Formula SAE Paddle Shift System Group Members Richard

Formula SAE Paddle Shift System Group Members Richard

Formula SAE Paddle Shift System Group Members Richard Pittman - EE Musab Hmeidan - EE Sean Feschak ME/EE Kevin Castillo - CpE 02/01/2020 1 Motivation UCF Formula SAE Team o Replace mechanical push-pull cable o Increase competitiveness of team Represents a product that could have other useful applications o Enable handicapped riders o Drag-racing motorcycles o Other forms of amateur and professional racing All members interested in project and subsystems Presenter: Richard 02/01/2020 2 Goals

Accessibility and ease of use Reliable and highly durable Maintainable Controllable Transferable Safe Presenter: Richard 02/01/2020 3 Requirements Requireme nt ID Requirement Description EPS. EPS. EPS. EPS. EPS. EPS. EPS. EPS. EPS. Steering wheel mounted gear display 1 2

3 4 5 6 7 8 9 Presenter: Richard Display brightness, 400 nits minimum Total system weight, 15 lbs maximum Operating temperature range of 20 to 120 F. Water Resistant Impact Resistant GPS tracking Data logging with removable SD card Complete gear shifting functionality 02/01/2020 4 Constraints Small Budget from the Formula SAE team Must pass all Formula SAE rules and regulations Designed around current Formula SAE car Must be able to transfer over to future FSAE car Presenter: Richard

02/01/2020 5 Challenges Challenged with 5V output of Tiva-C development board o Swapped MCU to Arduino UNO Challenged with learning how to properly create a schematic on Eagle with no library files for some parts o Had to create the .lbr files based upon Cad file dimensions Challenged with coding for components o Group is not familiar with many of the components Challenged with Soldering of SMD products o Group is not properly equipped to handle such a task with the equipment they have Presenter: Sean 02/01/2020 6 Block Diagram Presenter: Sean 02/01/2020

7 Strategic Components Shift Component o Low Power Consumption o Fast Response time o Reliable MCU o Able to control all Inputs and be able to give the number of outputs needed GPS o Accurate and easy to use for data logging Display o Highly visible o Small o Use of few wires Presenter: Sean 02/01/2020 8 Shift Methods Pneumatic shifters Requires Tank Limited number of shifts with no Air Compressor Air compressor has large power consumption and weight

Presenter: Sean Electronic Actuator Uses short bursts of power Unlimited Shifts Does not require other components to function 02/01/2020 9 Actuator Takes a minimum of 11lbs of force for the lever to shift into gear. o The actuator chosen has 35lbs of force in both the push and pull functions. The actuator also needs to travel 1 1/8 in both directions for a shift to occur. o The actuator chosen has a travel of 1 in both directions making it ideal for shifting will not push too far past the required amount adding extra stress on the transmission. Presenter: Sean 02/01/2020 10 MCU Arduino Uno (ATmega328P) Primary Features Clock Flash Memory

SRAM Operating Voltage Extended Temperature Current Consumption Presenter: Kevin Values 16 MHz 32 KB 2 KB 5V -40 - 85 46.5 mA, active 1456 A, sleep Tiva C Launchpad (TM4C123GH6PM) Primary Features Clock Flash Memory SRAM Operating Voltage Extended Temperature Current Consumption Values 80 MHz 256 KB 32 KB 3.3V -40 - 125

45 mA, active 1.38 A, hibernate 02/01/2020 11 GPS - Ability to attach a larger antenna to the ANT pad - Compatible with a majority of Arduino libraries capable of parsing NMEA 0183 data - Used TinyGPS for parsing Adafruit Ultimate GPS (MTK Primary Features 3339) Values Satellites Size Update Rate Position Accuracy Velocity Accuracy Cold Startup Time Acquisition Sensitivity Tracking Sensitivity Maximum Velocity Voltage In Range Operating Current Presenter: Kevin Output Operating 22 tracking, 66 searching 16mm x 16mm 1 to 10 Hz

3 meters 0.1 meters/s 34 seconds -145 dBm -165 dBm 515 m/s 3.0 4.3 VDC 25 mA tracking, 20 mA navigation NMEA 0183, 9600 baud 12 02/01/2020 -40 to 85 GPS Imaging GPS Visualizer: Do-It-Yourself Mapping Online utility that creates maps and profiles from GPS data. Free and easy to use Powerful and extremely customizable. Presenter: Kevin 02/01/2020 13 GPS Testing Software Test Description

Passing Criteria Rapid Shifting Shift once per second for All 60 outputs from MCU are correct one minute Save Data Save data to external storage, with formatting GPS Short Distance Read Move the GPS in 4 meter All coordinates match Google Maps/Earth increments and read coordinates with less than 5% error location GPS Rapid Short Distance Read Move the GPS at approximately 60 mph and read location and speed every 150 milliseconds Formula One Track Run

