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Group Members: -Adam Lint -Chris Cockrell -Dan Hubbard Sponsors: -Dr. Herb Hess -Dr. Brian Johnson. HydroFly: Fuel Cell Project. Final Presentation Outline. Introduction Project Objectives Project Specs Final Design Solution and Validation Individual Components Entire System - PowerPoint PPT Presentation
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Group Members:
-Adam Lint
-Chris Cockrell
-Dan Hubbard
Sponsors:
-Dr. Herb Hess
-Dr. Brian Johnson
HydroFly: Fuel Cell Project
Final Presentation Outline
•Introduction–Project Objectives–Project Specs
•Final Design Solution and Validation–Individual Components–Entire System
•Problems Encountered•Final Steps to Completion•Budgeting•Questions
Objectives –Interface a Fuel Cell to the AMPS
–Ensure Safe Operation
Functional Specifications
Overall interface design specifications:
• AC signal MUST BE present on the AMPS
• 18-36V DC input from the fuel cell
• Output 208 +/- 2% V AC (L-L 3-phase)
• Output frequency at 60Hz +/- 0.2Hz
• Power flow of 75W through the interface
• Dimensions: fit on cart with dimensions 32” x 27” x 18” (2 shelves)*
*not including fuel cell, transformers or inductor bank
Final Presentation Outline
•Introduction–Project Objective–Project Specs
•Final Design Solution and Validation–Individual Components–Entire System
•Problems Encountered•Final Steps to Completion•Budgeting•Questions
DC/DC Converter
•ABSOLPULSE BAP265 - Customized–Input 18 – 36 VDC
•Protection: Current limiting, thermal fuse, reverse polarity protection, 500VDC isolation from output/chassis
–Output 120VDC ±1% •Protection: Current limiting, thermal shutdown
–Power capability: 200W–Efficiency: ~80% (within 0º – 50ºC)–Cost: ~$318.00
DC/DC Converter
•Verification–Input and output specifications exceeded–Device operates efficiently at 160W
•not tested at 200W because of power supply limitations
–Measured Efficiency: 86-87%
DC/AC Inverter
•Tier Electronics – Custom Package–Input 80-200VDC–Output: variable 3 phase AC –Switching circuitry: 600V IGBT devices–Rated current: 3A RMS at 5kHz–TI 2401 DSP: fully programmable–I/O plug
• +15V output, receive and transmit outputs, auxiliary inputs and outputs (digital and analog).
–Other specifications•Max output voltage: ~90VLLwith 120V DC input•No Previous programming
–Cost: $500
DC/AC Inverter
•Verification–Proper operation verified at 120V DC input with ~6kHz switching frequency programmed
Transformers•3 single phase transformers ( - Y connected):
–Estimated 75VA rating per phase–Steps up voltage to 208VLL (RMS)–Filters PWM output –Provide a ground isolation
•Experimental Verification (120V output – single phase)–Phase A turns ratio: 1:2.6–Phase B turns ratio: 1:3.2–Phase C turns ratio: 1:4.3
The different turns ratios have been accounted for in the inverter control. The magnitude of each phase can be adjusted to get 120VL-n on the output of each phase when connected in - Y configuration – this has not yet been fully verified.
Inductor Bank
• Provides ~142mH per phase for use in controlling power flow (experimentally verified).
• Reduces system sensitivity to changes in voltage magnitude and/or phase.
Zero Detection
• Board designed and built by Dan Hubbard
• Gives a timing reference to the TI-2401 DSP on the DC/AC Inverter
• Provides the ability to create a 3-phase signal synchronized with the 3-phase system on the AMPS and, ultimately, control the power flow to the AMPS
Zero Detection
Phase 1 Zero Detection Circuits
Phase 2 Zero Detection Circuits
Phase 3 Zero Detection Circuits
Vop(1)
Vop(2)
Vop(3)
Von(1)
Von(2)
Von(3)
Zero Detection
12 98
U1A
74HC4075
1
23
U2A
74HC86
4
56
U2B
74HC86
9
108
U2C
74HC86
Vo1
1 2U3A
74HCT04
3 4U3B
74HCT04
1122
13
U4A
74AC11
Vo2
Pulse Sequence: 1R – 3F – 2R – 1F – 3R – 2F
Vo2(t)
Vo1(t)
Zero Detection
• 2-layer board – Vcc, GND
• Required external power supply: ±18V• On-board linear voltage regulator: 3.3V• Inputs (3): 120VAC (3-phase)• Outputs (2): serial pulse stream, phase 1
(falling) ref signal
Zero Detection – PCB Board
Zero Detection - Verification•Circuitry operates as expected
•Pulse width of approximately 50µs
•Slight error (~20µs) accounted for in software
Power Flow
PVfc VAMPS
Xsin ( )
QVfc VAMPS
Xcos ( )
VAMPS2
X
Given:
For 75W power flow and zero reactive power:
Xline 53.533 VAMPS 122V
Vfc 122.492V ms 0.238ms
To stay within ±10% P and Q:
120.9V VAMPS 123.1V 0.214 ms 0.262
SoftwareThree Main Functions
•Records/Monitors Zero Detection Points
•Gives our PWM a starting point
•Data used to dynamically adjust carrier frequency of PWM
•Detects possible faults situations and shuts off PWM
•Creates Sine-Triangle PWM
•Triangle wave carrier frequency (~ 6 kHz)
•Sine wave generated from sine lookup table
•Values passed into Compare Registers which control PWM outputs with user-controlled dead-band time (4 us)
•Controls Power Flow
•Delta incrementally added over 100 cycles to generate a power flow of 75 W
StartSystem
Initialization While (1)
Switch State
Case 1
Case 2
Case 3
Case 4
Case 5
Default
Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
ISR
Increment OverflowCounters
Reset ISR Flag
Return
Timer 2 Overflow
Interrupt
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
Software
Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Phase 1 Falling?
