Download CDR (Critical Design Review) - UCF EECS

DEPARTMENT OF ELECTRICAL & COMPUTER ENGINEERING
UNIVERSITY OF CENTRAL FLORIDA
Group 28
Karel Castex, Julio Lara, David Wade, Jing Zou
Motivations and Goals
•
Common interest in power electronics and power systems
•
Renewable energy
•
Unstable and uncontrollable
•
To design a controller that can optimize the overall performance of an
integrated wind and solar power system.
Objectives
•
Small scaled
•
Self-sustained
•
Efficient
•
User friendly
Requirements
•
Able to produce steady output power
•
Able to charging the batteries with variations
•
Consume as little power as possible
•
Safe both for users and electronic devices
Specifications
Solar Panel
Output Power
>75W
Open Circuit Output Voltage
>12V
Short Circuit Output Current
>4A
Weight
< 20lb
Wind Turbine
Output Voltage
Output Power
Generates power at
Size
>12V
> 250W
> 3mph
Small
Specifications
Microcontroller
Clock Frequency
Low
Serial Ports
Yes
Programming Language
High level similar to C
Programming Memory
≥16K
Analog Pins
Yes
Digital input/output Pins
Yes
PWM Output Pins
Yes
Programming Debugging
Yes
Power consumption
Low, good sleep mode
LCD
Current Draw
Low
Voltage
Low
Lines Needed
1 to 3
Specifications
Battery Bank
Voltage
Depth of Discharge
12V
75%
Lifespan Cycles
1000-2000
Efficiency
72-78%
Cost
Low
DC/DC Inverter (Voltage Regulator)
Maximum Voltage
> 15V
Output Voltage
> 12V
DC/AC Inverter
Continuous Max Power
Input Voltage
Output Voltage
1200 - 1500W
12V
110-120VAC
Overall Block Diagram
Switching Algorithm
Energy Source
Solar Energy
Wind Energy
Solar and Wind Energy(low wind speed)
Solar and Wind Energy(high wind speed)
𝐄𝐰𝐢𝐧𝐝
𝐄𝐬𝐨𝐥𝐚𝐫
Wind Generator: Alternatives
THE WORKHORSE
250W
Hyacinth P-300W
Apollo 550W
Rated Power
250W
300W
450W
Rated Voltage
12 VAC
12 VAC
12 VAC
Starting wind speed
6 m/s
3 m/s
3.5 m/s
Rated wind speed
15 m/s
12.5 m/s
13 m/s
$129
$275
$438
Model
Price
Wind Generator
P-300W Hyacinth
Wind Generator: Three-phase full-wave bridge rectifier Diode 50A 1000V
Model
SQL5010
VRRM
IO
@T
IFSM
IR
VFM
@IFM
V
A
℃
A
μA
V
A
1000
50
55
50
10
1.2
12.5
Wind Generator Battery Charging System: Main Components
•LTC3789 - High Efficiency, Synchronous, 4-Switch Buck-Boost
Controller
•LTC4000 - High Voltage High Current Controller for Battery Charging
and Power Management
Wind Generator Battery Charging System: Main Components
LTC3789 High Efficiency, Synchronous, 4-Switch Buck-Boost Controller details:
•Single Inductor Architecture Allows VIN Above, Below or Equal to the Regulated VOUT
•Programmable Input or Output Current
•Wide VIN Range: 4V to 38V
•1% Output Voltage Accuracy: 0.8V < VOUT < 38V
•Synchronous Rectification: Up to 98% Efficiency
•Current Mode Control
•Phase-Lockable Fixed Frequency: 200kHz to 600kHz
•No Reverse Current During Start-Up
•VOUT Disconnected from VIN During Shutdown
•True Soft-Start and VOUT Short Protection, Even in Boost Mode
Buck-Boost Controller: 4V Input
Output: 11.3V @ 1.8A fsw = 400kHz
Buck-Boost Controller: 15V Input
Output: 12V @ 2A
fsw = 400kHz
