Wayne State University College of Engineering Mechanical Engineering Department

Group Project Plug-in Electrical Motorcycle Honda Rebel 2009

EVE 5120 Individual Report Submitted to: Dr. Srinivasan Venkatesan

Mechanical Engineering Department

TALAL RIYADH ABDULRAZZAQ (eg-8215)

CONTENTS

Subject ACKNOWLEDGEMENT Introduction Objective

Why motorcycle Selling a product

Page 2 3
3 3

3 4 7 7

Selecting components and the hardware market. Financial matters Conclusion

Fundamentals of Batteries Group project report

ACKNOWLEDGEMENT

I take immense pleasure in thanking Dr.Srinivasan Venkatesan ,Mechanical Engineering Department at Wayne State College of Engineering for his able guidance and useful suggestions, which helped me in completing the project work, in time. His willingness to motivate us contributed tremendously to our project. I also would like to thank him for showing us some examples that related to the topic of our project.

Talal R. Abdulrazzaq Eg-8215 16th of April 2011

Introduction
Fundamentals of Batteries Group project report 2

Twist the throttle and the bike rolls away smoothly. The noise or lack thereof, is what hits you first. It is so quiet at in-town speeds you can sneak up on bicycle messengers. No oil, no gas, no exhaust, no transmission, so it smells like neither, you are also much more aware of your surroundingsa huge safety advantage in the city. With wind noise replacing the sound of the machine, the result is a seraphic feeling of sail-boarding down the street. Eyes follow you and all have the same terrible itching question Is that thing electric?" No it is our new era.

Objective

Since bikers nowadays are interested greatly into converting ICE driven motorcycles into Electric driven motorcycles, we have attempted to prepare a study of what is needed to accomplish this task by applying what we have learned in AET 5120.

Why motorcycles?

They are easier to maintain, less costly, stylish, and efficient in crowded environments, effective means of transportation in the city or rural areas. The old scheme that dictates a resident of a poor country cannot afford to buy a mean of transportation is decaying due to the fact that the lenders market is prospering and people can afford to buy a transportation media of their choice. But if we do a futuristic calculations for ICE driven luxury transportation Medias, then we would be impacting our environment to a level beyond earths capability to handle humans ill-foreseen industrial wastes. Scientist say that Climatic global change is only the threshold of livable climate collapse.

Selling a product

One of the aspects to sell a product is its capability to replace an existing, reliable, appealing, product. Some bikers say a car moves the body, while a bike moves the soul.So the first step is to be able to drive the converted electric motorcycle to deliver the same mileage, cost, deliver the same power output, if not better, experience the kick in acceleration to meet the bikers idea of a ride, and of course taking the curb weight in consideration. Initiating a comparison, research, and calculation procedure that would end with obtaining those targeted specifications that makes the biker look at an electric bike rather than his own. Studying consumers acceptance to available catchy products offered

Fundamentals of Batteries Group project report

by big well established companies (BMW, HONDA, YAMAHA, KAWASAKI, HARLY-DAVIDSON) is essential to catch and integrate attractive technology and broaden the horizon for new and fresh ideas. Pin pointing electrically powered motorcycle leverage over its contemporary ICE powered rival. Higher efficiency ( around three times ), simplicity, reliability , low cost and noise , zero emissions , running cost , and of course the most important factor namely the economic security due to the fact that 1973 was considered a milestone by many nations, it made the public understand the meaning of economic security and dependency on foreign supplied power sources, this triggered a big wave of alternative energy to be broadly researched and finding means to integrate the findings efficiently into the nations power basis down to positively impact a household. All of these reasons would give away leverage to Electric driven transportation Medias and slip the dependency ICE, and we are getting there. Selecting components and the hardware market.

After establishing the targeted aspects to convert ICE motorcycle, and establishing volume to weight availability by taking out the extra components that would not be used to in the conversion process to an electric motorcycle, we are to evaluate different makes for the various components that we need to use to replace the ICE system and build an electric system.

Each part that is to be taken out has to have a counterpart that would makeup for that obsolete ICE part, if not invite more desirable features that would improve the main lines of our objectives. In order to compete in the market and score commercial success, companies have to be talented and diverse in providing the consumer with new , reliable , and attractive hardware features that would fit if not improve and add desired advantages that would elevate our own preset target specifications. To supply the motorcycle with the necessary power to drive it to appeal level, it must be able to compete with the market and satisfy consumers thirst for new high tech impression. An essential part would be the selection of the battery which would hold the necessary energy supplied to the bike, in addition to the required energy and power, specific power and energy, power and energy density, allowed weight and available volume must be met. The battery pack cost was found to be the most hindering factor in the way of all electric motorcycle or vehicles spread into the consumer market. Available battery cells are still limited in terms of peak power over mileage long time performance experiences, pack weight, and volume it would occupy if it would be utilized in transportation media such as our motorcycle. In addition to cost, the other major factor for a consumer was found to be the safety issue, Stereo type tales are still remembered and amplified, this is a considerable factor to be alerted of when charting for successful sell of a new technology, it does have a grave impact on consumer

Fundamentals of Batteries Group project report

selection of our product, this kind of ideology is common and expected for any new wave of change, as it happened with air commercial transportation before.

