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Team HydroFly: Fuel Cell Team Members: Adam Lint Chris Cockrell Dan Hubbard Sponsors: Dr. Herb Hess Dr. Brian Johnson Overview • • • • • • 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 ? 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 /2 00 5 2/ 28 /2 00 5 3/ 28 /2 00 5 4/ 25 /2 00 5 5/ 23 /2 00 5 6/ 20 /2 00 5 7/ 18 /2 00 5 8/ 15 /2 00 5 9/ 12 /2 00 10 5 /1 0/ 20 05 11 /7 /2 00 5 12 /5 /2 00 5 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?