Wind Generator Battery Charging System: Main Components
LTC4000 Charging Controller & Power Manager details:
•Complete High Performance Battery Charger When Paired with a DC/DC Converter
•Wide Input and Output Voltage Range: 3V to 60V
•Input Ideal Diode for Low Loss Reverse Blocking and Load Sharing
•Output Ideal Diode for Low Loss PowerPath™ and Load Sharing with the Battery
•Instant-On Operation with Heavily Discharged Battery
•Programmable Input and Charge Current: ±1% Accuracy
•±0.25% Accurate Programmable Float Voltage
Battery Charging System: 12V Input
Output: 13.4V
Battery Charging IC Component
Vin (Max) (V)
Linear
Technologies
Texas Instruments
60 V
40 V
Cell Chemistry
lithium, nickel and
lead acid
Lead Acid
# Series Cells
Multiple
Multiple
Charge Current
(Max) (A)
20
>2 A
Charge Status
Outputs
2
2
Control Topology
Approx. Price (US$)
Switch-Mode
$3.95
Switch-Mode
$3.35
Photovoltaic Panels Types
•
Mono-Crystalline Silicon
•
Polycrystalline Silicon
•
Thin Film and Amorphous Silicon
Polycrystalline Silicon
SunWize SW-85P
Solarland SLP-085
Rated Power (W)
85
85
Rated Voltage (Vmp)
17.4
17.2
Rated Current (Imp)
4.9
4.94
Open Circuit Voltage (Voc)
22.0
21.6
Short Circuit Current (Isc)
5.4
5.5
Weight (lbs)
18
18.52
Cost
$249.85
$260.00
SunWize SW-85P
Mounting Angles for Central Florida
Month
Month
Jan
Feb
Mar
Apr
May
June
46°
54°
62°
70°
78°
86°
Jul
Aug
Sept
Oct
Nov
Dec
78°
70°
62°
54°
46°
38°
Mounting Bracket
Solar Charger with MPPT
Morningstar SSMPPT
Solar Boost 2000e
Peak Efficiency
97.5%
95%
Nominal Battery
Voltage
12V to 24V
12V to 24V
Maximum Battery
Current
15A
20A
Current Consumption
35mA
90mA
Cost
$199.00
$227.80
SunSaver MPPT Solar Charger
Switching Algorithm
Energy Source
Solar Energy
Wind Energy
Solar and Wind Energy(low wind speed)
Solar and Wind Energy(high wind speed)
𝐄𝐰𝐢𝐧𝐝
𝐄𝐬𝐨𝐥𝐚𝐫
Switching Circuit
Single P-Channel Power MOSFETS
•
Texas Instruments CSD25211W1015 Power Management
2N7000 N-channel MOSFET
•
60V
•
0.2A
•
5 Ohm
1 inch
Controller Box
•
•
•
Grouping linked actions to
easily explain most IRPS
functionality
Controller box is important
part of IRPS circuitry but not
entire PCB design
Encompass microcontroller,
voltage sensors, current
sensor, temperature sensor,
LCD,USB interface
LCD SCREEN
Temperature
Sensor
Load program
code
•
IRPS concept for
encapsulation of making
decision main components
Voltage
Sensor
Micro
Controller
Voltage
Sensor
Voltage
Sensor
Voltage
Sensor
Current
Sensor
Microcontroller
•
Low Clock Frequency
•
Several Analog Inputs
•
PWM Output Pins
•
Serial UART Pins
•
Programming Debugging Feature
•
Programming Memory ≥ 16Kb
•
High Level Programming Language (Similar to C)
•
Convenient Software, Libraries, IDE
•
Desirable Good Community Support
Microcontroller
Atmel ATmega328
Atmel AT91SAM7X512
MSP430 (CC430)
PIC24F
32 Kb
128 Kb
32 Kb
64 Kb
Clock Speed
16 MHz
48 MHz
20 MHz
20 MHz
Voltage
5V DC
3.6V DC
3.6V DC
3.3V DC
14 I/O (6 PWM), 6
Analog Input
20 I/O (4 PWM,4
UART,SPI,I2C, 8 ADC
Analog Input)
30 I/O (6 ADC,2
UART,SPI,I2C,PWM)
64 I/O (16
ADC,4
UART,SPI,I2C)
8 bit
32 bit
