Download - HydroFly: Fuel Cell Project
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Group Members:
-Adam Lint
-Chris Cockrell
-Dan Hubbard
Sponsors:
-Dr. Herb Hess
-Dr. Brian Johnson
HydroFly: Fuel Cell Project
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Final Presentation Outline
•Introduction–Project Objectives–Project Specs
•Final Design Solution and Validation–Individual Components–Entire System
•Problems Encountered•Final Steps to Completion•Budgeting•Questions
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Objectives –Interface a Fuel Cell to the AMPS
–Ensure Safe Operation
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Functional Specifications
Overall interface design specifications:
• AC signal MUST BE present on the AMPS
• 18-36V DC input from the fuel cell
• Output 208 +/- 2% V AC (L-L 3-phase)
• Output frequency at 60Hz +/- 0.2Hz
• Power flow of 75W through the interface
• Dimensions: fit on cart with dimensions 32” x 27” x 18” (2 shelves)*
*not including fuel cell, transformers or inductor bank
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Final Presentation Outline
•Introduction–Project Objective–Project Specs
•Final Design Solution and Validation–Individual Components–Entire System
•Problems Encountered•Final Steps to Completion•Budgeting•Questions
![Page 6: HydroFly: Fuel Cell Project](https://reader030.vdocuments.site/reader030/viewer/2022032414/56813336550346895d9a30df/html5/thumbnails/6.jpg)
DC/DC Converter
•ABSOLPULSE BAP265 - Customized–Input 18 – 36 VDC
•Protection: Current limiting, thermal fuse, reverse polarity protection, 500VDC isolation from output/chassis
–Output 120VDC ±1% •Protection: Current limiting, thermal shutdown
–Power capability: 200W–Efficiency: ~80% (within 0º – 50ºC)–Cost: ~$318.00
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DC/DC Converter
•Verification–Input and output specifications exceeded–Device operates efficiently at 160W
•not tested at 200W because of power supply limitations
–Measured Efficiency: 86-87%
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DC/AC Inverter
•Tier Electronics – Custom Package–Input 80-200VDC–Output: variable 3 phase AC –Switching circuitry: 600V IGBT devices–Rated current: 3A RMS at 5kHz–TI 2401 DSP: fully programmable–I/O plug
• +15V output, receive and transmit outputs, auxiliary inputs and outputs (digital and analog).
–Other specifications•Max output voltage: ~90VLLwith 120V DC input•No Previous programming
–Cost: $500
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DC/AC Inverter
•Verification–Proper operation verified at 120V DC input with ~6kHz switching frequency programmed
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Transformers•3 single phase transformers ( - Y connected):
–Estimated 75VA rating per phase–Steps up voltage to 208VLL (RMS)–Filters PWM output –Provide a ground isolation
•Experimental Verification (120V output – single phase)–Phase A turns ratio: 1:2.6–Phase B turns ratio: 1:3.2–Phase C turns ratio: 1:4.3
The different turns ratios have been accounted for in the inverter control. The magnitude of each phase can be adjusted to get 120VL-n on the output of each phase when connected in - Y configuration – this has not yet been fully verified.
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Inductor Bank
• Provides ~142mH per phase for use in controlling power flow (experimentally verified).
• Reduces system sensitivity to changes in voltage magnitude and/or phase.
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Zero Detection
• Board designed and built by Dan Hubbard
• Gives a timing reference to the TI-2401 DSP on the DC/AC Inverter
• Provides the ability to create a 3-phase signal synchronized with the 3-phase system on the AMPS and, ultimately, control the power flow to the AMPS
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Zero Detection
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Phase 1 Zero Detection Circuits
Phase 2 Zero Detection Circuits
Phase 3 Zero Detection Circuits
Vop(1)
Vop(2)
Vop(3)
Von(1)
Von(2)
Von(3)
Zero Detection
12 98
U1A
74HC4075
1
23
U2A
74HC86
4
56
U2B
74HC86
9
108
U2C
74HC86
Vo1
1 2U3A
74HCT04
3 4U3B
74HCT04
1122
13
U4A
74AC11
Vo2
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Pulse Sequence: 1R – 3F – 2R – 1F – 3R – 2F
Vo2(t)
Vo1(t)
Zero Detection
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• 2-layer board – Vcc, GND
• Required external power supply: ±18V• On-board linear voltage regulator: 3.3V• Inputs (3): 120VAC (3-phase)• Outputs (2): serial pulse stream, phase 1
(falling) ref signal
Zero Detection – PCB Board
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Zero Detection - Verification•Circuitry operates as expected
•Pulse width of approximately 50µs
•Slight error (~20µs) accounted for in software
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Power Flow
PVfc VAMPS
Xsin ( )
QVfc VAMPS
Xcos ( )
VAMPS2
X
Given:
For 75W power flow and zero reactive power:
Xline 53.533 VAMPS 122V
Vfc 122.492V ms 0.238ms
To stay within ±10% P and Q:
120.9V VAMPS 123.1V 0.214 ms 0.262
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SoftwareThree Main Functions
•Records/Monitors Zero Detection Points
•Gives our PWM a starting point
•Data used to dynamically adjust carrier frequency of PWM
•Detects possible faults situations and shuts off PWM
•Creates Sine-Triangle PWM
•Triangle wave carrier frequency (~ 6 kHz)
•Sine wave generated from sine lookup table
•Values passed into Compare Registers which control PWM outputs with user-controlled dead-band time (4 us)
•Controls Power Flow
•Delta incrementally added over 100 cycles to generate a power flow of 75 W
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StartSystem
Initialization While (1)
Switch State
Case 1
Case 2
Case 3
Case 4
Case 5
Default
Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
ISR
Increment OverflowCounters
Reset ISR Flag
Return
Timer 2 Overflow
Interrupt
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
Software
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Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Phase 1 Falling?
