MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION GRADUATION THESIS AUTOMOTIVE ENGINEERING TECHNOLOGY CALCULATING, DESIGNING SMART STARTING SYSTEM USING BLDC MOTOR FOR OLD MOTORBIKES INSTRUCTOR: VU DINH HUAN, M.Sc STUDENT: NGUYEN HONG NHAT TRAN QUOC BAO SKL012840 Ho Chi Minh City, May 2024 HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY OF INTERNATIONAL EDUCATION GRADUATION PROJECT CALCULATING, DESIGNING SMART STARTING SYSTEM USING BLDC MOTOR FOR OLD MOTORBIKES NGUYEN HONG NHAT Student ID: 20145421 TRAN QUOC BAO Student ID: 20145401 Major: AUTOMOTIVE ENGINEERING Supervisor: VU DINH HUAN, M.Sc Ho Chi Minh City, May 2024 THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- Ho Chi Minh City, May 31𝑠𝑡 , 2024 GRADUATION PROJECT ASSIGNMENT Student name: NGUYEN HONG NHAT Student ID: 20145421 Student name: TRAN QUOC BAO Student ID: 20145401 Major: AUTOMOTIVE ENGINEERING Class: 20145CLA4 Supervisor: VU DINH HUAN, M.Sc Phone number: 0908850150 Date of assignment: Date of submission: 1. Project title: Calculating, designing smart starting system using BLDC motor for old motorbikes. Content of the project: - Learn and evaluate starting system on motorbike of the past and present. - Proposal and implementation of calculation of BLDC replacement system.
- Run test and evaluate the advantages and disadvantages compared to the previous system. Final product: - Product model - Graduation thesis (include theoretical basis, experimental results and system evaluation) CHAIR OF THE PROGRAM SUPERVISOR (Sign with full name) (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- ---- SUPERVISOR’S EVALUATION SHEET Student name: NGUYEN HONG NHAT Student ID: 20145421 Student name: TRAN QUOC BAO Student ID: 20145401 Major: AUTOMOTIVE ENGINEERING Project title: Calculating, designing smart starting system using BLDC motor for old motorbikes. Supervisor: VU DINH HUAN, M. Content of the project:.
Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, 05/31/2024 SUPERVISOR (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- PRE-DEFENSE EVALUATION SHEET Student name: NGUYEN HONG NHAT Student ID: 20145421 Student name: TRAN QUOC BAO Student ID: 20145401 Major: AUTOMOTIVE ENGINEERING Project title: Calculating, designing smart starting system using BLDC motor for old motorbikes. Name of Examiner:. Content and workload of the project. Approval for oral defense? (Approved or denied) .) Ho Chi Minh City, 05/31/2024 EXAMINER (Sign with full name) THE SOCIALIST REPUBLIC OF VIETNAM Independence – Freedom– Happiness -------- EVALUATION SHEET OF DEFENSE COMMITTEE MEMBER Student name: NGUYEN HONG NHAT Student ID: 20145421 Student name: TRAN QUOC BAO Student ID: 20145401 Major: AUTOMOTIVE ENGINEERING Project title: Calculating, designing smart starting system using BLDC motor for old motorbikes.
Name of Defense Committee Member:. Content and workload of the project .) Ho Chi Minh City, 05/31/2024 COMMITTEE MEMBER (Sign with full name) FOREWORD The team would like to sincerely thank the teachers of the Faculty of Vehicle and Energy Engineering, who have guided and imparted valuable knowledge to the team throughout our time studying at the university and in completing the diagram. Being educated in an environment equipped with the latest facilities and gaining knowledge from both educational programs and practical experiences is what the team has achieved after four years of study. With a solid foundation of knowledge and understanding, and the experiences in various technical research fields, the team was able to complete this project.
Additionally, the team extends deep gratitude to Vu Dinh Huan who has been a dedicated guide, leading us through each discussion session on creativity in scientific and technical research. His timely advice, support, motivation, and enthusiastic assistance have significantly helped the team both mentally and architecturally to overcome the challenging periods during the project's implementation. Furthermore, the team would also like to express heartfelt thanks to our families and friends for their wholehearted support, assistance, and feedback throughout the project. The team looks forward to receiving valuable contributions from all to further perfect the project.
