Project:
Electric Powertrain development and management for an international competition: MotoStudent. In particular, we were responsible for the design of the dashboard, data conversion board using AnalogToCan and CanController as backup logger, development and testing of the ECU, development of the BMS (Battery Management System), and finally, the development of the Battery Pack, the beating heart of the prototype.
Awards:
- Awarded as the best project
- Speed record: 212 km/h
- Acceleration record 0-150m: 6.120 sec
Dashboard
Features:
- 7-inch IPS display with 1024x600px resolution
- High visibility of 1300 cd/m2, even in direct sunlight
- 1.4GHz 4-core processor, 1GB RAM, 32GB FLASH
- ARM stm32 microcontroller (280MHz, 512Kbyte memory)
- Customizable layout for pilot preferences
- Digital inputs via CAN-bus communication
Data logging:
- Utilizes ARM stm32 microcontroller for data logging
- Communicates with embedded Linux system through SPI protocol
- Customizable layout based on data display needs
CAN-Bus:
- Supports one to three CAN-bus lines
- Conversion of analog to digital signals
- Proximity of sensors to boards enhances signal quality
Engine Control Unit
Torque Management:
- Manages rider's torque request
- Filters torque to determine necessary torque for the inverter
Predictor:
- Predicts residual charge level based on parameters
- Analyzes motor and inverter temperature, battery charge level
Optimization:
- Maximizes motor torque without damaging components
- Ensures motorcycle reaches the end of the race
Battery Management System
Functions:
- Manages cell balancing during the charge phase
- Disables main contactor if thresholds are breached (e.g., voltage, temperature)
Thresholds:
Main contactor disable thresholds:
- 2.5V per cell
- Cell temperature exceeding 75°
Wiring
The wiring of an electric motorcycle is a complex system of electrical cables that connects all electronic components of the motorcycle, allowing them to communicate and function in synchrony. This system plays a fundamental role in the operation and safety of the electric motorcycle.
