Power Train Report .pdf

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Team Éirloop Report
HYPERLOOP POD COMPETITION

Power Systems Overview

Revised by Karl Ussher 25.05.2018

Contents
OVERVIEW OF BRIEF

3

SCHEMATIC DIAGRAMS

4

BRAKING SCHEMATIC
COMPONENTS

5
6

OEM SPECIFICATIONS AND RATING
Power Supply: Genace B-60/120C-5000-6S1P
Circuit Breaker: Schneider LV438268
Contactor: Kelly KZJ-BC1
Motor Controller: Kelly KDZ82400E
Motor: Lynch D95B
Auto Motive Fuse
Pre-charge Resistor
Diode
Braking Solenoid
Isolating Switch Disconnector: Schneider 28901
SAFETY

6
6
6
6
7
7
8
8
8
8
8
9

INSTALLATION
Series of Procedures
LOTA
REVIEW

9
9
9
10

Overview of Brief

The following in a concise description of Team Éirloop’s power systems and proposed electrical safety
procedures. The team would like to extend our apologies for the delay in submitting the brief, this was
due to unforeseen circumstance with the lead time of our previous battery supplier. Due to the change
in suppliers it was required for the team to redesign this specific part of system with short notice.
This brief will comprise of the basic structure behind our design, which team Éirloop will begin
assembling and testing in the following weeks under supervision of the electrical technicians at the
Institute of Technology Tallaght. Specific schematics and input/output schedules for our processing units
will soon be completed. Currently most of our sensors and controllers have been tested and are
progressing well. Current and voltage sensors have only been recently confirmed from our sponsors R.S
and so have not been included in our diagrams but the proposed locations will be discussed.

Schematic Diagrams

Battery Configuration
The Pod will be powered by 24 22.2V nominal packs divided into two independent systems with a
nominal stored power of 88.8V at 15000mAh arranged in 3P24S. The pod will not have an integrated
BMS solution, all packs will be charged independently six at a time and connected into two static wiring
harnesses inside hermetically sealed vessels (HMV). Due to the nature of this design, an isolating switch
has been placed across each series connection to reduce risk of shock and to also provide a LOTA
solution. The HMV will be fused internally before the circuit is wired externally to the main circuit
breaker. This ensures any potential short circuit from the HMV to the circuit breaker is isolated. The
main power train will be ungrounded, but bonding to the chassis will be implemented via the motor

controllers.

Powertrain Schematic

Braking Schematic

Components

OEM specifications and ratings

Power Supply: Genace B-60/120C-5000-6S1P
Designation
Capacity
Discharge Rate
Max Burst
Configuration
Chemestry
Nominal Voltage Pack
Nominal Voltage Cell
Termination Point
Balancer Connector

GA1-24
5000
60
120
6S1P
Lithium Polimer
22.2
3.7
Crimp Ferrule
JST-XH

mAh
C
C

V
V
Not EC5

Circuit Breaker: Schneider LV438268
Type
Current Rating (@313K)
Rated Insulation Voltage: IEC 60947-2
Poles
Short Circuit Protection
Overload Protection
Breaking Capacity @250V
Breaking Time
Standards
IP degree of protection

TM-CB (Thermal
Magnetic)
400
750
3
Magnetic
Thermal
36
30
EN/IEC 60947
IP20

Amp
VDC
kA
ms
IEC 60529

Contactor: Kelly KZJ-BC1
Designation
Coil Voltage
Contactor Rating
Contactor Voltage Rating
Normal State Configuration
Standards

MC1, MC2
12
400
125
NO
IEC 60947-1 / 60947-4-7

V
Amps
V

Motor Controller: Kelly KDZ82400E
Designation
Rated Current
Vr
Frequency
Standby Battery Current
PWR Supply Current
Max Battery operating Range (B+)
Throttle Input
Brake Input
Full Power Operating Temperature Range
Nominal Operating Temperature Range
Shutdown Temperature (Case Temp.)
Motor Current Limit (1 Minute)
Motor Current Limit (Continuous)
Optional Features
Optional Out PWR
Volt Drop
Over Current Protection
Over Voltage Protection
Low EMC (Unwanted Noise/Unintentional Generation)
Fault Codes
Torque Control
Locking in “OFF” position by 1 padlock

CONT1, CONT2
400
120
16.6
<0.5
<150
18 -136
0-5
0-5
0-50
0-90
100
400
160
Waterproof
12
<3
Hardware
Hardware
Yes
LED
In configuration

Amps
V
KHz
mA
mA
V
V
V



Amps
Amps
Yes
V
V

Motor: Lynch D95B
Designation
Peak Power
Vr
Rated Current
Rated Torque
RPM
Rads.s
Peak Current
Armature Inertia
Inductance @ 15kHz
Speed constant Ks
Torque constant
No load Current
Copper loss full load
Weight

Harry, Sally
28.5
72
210
30
6000
628.31
400
0.0238
11
76
0.14
6
160
11

kW
V
A
Nm
RPM
Rad/sec
A
Kg.m^2
μH
Rpm/V
Nm/A
A
W
kg

Auto Motive Fuse
Designation
Brand
Rating
Voltage Rating
Body Material

F1-6
Pudenz
425
80
Ceramic

Amps
Vdc

Pre-charge Resistor
Designation
Rating
Rating

PCR1-2
1
10


W

DI1-2
200
3

V
A

Diode
Designation
Voltage
Amperage

Braking Solenoid
Designation
Actuation Control
Coil Voltage
Normal State Configuration
Compressed Air I/O
Standards
Protection class

BS1-2
Single Solenoid
12
N/C
EN 175301-803, form C
ISO 15407-1
IP65

VDC

Isolating Switch Disconnector: Schneider 28901
Designation
Current Rating/Pole
Poles
Voltage
Short Circuit Capacity
Connection
Conformity
Power Rating
Max op Temp
Min op Temp
IP Rating
Locking by 3 Padlocks in “OFF” position

ISW1, ISW2
40
4
250
75
IN40 - 63
IEC 947-1, EN 60947-1
220
343
248
IP40

A
Vdc
kA

kW
K
K


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