Progress Presentation 2 Team Hi-Voltage Tommy Drane Ajeya Karajgikar Will Patton Vanessa Pogue Nick Reagan Min-hee Sayer.

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.

Industrial Design

• Company logo

Market Research

• Current standard– SAE J1772– 120V/240V AC voltage– 70A current– 16.8 kW maximum

power delivery

Market Research

Frost &Sullivan by Sarwart Singh

Market Research

Home owners Car sharing companies (Zipcar)

Company fleets Company/Community parking garages

Selected Design: Schematics

Horizontal funnel

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.

Design Layout: Funnel with cover

Design Layout: Receptacle (resting)

Design Layout: Receptacle (active)

Design Layout: Rail/receptacle assembly

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

Questions