We wish our teachers, friends, and families abundant health, boundless energy, and much joy and happiness in life as they continue to carry out their noble mission of imparting invaluable knowledge to future generations. Ho Chi Minh, May 31th, 2024 I SUMARY This project presents the calculating and designing smart starting system using BLDC motor for old motorbikes to replace the brushed starter motor on older generation motorbikes. The results of the project have fully demonstrated the achieved parameters and can be installed on a motorbike and the motorbike can operate. In addition, the project also measured the actual rotation speed when installing a BLDC motor controller.
II TABLE OF CONTENTS FOREWORD. vi LIST OF FIGURES. vii LIST OF TABLES. ix CHAPTER 1: OVERVIEW.
Reason for choosing the topic. 2 CHAPTER 2: THEORETICAL BACKGROUND. Research and survey of the motorcycle in Viet Nam. Traffic situation in Viet Nam.
Pollutants of motorcycle emissions. New motorcycles emission standards. Emission standards for in-use motorcycles. Standards and compliance rates.
9 CHAPTER 3: OVERVIEW OF BRUSHLESS DC MOTORS (BLDC). Introduction to Brushless DC motors. Brushless DC motor construction. Principle operation of Brushless DC (BLDC) motor.
BLDC motor control methods. 𝟐/𝟑 Angle switch-on mode. Voltage and current control PWM mode. Rotor position sensors.
Sensor-less BLDC motor control. BLDC motor operating characteristics. Speed and torque. Back electromotive force.
Mechanical characteristics of BLDC motor. Working characteristics of BLDC motor .Comparing advantages and disadvantages BLDC motor to other motor types… .29 CHAPTER 4: CALCULATE SMART STARTING SYSTEM BLDC MOTOR. Theoretical basic of components. Motor controller brushless DC.
Parameter of a starter motor. Number of revolutions. Calculate BLDC motor. Calculate the number of teeth on gear shaft.
Tested against original parameters. Calculate parameter on axes. Calculate power on axes. Calculate torque on axes.
Basic size parameters of gears. Design revolving axle. Design of intermediate shaft. Design of BLDC motor mounting frame.
Design of spur gear drive shaft. Intermediate shaft bracket. 41 CHAPTER 5: CALCULATE AND DESIGN GEAR TRANSMISSION. Install BLDC Motor change starter motor.
Measure rotation speed of drive shaft. Measure rotation speed of intermediate shaft. The issues encountered with the Attila Elizabeth Fi scooter. Diagnose damage to air distribution structures.
Functions of valve:. 49 CHAPTER 6: CONCLUSION AND TOPIC DEVELOPMENT DIRECTIONS. Topic development directions. 53 V ABSTRACT BLDC: Brushless direct current DC motor: Direct current motor AC motor: Alternative current motor CO: Carbon monoxide HC: Hydrocarbons PM: Particulate matter g/km: Grams per kilometer EMF: Electromotive force PM: Permanent magnet Nd: Neodymium SmCo: Samarium Cobalt NdFeB: Neodymium Ferrite Boron S: South N: North IPM: Interior permanent magnet SPM: Surface permanent- magnet PMSM: Permanent magnet synchronous machine PWM: Pulse Width Modulation FB: Feedback Iav: Average current Vav: Average voltage BEMF: Back Electromotive Force DSPs: Digital signal processors SPI: Serial peripheral interface QFN: Quad Flat No-Lead QFP: Quad Flat Pack EMI: Electromagnetic Interference VI LIST OF FIGURES Figure 1 Basic Components of BLDC Motors 10 Figure 2 BLDC Motor Block Diagram 12 Figure 3 Stator of a BLDC motor 12 Figure 4 Stator structure design 13 Figure 5 Rotor magnet 14 Figure 6 Hall Effect 16 Figure 7 Horizontal-Structure BLDC Motor 16 Figure 8 commutation using an inventor 18 Figure 9 Basic block diagram of BLDC motor 18 Figure 10 Trapezoidal back emf of three phase BLDC motor 19 Figure 11 Sinusoidal phase back emf of BLDC motor 19 Figure 12 Brushless DC motor drive system 20 Figure 13 BLDC motor current and back electromotive force waveform 21 Figure 14 Hall position sensors 22 Figure 15 Typical sensor-less BLDC motor driver 23 Multiplexing the Speed Command to the Output Amplitude 24 Figure 16 Applied to the Motor Figure 17 TI's DRV10983 Sensor-less BLDC motor control driver 25 Allegro's A4964 sensor-less BLDC controller can operate either 25 Figure 18 with a microcontroller or as an