Post on 18-Jan-2016
transcript
Hybrid Power Controller (HPC)
Final PresentationSenior Design II
HPC Team MembersStephen AllardDavid Duke Brandon Kennedy Kevin Roberts
Dr. Mike Mazzola
Electrical Engineer• Website Design• System Integration• Testing• Generator Controller
Circuit
Electrical Engineer• System Integration• Enclosure• Integration Research• PCB Design
Electrical Engineer• Website Design• Programming• Controller Design• Component Research
Electrical Engineer• Programming• Test Circuit Design• Controller Design• Debugging
Advisor
Andy Lemmon, GRA
Co-Advisor
Outline• Problem• Solution• System Overview• Constraints
• Technical• Practical
• PCB Design• Enclosure• System Hardware• Testing• Questions
Problem
Existing residential backup power solutions are not adequate for long-term power
outages which follow large-scale natural disasters.
Solution
A hybrid power system that can address residential long-term power needs. This
system requires an autonomous controller which manages:
• solar panel array• tri-fuel generator• battery bank
"What does the HPC do?"
The HPC efficiently manages the Hybrid Power System to accomplish
the following objectives:
1- Keep the batteries healthy2- Supply the load when traditional backup power supplies cannot
System Overview
Solar Array
Battery Bank
Inverter
Load
Generator
Hybrid Power Controller
OEM
Device
Hybrid Power System
[1]
Technical and Practical Constraints
Technical ConstraintsName Description
Accuracy The Hybrid Power Controller must have an accuracy of +/- 100 mV on the battery bank voltage input and +/- 500 mA on the battery bank current input.
Input The Hybrid Power Controller must accept inputs up to 50 Volts DC.
Output The output of the device must provide signals to operate a 12 volt relay for start/stop generator operation.
Response Time The device must take samples from Hybrid Power System components and respond to changes within 1 second.
Supply Power The device must accept 24 Volts DC for supply power.
Practical ConstraintsName Description
Sustainability The device must be vibration resistant.
Manufacturability The device must fit into available space in the NEMA enclosure.
SustainabilityVibration Resistance
• Located within an enclosure mounted on a mobile trailer
• Need reliable connections
• Easy to connectSolution
• Use locking connectors[3]
Manufacturability
Size Limitation• Controller enclosure
must fit inside existing NEMA enclosure
• Limited spacing around other components, such as fuses and distribution panels
• The maximum available space is 10” x 10” x 5”
HPC
Manufacturability
Size Limitation• Controller enclosure
must fit inside existing NEMA enclosure
• Limited spacing around other components, such as fuses and distribution panels
• The maximum available space is 10” x 10” x 5”
PCB
DIMM 100 Breakout Board PCB Design
Prototype DIMM100 Breakout Board
DIMM 100 Breakout Board PCB Design
DIMM 100 Breakout Board PCB Design
Component PCB Design
Component PCB Design
Power Circuitry
Inputs and Voltage Dividers
Generator Output Circuit
Serial Data
Status LEDs
Enclosure
Finished Enclosure
Enclosure mounted in NEMA cabinet
System Hardware
Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.
Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.
Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.
Current Sensing
Battery Current Hall Effect
Solar Array Hall Effect
Calculated an Offset and Conversion Factor in Software
System Assembled
After the necessary hardware was completed, we began to test each subsystem and our constraints
Testing
Test Plan - Overview
• Technical Constraints• Complete System Test
Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage
• Multi-meter: 24.365 V• HPC: 24.371• Accuracy: + 6 mV
Within +/- 100 mV
Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage
• Multi-meter: 24.365 V• HPC: 24.371• Accuracy: + 6 mV
Within +/- 100 mV
Technical Constraints -- Accuracy: +/- 500 mA on Battery Current
• Multi-meter(1mV = 1 A): -36.336 A
• HPC: -36.513• Accuracy: -177 mA
Within +/- 500 mA
Technical Constraints -- Accuracy: +/- 500 mA on Battery Current
• Multi-meter(1mV = 1 A): -36.336 A
• HPC: -36.513• Accuracy: -177 mA
Within +/- 500 mA
Technical Constraints -- Inputs -- HPC must accept up to 50 VDC
• HPC reads inputs up to 50 VDC using voltage divider circuits
Sensor Inputs up to 50 VDC
Technical Constraints -- Outputs
The output of the device must provide signals to operate a 12 volt relay for start/stop
generator operation.
Load Cutoff
[4]
• Send serial “FF” to OEM Interface to Drop load when Battery Voltage reaches critical level
• Send “OO” to reconnect load
Technical Constraints -- Response Time
• HPC must respond to system changes within 1 second: o Protects
Batterieso Increases
Runtime for customer
• HPC responds within allotted time
Technical Constraints -- Response Time
• HPC must respond to system changes within 1 second: o Protects
Batterieso Increases
Runtime for customer
• HPC responds within allotted time
Technical Constraints -- Supply Power -- Controller must accept 24 VDC for power
• 24 VDC is stepped to 5 VDC using switching regulator
• Controller is successfully powered by battery bank
• Board Power Indicator LED
Complete System Test
Usage Case Status
Generator Mode
UPS Mode
Critical Mode
Complete System Test
Usage Case Status
Generator Mode Fully Functional
UPS Mode
Critical Mode
Complete System Test
Usage Case Status
Generator Mode Fully Functional
UPS Mode Fully Functional
Critical Mode
Complete System Test
Usage Case Status
Generator Mode Fully Functional
UPS Mode Fully Functional
Critical Mode Fully Functional
Bill of Materials
References[1] Inverter Generator with CMD Triple-Fuel System. [2012, Nov. 28]. Avalable: http://www.generatorsales.com/order/Honda-EU3000iS-Tri-fuel.asp?page=EU3000iS_Tri_Fuel
[2] US Digital. [2012, Noc. 28]. Available: http://www.usdigital.com/products/cables-connectors/cables/5-pin/ca-fc5-sh-lc5
[3] Digi-Key Corporation. [2012, Nov. 28]. Available: http://www.digikey.com/product-detail/en/C091%2031W107%20100%202/361-1317-ND/1647574
[4] Mate Serial Communications Guide. Rev. 4.04., OutBack Power Systems, Arlington, WA, 2008.
[5] Owner’s Manual Generator EU3000is. Rev. 1.0., Honda Motor Co., Printed in Japan.
Questions?