The instant availability of high torque is a plus in the case of electric motor usage in an motorcycle, this would make it beneficial to use a single speed transmission media while the presence of multi speed transmission is meaningless weight of the transport media is essential, the power would be their immediately ready to satisfy the bikers emotional soul ride. Manufacturers do offer various types and designs that would easily fit our requirements; we have found that brushless DC motors advantages would fit nicely into our electric motorcycle persona and would be an asset in an electric motor system, after all better efficiency, smooth and easy torque and speed control without worrying about maintenance is what we seek in a long lasting component to be elected for our project.

the need for a controller, which would start / stop the electric bike, govern the speed and torque, provide forward or reverse rotation, and provide safety and overload protection, in addition to other main advantages that have been standardized for a controller by manufacturers, Again many types are provided by manufacturers, which would make the selection process easier due to diversity and well established brands. Any electric storage device will eventually lose its stored charge one way or the other, so we need to have a charging system to recharge the batteries, this system has to have the ability to pump electricity into the batteries as quickly as the batteries will allow, and to monitor the batteries and avoid damaging them during the charging process, this is done by monitoring the battery voltage, current flow, and battery temperature in the aim to minimize charging time. The charger sends as much current as it can without raising the battery temperature too much. Again Suppliers provide many types of chargers with diverse brands that would add additional features to our existing project objective. A regenerative braking system would be most beneficial for our project , especially in-city driving conditions, it would feed back precious charge to the power storage unit by recharging each time we use the brakes, this would have a positive effect on mileage and cost.

A BMS system is a must; it is the trusted guard that keeps the power source protected from over charge/discharge, over/under temperature state, over-current detection, cell balancing, cell/pack health monitoring, and state of charge monitoring, in some designs it would even interfere with the Thermal management system by controlling air flow over the guarded power cell.

Fundamentals of Batteries Group project report

Now , a biker needs to have something to throttle up , bikers dont give up easily on the sensation of having their hands and fingers control speed and brakes, after all without those two together , it would simply be a bicycle to them , even if a console is provided with attractive design and shimmering buttons. Kicking in speed means twisting the hand on the handle, no twist .. No speed then no good bike. Battery Thermal management system is critical in achieving performance and extended life of batteries in electric and hybrid transportation Medias under real driving conditions. The goal of a thermal management system is to deliver a battery pack at an optimum average temperature with only small variations between the modules and within the pack. Lithium ion based power cells are notorious for their thermal sensitivity. The simplicity of an air battery cooling system is advantageous in our motorcycle; we would harness nature to provide the coolant, rather than having a closed cooling system with coolant media that would in any way have a negative mark on our projects green sense. But air has to be directed along the finned heated heat sinks of the power source, through channels all around the power source so as to absorb the most of generated heat of that power source. The working conditions must be pre-calculated and established, after all somebody could be using our motorcycle in an ambient that does fall outside the power source zone of comfort, such as using it in Alaska or Siberia, where air cooling is not recommended. We have designed a simple BTMS for our project; it is a passive horizontal BTMS. General BTMS Design Steps: 1. Define the BTMS design objective and constraints. 2. Obtain module heat generation and heat capacity. 3. Perform a first-order BTMS evaluation. 4. Predict the battery module and pack behavior. 5. Design a preliminary BTMS. 6. Build and test the BTMS. 7. Optimize the BTMS. Taking all the previous parts in consideration, the last item would be the DC-DC converter which is essentially needed to down tune our existing voltage into a normal 12 Volt that all onboard electronic parts would handle, in addition to fixing that output voltage even when the power source faints away before the recharge indicator signals us declaring that we are in a limp mode and recharge is extremely advisable.

Financial matters:

Fundamentals of Batteries Group project report

Any attractive project that cannot sell is not successful at all. Keeping track of new hardware cost, evaluating old hardware, and budgeting expenses will lead to a thorough and reliable data base for the projects cost analysis. At the end of the day we need to find out what we will get for the money we have in our hand.

The bill of material would give a brake down of the projects cost based on sold and purchased items that are needed to build an electric motorcycle, including projected tax. In our case our project has a price tag of $ 12600 which is about four times more than the ICE version. Most of the expenses are due to the cost of the electrical power source, an electrical power system is expensive, even if we to use another type of electrical power source, the ICE price cannot be beaten at this moment.

Cost analysis provides a total study of the project; it projects a futuristic view of cost. Cost analysis would validate the use of alternative power source rather than conventional power source .we have included a cost comparison with the ICE version of our motorcycle, and we did go through city and highway driving and main populated US cities, such a study will shed light on the importance of regenerative charging in addition to validate the use of a clean power source in a densely populated and busy areas.

Conclusion:

Inspite of the attractive and appealing advantages of an electrical driven motorcycle, Recharge time, range, and cost are still the most important disadvantages of our Electric Rebel project. But, Cost is the greatest setback and would have a negative impact on the consumer. But nowadays, we are at the verge of new technology that would simply refuse to stay hidden in books and research papers for a longer time, people are growing more conscious of their surrounding and their own health, they started to ask for laws that pave the way for healthier environment. simple facts have been established There is a limited amount of natural resources, earth population is expanding explosively, global warming, respect for the planet, increased lung ailments due to impurities in the air, diseased game and wildlife, The green awareness is raising many obstacles in the way of the continuity of old inefficient and unsafe technologies that belong to the past. A day would come that it would be illegal to use ICE engines, as is smoking illegal nowadays inside public buildings.

Fundamentals of Batteries Group project report