Pulse Detected and System
Synced?
System Synced
Record Times/Reset Counters
Yes
Yes
No
No Set Next State
PWM Calculations/ PWM Sync Check
Break
Software
Phase 1 Falling Reference Signal
Zero Crossing Pulse Stream
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Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Pulse Ended?
Increment/Decrement Counters
Record TimesYes
No
Set Next State
PWM Calculations/ PWM Sync Check
Break
Software
Phase 1 Falling Reference Signal
Zero Crossing Pulse Stream
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Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Half Period?
Calculate Time Between Pulses
Calculate Pulse Width
Yes
No
Calculate Half Period
PWM Calculations/ PWM Sync Check
Break
Set Next State
Software
Phase 1 Falling Reference Signal
Zero Crossing Pulse Stream
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Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Increment/Decrement Counters
Calculate Actual Zero Crossing with Error Adjust
PWM Calculations/ PWM Sync Check
Break
Set Next State
Detect Fault?Yes
No
System Shutdown
Software
Zero Crossing Pulse Stream (Fault)
Zero Crossing Pulse Stream (No Fault)
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Waiting for Pulse
Waiting for Falling Edge
Calculations
Zero CrossingAnalysis
PWM State
Start
Triangle Wave Rising Edge?
Convert to Q15 Format
Calculate Phase Counts
YesNo
PWM Calculations/ PWM Sync Check
Break
Calculate Timings/Update Carrier Frequency
Turn on PWM Output
Calculate/Load Sin Positions in CMPR Registers
Increment Counters
Increment Counters
Software
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Final Presentation Outline
•Introduction–Project Objective–Project Specs
•Final Design Solution and Validation–Individual Components–Entire System
•Problems Encountered•Final Steps to Completion•Budgeting•Questions
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Problems EncounteredThree Main Problems
•Zero Detection Reference Signal: Triggered Falling Edge instead of Rising
•Edited software accordingly
•Resulted in simpler sine-triangle PWM software
•Transformer: Core Losses drew too much current from Fuel Cell
•Found smaller transformers
•Recalculated Turns Ratios
•TI2401 DSP: Flash Memory Damaged
•Flex-Trace Connection used to program DSP still a risk
•Ordered new DSP and is scheduled for delivery on Monday
•Expected repair date: 12/13/05
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Final Steps to Completion
• Replace DSP – 12/13/05
• Finish interfacing 12/13 – 12/15– Upload and test the code for voltage magnitude and
phase required for synchronization and power flow
• Final Demonstration 12/15
• Final Report 12/15
• User’s Manual – included in final report
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Item Predicted Cost Actual ExpendituresDC/DC Converter $318.00 $398.00DC/3-Phase AC Inverter $500.00 $500.00Hydrogen $45.00 $62.50Poster/Report Binding $70.00 $70.30Protection Circuitry $50.00 $28.80Filtering (Inductor Bank) $50.00 DonatedTransformer $125.00 DonatedPrinted Circuit Boards $350.00 $180.00Circuit Components $150.00 $159.96Utility Cart $100.00 $58.00Miscellaneous $300.00 $0.00Code Composer Studio $495.00 DonatedXDS510PP-Plus Parallel Port Emulator $999.00 Donated
Total Predicted Budget $3,552.00Total Donated $1,669.00
Total Expeditures $1,395.06Total Budget Left $487.94
Budget
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QUESTIONS?
DCDC
DCAC
Trans-formers and
inductor bank
INPUT18-36V DC
120V DC ±1%
AC 3-phase
Synchronous Freq.
Output: 208VLL
OUTPUT208V ± 2%
AC 3-phase
Synchronous Freq.
:
Zero-Detection Circuitry
Control
Y
75W
Special thanks to Greg Klemesrud, JJ, Steve Miller, Don Parks