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Power Melder Midterm Presentation December 2nd, 2008 About Us Christopher Harper EE Tina McGlaston CPE Power conversion electronics Humaninterfacing Daniel Wilson CPE Tyler Pettit EE Control Loops Power-factor correction Humaninterfacing Overview Current Problem Solution Constraints Practical Constraints Technical Constraints Progress Test Plan Questions Current Problem Small generators cannot power large loads. Solution Parallel power generation System Overview DC-DC Converter Subsystem Master/Slave bus ADC Bridge From generator rectifier μC Power factor correction DC-DC converter Shunt resistor Output bus Practical Constraint: Economic The Power Melder must cost less than a typical consumer generator with similar capacity. [1] Practical Constraint: Safety Input Isolation Fuses Conductor Separation Voltage Between Conductors ( AC Peaks or DC Volts ) Minimum Bare Board Spacing B1 B2 B3 B4 … … … … … 301-500 0.25mm (.01 in.) 2.5mm (.1 in.) 12.5mm (.492 in.) 0.8mm (.0315 in.) … … … … … B1 - Internal Conductors B2 - External Conductors, uncoated, Sea level to 3050m ( 10K ft.) B3 - External Conductors, uncoated, over 3050m ( 10K Ft.) B4 - External Conductors, coated with permanent polymer coating [2] Technical Constraints Name Description Input Power Must accept 90-300V DC or AC 50-200Hz Output Power Must provide a single output DC bus between 12V and 14.5V for use with an AC inverter Output Stability Must be stable to within 10% of nominal value with a maximum of 10% ripple Accuracy Measured power draw and power limiting must be accurate to within 10W Power Capability Must be capable of drawing 150W from any acceptable power source Human Interfacing • User Interface • 4 line x 20 character LCD • 12-key keypad for input • User interface will allow the user input various information about the generators in use. Human Interfacing 6 Menus/Screens Home Generator Mode Sharing Power Done # always takes user to Home menu * serves as ENTER button Human Interfacing Home Menu Displays operating mode of each generator Displays output power of each generator Displays total power of system Human Interfacing Generator Menu Allows user to select which generator to configure User can always hit # to cancel and go back to Home Menu Human Interfacing Mode Menu Allows user to select whether the generator selected will operate in Sharing, Primary, or Backup mode User can always hit # to cancel and go back to Home menu Human Interfacing Sharing Menu Allows user to set sharing percentage of selected generator User can always hit # to cancel and go back to Home menu User must hit * after finished Human Interfacing Power Menu Allows user to set maximum power to draw from selected generator User can always hit # to cancel and go back to Home menu User must hit * after finished Human Interfacing Done Menu Updates generator information and redirects user to Home menu Human Interfacing User Interface Demo Power Factor Correction First Hardware Prototype Completed Circuit After Failure Power Factor Correction Re-constructed circuit Several failures Attempted to order new PFC chip (ML4821) Removed PFC from design Lost Input Voltage Range Technical Constraint PCBs Rectifier + Rectifier - Layout for DC-DC Converter PCB PCBs Layout for Master Controller PCB PCBs Power Melder PCBs Converter PCB Master Controller PCB Populated Master Controller PCB Enclosure Parts for Power Melder Enclosure Test Plan - Subsystem Subsystem testing Converter different input voltages too little power different and varying loads Master controller keypad LCD different menu selections Test Plan - System Test with… one source (each converter) failing source (not enough power capability) different operation modes Primary/backup Percent sharing varying loads varying input voltages Questions?