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Old 03-29-2016, 03:47 PM   #1
dhpt99
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Default 4x4 Golf Cart - Mechanical Engineering Senior Design Project Help

For my senior design project I'm going to create a 4x4 electric golf cart but am having a hard time figuring out how the gas pedal communicates with the speed control. My plan is to use a EZGO TXT as the donor unless you guys can think of a better donor cart and the reasons why. Then modify a spare rear axle into a front axle.

I just need to learn what kind of signal the gas pedal gives the speed control so that I can run a second speed control for the front axle and be able to control it with a micro processor so that I can create an automatic AWD system for the project.

Thanks for the help.
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Old 03-29-2016, 05:29 PM   #2
LVCJ
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Default Re: 4x4 Golf Cart - Mechanical Engineering Senior Design Project Help

Sounds like a cool project.
Goggle, Bad Boy Buggy. They run 2 motors, 1 for each axle. This may help with your research
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Old 03-29-2016, 06:16 PM   #3
JohnnieB
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Default Re: 4x4 Golf Cart - Mechanical Engineering Senior Design Project Help

The EZGO TXT carts use what they call an ITS (Inductive Throttle Sensor)

Basically, it is a proximity sensor that a ferrous slug is inserted into to vary the current passing through the sensor's input bridge.

Attached is a block diagram and schematic for it as well as a picture of it installed in the pedal box. The throttle pedal moves the iron slug via a mechanical linkage.

Also attached is the US Patent for the sensor.

Alltrax (aftermarket controller manufacturer) might be able to provide information on how to sync two controllers from one ITS sensor. http://www.alltraxinc.com/

Please keep us abreast with the project, and post plenty of pictures.
Attached Images
File Type: jpg ITS sensor - Block diagram.JPG (49.6 KB, 0 views)
File Type: jpg ITS sensor - Schematic.JPG (88.3 KB, 0 views)
File Type: jpg Ezgo ITS & Pedal Switch.jpg (125.3 KB, 0 views)
Attached Files
File Type: pdf ITS Patent - 5247253.pdf (459.6 KB, 0 views)
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Old 03-29-2016, 06:23 PM   #4
dhpt99
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Default Re: 4x4 Golf Cart - Mechanical Engineering Senior Design Project Help

Thanks! And I will, we have to have it done by next December and are going to try to integrate a lot of sensing into it and make an interactive display to control it all.

So what voltage range does the speed controller input?
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Old 03-29-2016, 07:06 PM   #5
JohnnieB
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Default Re: 4x4 Golf Cart - Mechanical Engineering Senior Design Project Help

Quote:
Originally Posted by dhpt99 View Post
Thanks! And I will, we have to have it done by next December and are going to try to integrate a lot of sensing into it and make an interactive display to control it all.

So what voltage range does the speed controller input?
Most carts are typically from 36V to 48V, but some readily available controllers go up to 72V, and beyond.
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Old 03-29-2016, 08:30 PM   #6
dhpt99
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Default Re: 4x4 Golf Cart - Mechanical Engineering Senior Design Project Help

I mean from the pedal. What kind of voltage inputs is the speed control seeing from the pedal output
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Old 03-30-2016, 07:55 AM   #7
JohnnieB
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Default Re: 4x4 Golf Cart - Mechanical Engineering Senior Design Project Help

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Originally Posted by dhpt99 View Post
I mean from the pedal. What kind of voltage inputs is the speed control seeing from the pedal output
It depends on the make/model of the controller. The controller provides power to the ITS sensor and interprets the results that is fed back from the ITS sensor. Basically, there are three parts to the throttle circuit and two of them are inside the controller.

The voltages on some of the Curtis controllers start at about 0.5V with the pedal up and go to about 1.5V with pedal down.
On the other hand, with Alltrax controllers, it is 10V with pedal up and 6V with pedal down.
Yes, with one the voltage increases when pedal is pushed while it decrease with the other, yet both us the same ITS sensor.
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