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12/06/2005 HydroFly Flywheel Gavin Abo Nate Stout Nathan Thomas Hydrofly • Two Teams – Flywheel – Fuel Cell • Adam Lint • Chris Cockrell • Daniel Hubbard Sponsors & Mentors • • • • • Brian Johnson Herb Hess Satish Samineni Greg Klemesrud John Jacksha Presentation Outline I. Introduction II. Objectives III. Specifications IV. Design Functionality V. Test Plan VI. Schedule VII. Budget VIII. Future Work IX. Questions I. Introduction Why is the project being done? - To correct short voltage sags (Less than 1.5 seconds) to maintain a stable voltage to critical loads. II. Primary Objective • Interface a flywheel to the AMPS with the ability to correct for voltage sags occurring on the AMPS. – Implement the design by Satish Samineni Secondary Objectives • • • • • • Spin a flywheel Communicate between converters Operate each converter with its own PWM Provide power to AMPS Make the system safe Operation Manual III. Specifications The AMPS Three-Phase Series Transformer DC Bus Voltage DC power supply max. ripple DC Bus Capacitance Flywheel Moment of Inertia Maximum Flywheel Stored Energy Induction Machine Ratings SVPWM Switching Frequency SPWM Switching Frequency Maximum Sag Correction Duration Maximum Magnitude of Sag Correction Sag Correction Response Time Magnitude Sag Correction Tolerance 2 Tier Converters DSP Program Language Sample Rate for Voltage Correction Flywheel Speed Sensor 3 Phase, 208 V, 60 Hz, 5 kVA 7:10 turns ratio, 34.8 kVA 450 V max 50V DC 2 x 250V 1000 μF (grounded between the 2) 5.406 kg-m2 91.305 kJ 208 V, 32.6 A, 60 Hz, 10 hp, 4 pole 1 kHz 10.8 kHz 1.5 s 37% (or 63% of rated) @ 0.95 pu Within 2 cycles Within 0.95 pu 0.05 pu of rated 6 IGBTs 75A, JTAG (software not included), etc. C with inline ASM from TI 20k samples per cycle Position Encoder Goals that have not been met • Fully Operational STPWM Code – Setup voltage LEMs and acquire voltages • 3 voltages LEMs not yet received, but on the way • Converter can acquire two voltages, but must scale by calculation of transformer ratio. – Implement sine wave lookup table • Fully Operational SVPWM Code – Setup voltage LEMs and acquire voltages – Setup position encoder and acquire theta • Setup communication between boards – Sag status – Tsag • Need to determine best pin, currently would lose temp sensor for board protection. • Starting induction motor • Power the DC bus capacitors IV. Design Functionality • • • • • • • • Block Diagram Circuit Schematic Sub Circuit Schematics Organizational Chart Code Flow Diagram Programming Documentation Safety Features Block Diagram Circuit Schematic Series Transformer Diagram Source B Phase + Vinjected - + Vinjected - Flywheel Energy Storage System C Phase Load A Phase + Vinjected - In phase x 2sin y sin x( ) y ( ) z( ) Out of phase z x y a x 75 deg y 4 4 3 3 2 2 1 x( 75 deg) 1 0 y ( ) 0 a( ) 1 1 2 2 3 3 4 10 5 0 5 10 4 10 5 0 5 10 DC link charging power supply We used simple rectifier circuits to generate the DC voltage Organizational Chart Interface a flywheel to AMPS to correct for voltage sags on the system Program the switching times calculation Spin a flywheel Provide power to AMPS Operate a space vector PWM scheme Operate a sine–triangle PWM scheme Program matrix math functions Program a Phase locked loop Communicate between converters Program the triangle wave Sag Status Program the sine wave look up table Code Flow Diagram In order to help organize the code, we produced the following... Start Interrupts Space Vector spin flywheel up to minimum speed Has minimum speed been reached? Slow the motor Determine magnitude of the sag Measurement Error Flywheel below minimum speed Less than 0.63 p.u.? Check for sags Stop All PLL Start Sag Detected? Sine Triangle PWM Sag Persisting? DC link lost its voltage level The Programming • All code is mathematically verified and set up to be interfaced to the DSP • Testing still needs to be done. Documentation • Not Completed – Final Report – Operations Manual • Completed – – – – Test plan Poster Life Cycle Report Product Reliability Report Safety Features • • • • Plexiglas around all four sides of the cart Capacitor interface with banana jack leads Capacitor shorting bars Power strip as power connection V. Test Plan Sample Test FVSCS specifications Turn on the power strip. Verify that the DC bus has 450 volts on it. Verify that the flywheels is spinning at 1755 RPM with a strobe. Connect an oscilloscope to the sag bit line of the boards. Verify that the sag bit is in the low (0V) state. Initiate the 3 phase symmetrical fault on the line. Verify that the sag bit goes high (3.3V) state. Check SEL relay data to verify that the fault was corrected. - For the full duration of the sag. - To within 0.95 0.05 p.u. of nominal voltage. - Correction occurring within two cycles Record VI. Schedule • This Week Final Demonstration – To be scheduled W, Th, or Fri • 12/12/2005 Final Report II Due – Includes Documentation VII. Budget Quantity Item 2 1 1 DC/AC Converter DSP Software XDS510PP-Plus Parallel Port Emulator 1000 F Capacitors 250 V Craftsman Utility Cart (Mfr. model #59345) 3-Phase Transformer 120V 20A Diodes Wall Transformer 48 VDC 500 mA Plexiglas 4’ x 8’ Sheet + cutting tool Voltage Transducer Current Sensor Time Delay Relay 8 pin octal relay base 200 V 20A Diodes Design Poster/Report Binding 2 1 1 10 1 1 3 6 2 2 10 1 Company Tier Electronics Texas Instruments Spectrum Digital Unit SubTotal with Price Freight $1,700 $3,428.04 $495 Donated $974.25 Donated Futurlec Sears (Lewiston, ID) $2.5 $62.99 $8 $62.99 UI G10 Lab Digi-Key Jameco -$1.138 $10.95 Salvaged $18.59 $17.44 Moscow Building $57.31 Supply LEM USA $37 LEM USA $21 Surplus Sales $49 FM Stores $4.66 Digi-Key $1.00 UI Commons Copy $66 Center Total Expenditures Total Value of donated Items Proposed Budget Remaining Budget $57.31 Donated Donated $104 $9.32 $23.01 $66 $3,794.70 $1706.25 $4,825.00 $1,030.30 VIII. Future Work • Unbalanced sags • Better DC link charging supply • Interface an visual human machine interface (HMI) – Error reporting – Event recording IX. Questions http://www.ece.uidaho.edu/hydrofly/website