16 bit
16 it
Arduino Board
Netduino Board
TI Dev. Board
Microchip Board
Arduino (Similar to C)
C,C#
C
C,C++
IDE
Arduino IDE (Free)
Visual Studio (Free)
TI IDE (<16 Kb Free)
MPLAB IDE
Price
Board - $30,
ATMega328 - $2.88
Board - $34.95,
AT91SAM - $14.06
Board - $100
IDE- $200 if > 16Kb
Board - $70
Flash Memory
Digital I/O
CPU
Development
Prog. Language
Microcontroller
Atmel ATmega328
Atmel AT91SAM7X512
MSP430 (CC430)
PIC24F
32 Kb
128 Kb
32 Kb
64 Kb
Clock Speed
16 MHz
48 MHz
20 MHz
20 MHz
Voltage
5V DC
3.6V DC
3.6V DC
3.3V DC
14 I/O (6 PWM), 6
Analog Input
20 I/O (4 PWM,4
UART,SPI,I2C, 8 ADC
Analog Input)
30 I/O (6 ADC,2
UART,SPI,I2C,PWM)
64 I/O (16
ADC,4
UART,SPI,I2C)
8 bit
32 bit
16 bit
16 it
Arduino Board
Netduino Board
TI Dev. Board
Microchip Board
Arduino (Similar to C)
C,C#
C
C,C++
IDE
Arduino IDE (Free)
Visual Studio (Free)
TI IDE (<16 Kb Free)
MPLAB IDE
Price
Board - $30,
ATMega328 - $2.88
Board - $34.95,
AT91SAM - $14.06
Board - $100
IDE- $200 if > 16Kb
Board - $70
Flash Memory
Digital I/O
CPU
Development
Prog. Language
Voltage Sensor
•
Connected to one Microcontroller ADC
port
•
It measures Wind Turbine, Solar panel,
Both batteries output voltage
•
Voltage Divider with a voltage follower
and low pass filter
•
Sensors scale down input voltage to 3.3 V
which is the 100% microcontroller ADC
reference
•
5.1V Zener Diode place in parallel to
Microcontroller to control spikes
•
Microcontroller receives data through
internal ADC port and process it
Temperature Sensor
TMP36
DS1624
2.7 – 5.5 V
2.7 – 5.5 V
One analog input port
I2C Bus
Method
Voltage drop
Digital output buffer
Range
-40 °C to +125 °C
-55 to +125 °C
Price
$2 per unit
Free (Sample)
Supply Voltage
Connection
Current Sensor
Allegro ACS712
Maxim MAX4172
Honeywell CSLA2CD
AC/DC
AC/DC
DC
Supply Voltage
4.5V – 5.5V
3V – 32V
6V – 12V
Operating
Temperature
Bandwidth
-40°C - 85°C
-40°C - 85°C
-25°C - 85°C
80kHz
800kHz
Output Sensitivity
66 mV/A – 185 mV/A
6.25 mV – 100 mV
32.7 mV
Output Rise Time
5µs
5µs
3µs
Price
$6.18
$ 4.48
$29
Easy to mount in on
standard PCB
Ideally for high current flow
Amplification, totally
isolation
Only works with DC
Bulky size
Current
Main advantage
Disadvantage
Current Sensor
Allegro ACS712
Current
AC/DC
Supply Voltage
4.5V – 5.5V
Operating
Temperature
Bandwidth
-40°C - 85°C
80kHz
Output Sensitivity
66 mV/A – 185 mV/A
Output Rise Time
5µs
Price
$6.18
Main advantage
Disadvantage
Easy to mount in on
standard PCB
Switching Algorithm
Energy Source
Solar Energy
Wind Energy
Solar and Wind Energy(low wind speed)
Solar and Wind Energy(high wind speed)
𝐄𝐰𝐢𝐧𝐝
𝐄𝐬𝐨𝐥𝐚𝐫
LCD
105 mm
•
Serial Enabled 20x4 LCD - Black on Green 5V
•
Faster boot-up time
•
User definable splash screen
•
Embedded PIC 16F88 utilizes onboard UART for
greater communication accuracy
•
VDD connect to 5V, GND to ground, RX and TX
pins to microcontroller AT91SAM7X512 UART
port chosen
•
LCD is mean to display IRPS important reading
such as: Solar Panel Voltage, Wind Turbine
Voltage, Current Mode of Operation, Both
Batteries percent of charge, Current System
Output.
