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Team HydroFly: Fuel Cell
Team Members:
Adam Lint
Chris Cockrell
Dan Hubbard
Sponsors:
Dr. Herb Hess
Dr. Brian Johnson
Overview
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Project Purpose
Project Objective
Background (Fuel Cell and AMPS)
Basic Design Description
Additional Design Considerations
Schedule and Budgeting
Purpose:
Why are we interfacing the fuel cell to the Analog Model
Power System?
Alternative Energy Source
Flexibility for the AMPS
Objective:
Interface the Fuel Cell to the
Analog Model Power System
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What is a Hydrogen Fuel Cell?
Different Types
•Phosphoric Acid
•Proton exchange membrane (PEM)
•Solid Oxide (SOFC)
•Molten Carbonate (MCFC)
•Alkaline
Proton exchange membrane (PEM)
•Low temperature
•Low Noise
•Zero Harmful Emissions (water and heat)
•Portable
•Capacity of up to 10KW
What is a Hydrogen Fuel Cell?
Operation of a PEM fuel cell
•Chemical reaction similar to a battery
•Does not need to be “charged” as long as hydrogen is supplied
Avista SR-12 PEM Hydrogen Fuel Cell
Donated by Genesis FuelTech in 2003
•500W Peak Power
•DC output (23V - 43V)
•12 Fuel Cell Cartridges
•Spare Parts Available
•80°C Operating Temp.
Analog Model Power System
•Acquired from Idaho Power in the mid 1990’s
•Models a typical power transmission system
Added Features:
1. A fault matrix in which three
faults can be placed on the system,
either simultaneously or in an
evolving manner.
2. The ability to load impedance
faults onto the system.
3. SEL (Schweitzer Engineering
Labs) relays into the system.
DC to DC Converter
12V/24V DC
DC
DC
23-43V DC
DC/DC Converter
• Purpose: Regulate output voltage from fuel cell
to a constant DC voltage
• Requirements
– Input Voltage: 23-43 VDC (min)
– Input Current: 25 A (min)
– Power Rating: 500 W (min)
– Output Voltage: 12/24 VDC
DC/DC Converter
• Wide Input Range
(20-45 V)
• 600 W Power Rating
• 12 VDC Output
• Audible/Visual Indicators
MajorVTC600-32-12
DC/DC Voltage Converter
DC/DC Converter
MajorVTC600-32-12 DC/DC
Voltage Converter
DC to AC Converter
12V AC 3-phase
Synchronous Freq.
12V DC
DC
DC
23-43V DC
DC
AC
DC to AC Converter
•Purchase from Tier Electronics in Oconomowoc, WI
•Specifications:
•Input Voltage: 12 VDC +/- 0.5 VDC
•Input Current: 50 A Continuous/ 55 A Peak
•Power Rating: 500 W
•Output Voltage: 12 VAC 3-phase @ 60 Hz
DC to AC Converter
Mini Universal Power Converter (UPC) from Tier Electronics
Features:
• 40MHz Re-Programmable TI-2400 series DSP
• 24KHz PWM Switching frequency (offers greater control)
• Communication Module for asynchronous serial communication
• Expansion capabilities for monitoring and controlling external signals
Filtering
•Why?
–Distortion on the 3-phase AC voltage
1
0.5
y ( x)
0
0.5
1
0
1
2
3
4
5
6
7
x
Corrected by using a simple LC Filter
Transformer: 12V to 208V AC
208V AC 3-phase
Synchronous Freq.
12V AC 3-phase
Synchronous Freq.
12V DC
DC
DC
12:208
DC
AC
Transformer
23-43V DC
:
Transformer
•3 Phase
•Delta to Delta Configuration
•Input: 12 Volts AC
•Output: 208 Volts AC
BLOCK DIAGRAM
208V AC 3-phase
Synchronous Freq.
12V AC 3-phase
Synchronous Freq.
12V DC
DC
DC
12:208
DC
AC
Transformer
23-43V DC
:
Synchronous Signals
Voltage/Current Readings
Synchronization
• To correctly provide supplemental power to
AMPS, our AC signal must be in phase with
the system
• Why?
– If the two signals are out of phase when
connected to each other, massive current spikes
will appear and it will take longer for the signal
to stabilize.
Synchronization
• Phase-Lock Loop
• Fast Response
• Will accurately correct any error
– Zero-Point Crossings
• Sample Rate
• Frequency
• 3-Phase Timings
Microprocessor
TI 2400 Series DSP
–
–
–
–
16-bit data Fixed-Point
20-40 MIPS
On-Chip Flash Memory
Other Features: A/D
Converter, CAN Module,
SCI, SPI,
Device Protection
•Protect from what?
–Incorrect power flow
–Exceeding component rating
•How to protect it?
–Switches (Control)
–Fuses
Schedule
Initial Design for Prototypes
Project Briefings (w eekly - Semester 1)
Design Review
Simulation: Interfacing Components to AMPS
Ordering Voltage Inverter and Buck Converter
Demonstrate Working Simulation
Project Report and Notebook Due (Semester 1)
Summer Break
Project Briefings (w eekly - Semester 2)
Interface Fuel Cell Components to AMPS
Revise Voltage Control System
Finalize Protection Circuitry
Complete/Debug Interfacing to AMPS
1/
31
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5
2/
28
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3/
28
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25
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23
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20
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18
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15
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20
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12
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1/
2/
20
06
Final Product Demonstration/Release/Final Report
Budget
Item
Price
DC/DC Converter
$800
DC/3-Phase AC Converter
$2,000
Transformer
$125
Hydrogen
$45
Design Poster/Report Binding*
$15
Project Display Costs*
$35
Protection Circuitry
$100
Filtering
$50
Miscellaneous
$300
Total
$3,470
*Cost divided evenly between Fuel Cell and Flywheel Groups
Questions?