All coordinates match Google Maps/Earth One lap around the track, coordinates with less than 5% error reading and recording All speeds match actual speeds with less than location, speed, shifts and 5% error time once per second All shifts match actual shifts All times match actual times Presenter: Kevin All data is saved, correct and formatted All coordinates match Google Maps/Earth coordinates with less than 5% error All speeds match actual speeds with less than 5% error 02/01/2020 14 Slot Works well with Arduino Useful resources online Quick and easy to use Power Input Pin usage LED Activity Socket Type Mounting

Presenter: Kevin Details Description 3-5V Onboard 5v->3v regulator 4 Pins Yes Read and write 2Gb+ of storage Lights up when the SD card is being read or written Easy to insert and remove Push-Push Four #2 mounting holes Can be Mounted securely 02/01/2020 15 Coding Plan Presenter: Kevin 02/01/2020

16 Driver Controls - Integrated into current steering wheel setup Ergonomically designed Paddles for upshift and downshift Thumb button for neutral Conforms to FSAE competition rules Presenter: Richard 02/01/2020 17 Wiring Harness - Essential component of the system - Must be able to withstand a motorsports environment - Constructed using mil-spec components - mil-spec techniques used during construction

Presenter: Richard 02/01/2020 18 Display Types TFT LCD Display High cost for High brightness Dot Matrix Display Many LEDs not needed 16 Segment Display Hard to see in direct sunlight Bright (Visible in direct sunlight) Cheap Presenter: Sean 02/01/2020 19 Display Able to be seen clearly direct sunlight Displays the Characters 1, 2 , 3, 4, 5, 6, and N Should be small enough to fit on the Steering Wheel but large enough to clearly see Image provided by Maxim Presenter: Sean 02/01/2020

20 PCB of Main Board Removed from Arduino Uno Presenter: Sean On board USB to serial converter DC jack and power regulator (712V input) Power regulator (3.3V output) ICSP connector Serial communication LEDs 02/01/2020 21 Display Driver Design Requirements: Design the Driver to be the same size of the Display Use less than 4 wires Be able to be fully enclosed Presenter: Sean 02/01/2020 22

Gear Position Sensor Communicates the gearshifts position to the electrical system of the vehicle. Assists driver to indicate current gear position. Presenter: Musab 02/01/2020 23 Gear Position Sensor Come up with a physically similar sensor to be able to fit it in its original place. Certain voltage and resistance values are associated with each gearshift. Neutral Resistance ()) open 1 570 1.8 2 830 2.26

3 1500 3 4 2700 3.68 5 6800 4.38 6 15000 4.70 Gear Presenter: Musab Voltage (V) 5 02/01/2020 24

Gear Position Sensor Applied reverse engineering to factory sensor. Realized the values of resistance and voltage for gears. Used voltage divider to obtain the voltages for each gear. Presenter: Musab 02/01/2020 25 Gear Position Sensor Different approach to design. Use of hall sensors, magnet, and 7-segment LED indicator. MCU reads signals of the hall sensors and outputs gear number to the segment through a counter/decoder. Presenter: Musab 02/01/2020 26 Power Battery

Battery Family: Lithium Iron Phosphate Voltage: 12V Capacity: 35Ah Charge Rate: 10A Weight: 3.75 lbs Operating Temp: 40-140F Presenter: Musab 02/01/2020 27 Power Component Requirements Component Current (Input) Voltage (Input) Arduino 50 mA 5V Relay 40mA 5V

SD Card 5mA 3.3-5 V GPS 30mA 5V Display 180mA 5V Actuator 4.6A 12 V Gear Position Sensor 16mA 5V Presenter: Musab 02/01/2020

28 Power Must provide recommended voltage rating of 5V for the MCU. Power wasted=(Vin-Vout)(load current) Name Iout Efficienc Footprin BOM y t Cost Topolog y LM2672 1A 96% 218mm2 $2.42 Buck LM1086 1.5 A

47% 400mm2 $1.72 Buck LM2675 1A 90% 313mm2 $2.41 Buck Presenter: Musab 02/01/2020 29 Power 5V switching regulator Vo=Vref(1+R2/R1) 5V linear regulator

Presenter: Musab 02/01/2020 30 SAE Testing FSAE Applicable Formula SAE Competition Rules T4.6 Accessibility of Controls All vehicle controls, including the shifter, must be operated from inside the cockpit without any part of the driver, e.g. hands, arms, or elbows, being outside the planes of the side impact structure defined in rule T3.25 and T3.34. T4.8 Driver Egress All drivers must be able to exit to the side of the vehicle in no more than 5 seconds. Egress time begins with the driver in the fully seated position, hands in driving position on the connected steering wheel and wearing the required driver equipment. Egress time will stop when the driver has both feet on the pavement. T6.5.4 The steering wheel must be attached to the column with a quick disconnect. The driver must be able to operate the quick disconnect while in the normal driving position with gloves on. All critical bolts, nuts, and other fasteners on the steering, braking, drivers harness, and suspension must be secured from unintentional loosening by the use of positive locking mechanisms. T11.2.1