independent motor controller Figure 19 Edge Aligned Bridge PWM Mode PMD = 1 26 Figure 20 Speed-Torque of BLDC motor 28 Figure 21 Working characteristics of BLDC motor 29 Figure 22 BLDC Motor 32 Figure 23 Motor controller brushless DC 32 Figure 24 Schematic representation of sensor-less BLDC Motor control 33 Figure 25 Sensor-less motor control driver 34 Figure 26 Gear shaft diagram 35 Figure 27 Front elevation view of intermediate shaft 38 Figure 28 Edge view projection of intermediate shaft 38 VII Figure 29 Intermediate shaft designed on Inventor software 38 Figure 30 Flat projection of iron frame 39 Figure 31 Edge view projection of iron frame 39 Figure 32 Iron frame designed on Inventor software 39 Figure 33 Front elevation view spur gear drive shaft 40 Figure 34 Edge view projection spur gear drive shaft 40 Figure 35 Spur gear drive shaft designed on Inventor software 41 Figure 36 Front elevation views intermediate shaft bracket 41 Figure 37 Edge view projection intermediate shaft bracket 42 Figure 38 Flat projection intermediate shaft bracket 42 Figure 39 Intermediate shaft bracket designed on Inventor software 42 Figure 40 Install spur gear drive shaft 43 Figure 41 Install into frame 43 Figure 42 Install intermediate shaft 44 Figure 43 Attach BLDC motor to the machine body 44 Figure 44 Attach BLDC motor to the machine body 45 Figure 45 Install intermediate shaft bracket 45 Figure 46 Connect the BLDC motor with motor controller brushless 45A 46 Figure 47 Battery 24V 46 Figure 48 Actual drive shaft speed 47 Figure 49 Actual intermediate shaft speed 47 VIII LIST OF TABLES Table 1 Emission Standards for New Motorcycles 6 Table 2 Motorcycles in-use emission standards 7 Table 3 Maximum limits of pollutants 7 Table 4 CO standards in other countries 8 Table 5 Compliance rates and the expected emission reduction 8 Table 6 Comparison of BLDC Motors and Traditional DC Motors 11 Table 7 Comparing a BLDC motor to a brushed DC motor 30 Table 8 Specifications BLDC motor 32 Table 9 Parameter transmitted through axes 37 Table 10 Parameter of gears 37 IX CHAPTER 1: OVERVIEW 1.
Reason for choosing the topic The automotive industry shifting towards electrification and adopting hybrid and electric vehicles, the role of brushless starter motors becomes pivotal in ensuring smooth and efficient engine starting because brushless starter motor is motivated by the increasing demand for high-efficiency and reliable starting systems in modern technical applications. They offer the possibility of increased efficiency, better performance, and longer lifespan, particularly for applications with frequent starts and stops. With the growing trend of fuel-efficient vehicles and the rise of auto start-stop systems, brushless starter motors could play a significant role in the future of mechanical, the ability to generate rotor achieve magnetic flux with rotor magnets, BLDC motors are more efficient and are therefore used in high-end white goods (refrigerators, washing machines, dishwashers, etc.), high-end pumps, fans and other appliances which require high reliability and efficiency. Brushless motor will gradually replace DC motor because of the following advantages: Attribute Speed and torque high Fast Dynamic Response Due to Low Inertia High efficiency due to the use of permanent magnets Long motor life Engine runs smoothly, low noise Noiseless Operation Wide speed range can be adjusted To find out the advantages and disadvantages of brushless starter motors compared to other types of motors mounted on motorbikes, and the feasibility of installing them on a vehicle, our group decided to choose the topic: "Calculating, designing smart starting system using BLDC motor for old motorbikes ” 1.
Research purposes Learn about the possibility of applying the BLDC starting system to motorbikes, especially older models. 1 Calculating and changing to a BLDC starting system can help improve the reliability, performance and long age of the starting system, while minimizing maintenance and repairs. Research subjects Research structure, operating principle of the starting system of old and new motorcycles. Calculating and designing the starting system using BLDC motor.