•
Any alert or system running exception
59.9 mm
Functionality Diagram
•
•
•
•
Blue (boxes, arrows)
mean logical stages
and system direction
flow
Light red accent
boxes describe
physical components
(interact with some
stages)
Red (boxes, arrows)
denote critical
system errors status
Green (boxes,
arrows) define
successful checking
of some components
Battery Bank
Attributes
Lead Acid
Li Ion
NaS
Ni-Cd
Zn-Br
Depth of
Discharge
75%
80%
100%
100%
100%
Cost
Low
Very High
High
High
Lifespan
(Cycles)
1000
3000
High and
auxiliary
heating
systems
needed
2500
3000
2000
Efficiency
72-78%
100%
89%
72-78%
75%
Self-discharge
Average
Negligible
Negligible
High
Negligible
Maturity of
Technology
Mature
Immature
Mature
Mature
Immature
Battery Bank
•
Deep-cycle lead-acid battery
 Periodically charge and discharge
 Large capacity
 High cycle count
•
Absorbed glass mat (AGM)
 Eliminate the potential of acid leaking
 Durable
 Easy to transport (lower shipping cost)
 Practically resist damage from freezing
 Negligible water loss
Battery Bank
•
Universal Power Group (UPG) UB12180
D5745 Sealed AGM-type Lead-Acid
Battery
7.15 in
 Nominal voltage: 12 volts
 Capacity at a 20 hour charge rate: 18Ah
 Internal resistance:18 mille-ohms
6.60 in
 Should be charged under constant
voltage.
3.06 in
Dump and Diversion Loads
•
Deal with the excess power
•
Able to dissipate the maximum power of the wind turbine and solar panels used
•
Vbattery = 14 volts
•
Power = Voltage x Current
Pwind = 448 watts
Psolar = 85 watts
Iwind = 32 amperes
Isolar = 6 amperes
Dump and Diversion Loads
•
WindyNation 12 volt dump load resistors
•
Rload = 0.73 ohms
•
Current = Battery Bank Voltage / Resistor’s resistance = 19.18 amperes
•
Pload = 268 watts
•
Ability to hold up to 312 watts of power continuously
Dump and Diversion Loads
•
Recall
Pwind = 448 watts
Psolar = 85 watts
•
Wire multiple 268 watt resistors in parallel
•
448 watts = (268 watts) x (number of 0.73 Ohm resistors needed in parallel)
•
Two of the WindyNation 0.73 ohm resistors needed for wind
•
One for solar
Dump and Diversion Loads
Next Step
•
Power supply for the Microcontroller, sensors, and LCD
•
Switching Between the battery and dump load
•
PCB
•
System test
Completion Summary
Research
Design
Parts Acquisition
Prototyping
Testing
Overall
0%
20%
40%
60%
80%
100%
Budget to the Date
Parts List
Total Cost
Purchased
$249.85
Number of
Parts
1
$286.60
yes
Mounting Bracket
FREE
1
FREE
yes
Hyacinth P-300W
$275
1
$275
yes
Morningstar SS- MPPT
$199.00
1
$211.50
yes
Printed Circuit Board (Student Special)
$33.00
2
$66.00
DS1624 Temperature Sensor
$9.00
1
FREE
ACS712 Current Sensor
$6.18
1
$6.18
Voltage Sensor
$5.00
4
$20.00
LCD Screens
$29.95
1
$29.95
yes
UPG UB12180 AGM-type Battery
$49.98
2
$99.96
yes
300 Watt Dump Load for 12 Volt Systems
$21.98
3
$65.94
yes
DC/AC
$50.00
1
$50.00
Power P-Channel MOSFET
FREE
6
FREE
yes
Atmel AT91SAM7X512
$21.51
2
$43.02
yes
Netduino
$34.95
1
$34.95
yes
LTC3789 Buck-Boost Controller
FREE
1
FREE
LTC4000 Battery Charging IC
FREE
1
FREE
Total:
$1053.10
SW-S85P Solar Panels
Cost per Part
yes
Questions?