sharing companies (Zipcar)
Company fleets Company/Community parking garages
Selected Design: Details
• Extension off of a golf cart– To simulate ground clearance of an electric car.
• Constraints– Wheel chock for general placement
– Funnel to aid exact placement
– Assume angular variation of 5º
• Ground unit on rails – Side to side movement.
– Allows greater tolerances.
• Car’s momentum forward to connect– Eliminates need for expensive motors
• For home garage use. Possibly for underground garage. – Eliminates need for weather proofing the ground unit.
Physical Mock Up
• Composed of four subsystems:– Ground/rail subsystem – Receptacle subsystem– Cart subsystem– Funnel subsystem
Manufacturing Plan
• Material Selections– High density polyethylene (cart, receptacle: body)– ABS plastic (wheel)– Shoulder screw (axle)– Cold rolled steel (runner/track, end plates)– Rubber/Urethane (ramps, receptacle: insulation)– Tin plated brass (receptacle: terminal– Non-corrosive brass (plug)– Stainless steel (arm, funnel)
Manufacturing Plan
• Prototype production plan– Machining– Welding– Water jet– Casting
• Mass production plan– Injection molding– Die casting– Machining
Bill of Materials
Part Material Vendor Part #
Price Each Quantity
Price Total
Cart High Density Polyethelene (HDPE) McMaster Carr 8671K15 $2.06 2 $4.12
Wheels ABS Plastic McMaster Carr 8587K45 $3.88 1 $3.88
Axle Sholder Screw McMaster Carr 91259A537 $0.99 4 $3.96
Track 1/8" thick Cold Rold Steel McMaster Carr 7779T12 $18.28 1 $18.28
Base 1/8" thick Cold Rold Steel McMaster Carr 8910K122 $22.81 1 $22.81
End Plates 1/8" thick Cold Rold Steel McMaster Carr Cut from Base $0.00
Ramps Rubber McMaster Carr 8981K159 $34.95 2 $69.90
Receptacle High Density Polyethelene (HDPE) McMaster Carr Cut from Cart $0.00
Arm High Density Polyethelene (HDPE) McMaster Carr Cut from Cart $0.00
Funnel Top Polycarbonate McMaster Carr 8574K21 $31.29 1 $31.29
Funnel Sides Polycarbonate McMaster Carr 3161T11 $13.02 1 $13.02
Plug High Density Polyethelene (HDPE) McMaster Carr 8671K63 $6.27 1 $6.27
Lower Torsion Spring R 302 Stainless Steel Torsion Spring McMaster Carr 9287K62 $4.12 1 $4.12
Lower Torsion Spring L 302 Stainless Steel Torsion Spring McMaster Carr 9287K17 $4.12 1 $4.12
Upper Torsion Spring R 302 Stainless Steel Torsion Spring McMaster Carr 9287K127 $4.50 1 $4.50
Upper Torsion Spring L 302 Stainless Steel Torsion Spring McMaster Carr 9287K122 $4.50 1 $4.50
Total Price $190.77
Plans
• Structural Analysis– Free body diagram
• Friction between rails and wheels.• Friction between receptacle and funnel.
– Spring analysis• Necessary spring constant
– Stress analysis• Material selection verification
– Power supply implementation
• Prototype Development