Hybrid Power Controller (HPC)
Mid-Semester PresentationSenior Design I
HPC Team MembersStephen Allard David Duke Brandon Kennedy Kevin Roberts
Dr. Mike Mazzola
Electrical Engineer• Website Design• System Integration• Testing• Controller Design
Electrical Engineer• System Integration• Enclosure• Integration Research• Controller Design
Electrical Engineer• Website Design• Programming• Controller Design• Component Research
Electrical Engineer• Programming• Test Circuit Design• Controller Design• Debugging
Advisor
Andy Lemmon, GRA
Co-Advisor
Outline• Problem• Solution• System Overview• Constraints– Practical– Technical
• Approach– Components– Software
• Progress– Timeline
• Questions
Problem
• In the event of a power outage, people lose contact with the outside world and suffer the loss of everyday conveniences. Most people do not possess sufficient knowledge of electrical components that would allow them to effectively use multiple forms of hybrid power.
Solution• Design and build a controller that
autonomously manages a personal solar panel array, battery bank, and generator, and that optimizes the use of the solar panel array.
System Overview
Solar Array
MPPT Charger
DC Distribution
Panel
Battery Bank
Mobile Inverter/ Charger
AC Outlet (load)
Generator
Hybrid Power
Controller
MATE
MPPT Charger
Mobile Inverter
Grid-tie Inverter (unused)
AC Outlet (load)
Solar Panel Bus
DC Bus
Technical and Practical Constraints
Technical ConstraintsName Description
Accuracy The Hybrid Power Controller will need to have an accuracy of +/- 100 mV on inputs.
Input The Hybrid Power Controller must be able to accept inputs up to 50 Volts DC.
Output The output of the device must be able to provide a signal to operate a 12 volt relay for start/stop generator operation.
Sampling Rate The device must be able to take samples from Hybrid Power System components 3 times per second.
Supply Power The device should be able to accept 24 Volts DC for supply power.
Practical ConstraintsName Description
Economic The parts must cost less than $200.
Manufacturability The device must fit into an enclosure that measures 10’’x10’’x5’’.
Economic
Cost Considerations• Price of competition: $420 [1]• Estimated cost of parts for HPC: <$200• Choosing a microcontroller to meet Dr.
Mazzola’s future needs
Manufacturability
Size Limitation• Controller enclosure must fit inside
existing NEMA enclosure• Limited spacing around other
components, such as fuses and distribution panels
Manufacturability
Approach
Powering the Microcontroller
Regulator Cost Vin VoutThrough-
hole compatible?
Our Choice
LTM8048 [2] $38 3.1V-32V 2.5V-13V No
DE-SW033 [3] $15 Up to 30V 3.3V Yes
LTM8029 [4] $8 4.5V-36V 1.2V-18V No
The micro-controller must be powered from the 24VDC battery bank. A regulator is needed with an input of 20-28VDC, and an output of 3.0-3.6VDC. Due to the large difference between the input and output voltage, a linear regulator will not suffice, due to excess heat. A switching regulator will be needed.
Powering the Microcontroller
Regulator Cost Vin VoutThrough-
hole compatible?
Our Choice
LTM8048 [2] $38 3.1V-32V 2.5V-13V No
DE-SW033 [3] $15 Up to 30V 3.3V Yes ✓LTM8029 [4] $8 4.5V-36V 1.2V-18V No
The micro-controller must be powered from the 24VDC battery bank. A regulator is needed with an input of 20-28VDC, and an output of 3.0-3.6VDC. Due to the large difference between the input and output voltage, a linear regulator will not suffice, due to excess heat. A switching regulator will be needed.
Microcontroller
Micro Cost/per +1000 Familiarity
Potential for further
developmentADC Our
Choice
PIC24HJ32GP202 $2.90[5] Yes little 10/12-bit
“Piccolo” F28027 $1.85 [6] No much 12-bit
“Piccolo“ F28069 $4.95[6] No most 12-bit
Microcontroller
Micro Cost/per +1000 Familiarity
Potential for further
developmentADC Our
Choice
PIC24HJ32GP202 $2.90[5] Yes little 10/12-bit
“Piccolo” F28027 $1.85 [6] No much 12-bit
“Piccolo“ F28069 $4.95[6] No most 12-bit ✓
Software Approach
If Solar Power is < than Load
Turn on Generator
Battery Voltage Low
Wait time and check generator operation
Battery Voltage Stable
If generator producing
Check for Load and
Solar Power
If Solar Power is > than Load
If Generator not
producing
Cut off Load
Sample Battery Bank
Progress
Data
[7]
Data
[8]
Data
[8]
Data
[8]
Data
[8]
Data
[8]
Test Circuit
Test Circuit
Voltage Adjustment
Timeline August September October November December
Research of Hybrid Power System Components, Design of Test FixtureManufacture of Test Fixture, Finalize Design Constraints of ControllerConstruct Prototype of Controller, Testing of Prototype with Test FixtureComplete Testing, Debugging, Finalize Prototype
References[1] Outback Mate 3 System Control and Monitor. [2012, Sept. 12]. Available: http://www.solarhome.org/outbackmate3systemcontrolandmonitor.aspx
[2] Digi-Key Corporation: LTM8048MPY#PBF. [2012, Sept. 24]. Available: http://www.digikey.com/product-search/en?mpart=LTM8048MPY%23PBF&vendor=161
[3] Dimension Engineering: 3.3V 1A Switching voltage regulator. [2012, Sept. 24]. Available: http://www.dimensionengineering.com/products/de-sw033
[4] Digi-Key Corporation: LTM8029EY#PBF. [2012, Sept. 24]. Available:http://www.digikey.com/product-detail/en/LTM8029EY%23PBF/LTM8029EY%23PBF-ND/3306831
[5] Digi-Key Corporation. [2012, Sept. 24]. Available: http://www.digikey.com/product-detail/en/PIC24HJ32GP202-I%2FSP/PIC24HJ32GP202-I%2FSP-ND/1635696
[6] C2000 32 bit 28x Piccolo™ Series. [2012, Sept. 26]. Available: http://www.ti.com/mcu/docs/mcuproductcontentnp.tsp?sectionId=95&familyId=919&tabId=2883
[7]WattMetrics. [2012, Sept 26]. Available: http://www.wattmetrics.com/support/connectingtoinverters/OutBack.aspx
[8] Mate Serial Communications Guide. Rev. 4.04., OutBack Power Systems, Arlington, WA, 2008.
Questions?