Pulse Detected and System
Synced?
System Synced
Record Times/Reset Counters
Yes
Yes
No
No Set Next State
PWM Calculations/ PWM Sync Check
Break
Software
Phase 1 Falling Reference Signal
Zero Crossing Pulse Stream
Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Pulse Ended?
Increment/Decrement Counters
Record TimesYes
No
Set Next State
PWM Calculations/ PWM Sync Check
Break
Software
Phase 1 Falling Reference Signal
Zero Crossing Pulse Stream
Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Half Period?
Calculate Time Between Pulses
Calculate Pulse Width
Yes
No
Calculate Half Period
PWM Calculations/ PWM Sync Check
Break
Set Next State
Software
Phase 1 Falling Reference Signal
Zero Crossing Pulse Stream
Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Increment/Decrement Counters
Calculate Actual Zero Crossing with Error Adjust
PWM Calculations/ PWM Sync Check
Break
Set Next State
Detect Fault?Yes
No
System Shutdown
Software
Zero Crossing Pulse Stream (Fault)
Zero Crossing Pulse Stream (No Fault)
Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Triangle Wave Rising Edge?
Convert to Q15 Format
Calculate Phase Counts
YesNo
PWM Calculations/ PWM Sync Check
Break
Calculate Timings/Update Carrier Frequency
Turn on PWM Output
Calculate/Load Sin Positions in CMPR Registers
Increment Counters
Increment Counters
Software
Final Presentation Outline
•Introduction–Project Objective–Project Specs
•Final Design Solution and Validation–Individual Components–Entire System
•Problems Encountered•Final Steps to Completion•Budgeting•Questions
Problems EncounteredThree Main Problems
•Zero Detection Reference Signal: Triggered Falling Edge instead of Rising
•Edited software accordingly
•Resulted in simpler sine-triangle PWM software
•Transformer: Core Losses drew too much current from Fuel Cell
•Found smaller transformers
•Recalculated Turns Ratios
•TI2401 DSP: Flash Memory Damaged
•Flex-Trace Connection used to program DSP still a risk
•Ordered new DSP and is scheduled for delivery on Monday
•Expected repair date: 12/13/05
Final Steps to Completion
• Replace DSP – 12/13/05
• Finish interfacing 12/13 – 12/15– Upload and test the code for voltage magnitude and
phase required for synchronization and power flow
• Final Demonstration 12/15
• Final Report 12/15
• User’s Manual – included in final report
Item Predicted Cost Actual ExpendituresDC/DC Converter $318.00 $398.00DC/3-Phase AC Inverter $500.00 $500.00Hydrogen $45.00 $62.50Poster/Report Binding $70.00 $70.30Protection Circuitry $50.00 $28.80Filtering (Inductor Bank) $50.00 DonatedTransformer $125.00 DonatedPrinted Circuit Boards $350.00 $180.00Circuit Components $150.00 $159.96Utility Cart $100.00 $58.00Miscellaneous $300.00 $0.00Code Composer Studio $495.00 DonatedXDS510PP-Plus Parallel Port Emulator $999.00 Donated
Total Predicted Budget $3,552.00Total Donated $1,669.00
Total Expeditures $1,395.06Total Budget Left $487.94
Budget
QUESTIONS?
DCDC
DCAC
Trans-formers and
inductor bank
INPUT18-36V DC
120V DC ±1%
AC 3-phase
Synchronous Freq.
Output: 208VLL
OUTPUT208V ± 2%
AC 3-phase
Synchronous Freq.
:
Zero-Detection Circuitry
Control
Y
75W
Special thanks to Greg Klemesrud, JJ, Steve Miller, Don Parks