T4.1.2 T4.2.4 During the template test, the steering wheel, steering column, seat and all padding may be removed. The shifter or shift mechanism may not be removed unless it is integral with the steering wheel and is removed with the steering wheel. The firewall may not be moved or removed. Cables, wires, hoses, tubes, etc. must not impede the passage of the templates required by T4.1.1 and T4.2. Presenter: Richard 02/01/2020 31 Overall testing - Overall system testing will be carried out in three stages - Stage one - Bench test the entire system to ensure it is operating properly as designed - Stage two - Initial testing on the Formula SAE car - Will be conducted with the FSAE car on stands for safety - Stage three - Testing to be carried out jointly between senior design group and Formula SAE team - To be conducted at an approved testing location

Presenter: Richard 02/01/2020 32 Group Dynamics Richard Pittman - Electrical Engineer SAE Member, knowledgeable in wiring of vehicles Sean Feschak - Electrical / Mechanical Engineer Knowledgeable in both the Mechanical and Electrical aspects of this project Musab Hmeidan - Electrical Engineer Knowledgeable in Power Systems Kevin Castillo Computer Engineer Knowledgeable Computer Programmer Richard Sean Musab Kevin Wiring harness Display GPS Shifting Solenoid/Actuator

Gear position sensor Neutral Paddles ECU SD card Design Integration Assisting with GPS Presenter: Kevin Power distribution Data transmission Programming Microcontroller 02/01/2020 33 Project Scheduling Task Name Senior Design Project Plan Meeting to initiate project Design flowchart and define roles Research microcontrollers

Research actuators/ solenoids Research displays Research GPS technologies Meeting to summarize research Design paper and continue research Meeting to revise paper Continue design paper Design paddles and 3D print Learn EAGLE PCB Design wiring harness Design upshift and downshift circuit Meeting before rough draft Design GPS system Finish and edit paper Order parts Break between semesters Begin senior design 2 Revise ordered parts Implement paddles Implement gear position sensor/ neutral button Design and test Actuator and Solenoid Design and test Software Design and test GPS/Display Design and test Paddles Design and test Gear Position Sensor Design and test Actuator Put system together Test final system Finish documents Present project Presenter: Kevin Start 06/02/2015

06/02/2015 06/02/2015 06/04/2015 06/11/2015 06/15/2015 06/20/2015 06/23/2015 06/24/2015 07/01/2015 07/02/2015 07/10/2015 07/13/2015 07/16/2015 07/20/2015 07/24/2015 07/24/2015 07/28/2015 08/06/2015 08/07/2015 08/24/2015 08/24/2015 08/25/2015 09/09/2015 10/07/2015 10/12/2015 10/19/2015 10/23/2015 10/26/2015 10/31/2015 11/05/2015 11/10/2015 11/20/2015 12/02/2015 End

12/02/2015 06/02/2015 06/04/2015 06/11/2015 06/15/2015 06/20/2015 06/23/2015 06/24/2015 07/01/2015 07/02/2015 07/10/2015 07/13/2015 07/16/2015 07/20/2015 07/24/2015 07/24/2015 07/28/2015 08/06/2015 08/07/2015 08/23/2015 08/24/2015 08/25/2015 09/09/2015 10/07/2015 10/12/2015 10/19/2015 10/23/2015 10/26/2015 10/31/2015 11/05/2015 11/10/2015 11/20/2015 12/02/2015 12/02/2015

02/01/2020 34 Budget Part Unit Price Quantity Display $40 1 Wiring $180 1 PCB Manufacturing $40 Breadboard Total Cost To Group Description

$40 Purchased $0 Purchased 1 $40 Purchased $10 1 $10 Purchased GPS Unit $50.68 1 $50.68 Purchased Microcontroller (exact TBA)

$20 3 $60 Purchased Voltage Regulator $10 3 $30 Purchased Paddle $25 2 $50 Purchased Actuator $300 1

$0 Purchased Micro SD $20 1 $20 Purchased Battery Free 1 $0 Already Installed Micro switch $5.86 2 $11.72 Purchased

Gear sensor $20 1 $20 Purchased Receiver $35 1 $35 Purchased Tool Box (Sockets, Bearings, Screws, etc.) $20 1 $0 Purchased Transistor

$2 3 $6 Purchased Total Cost Presenter: Richard Funded SAE SAE SAE $500 $373.4 02/01/2020 35 Current Status Subsystem Completion Status Prototype 100 Research

100 Integration 100 Power 100 Actuator Controller 100 90 Display 100 GPS Module 90 Programming 0 Presenter: Richard 10 20 30 40

50 60 70 80 90 100 02/01/2020 36 Questions 02/01/2020 37

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