preliminary design review october 16, 2012 christopher corey, josh crowley, john fischer, tim myers,...
TRANSCRIPT
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Smart ENergy Delivery (SEND)
Preliminary Design ReviewOctober 16, 2012
Christopher Corey, Josh Crowley, John Fischer, Tim Myers, Neil Severson,
Kristine Thompson
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SEND Mission
Design and implement smart microgrid energy delivery system
Combine multiple/varied energy sources in most efficient use of resources possible
Utilize advantages and address drawbacks of each source
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SEND Mission
Intelligently match energy collection to load requirement
Design system to be as grid-independent as possible
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Team Motivations
Develop innovative system that has ability to combine sources and pursues intelligent management of sources and loads
Team is varied in skill sets and fields of interests Reflected in requirements and functional
roles of project
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Project Motivation
Rwandan Orphans Project Catch-Up School Kigali, Rwanda Provide education for 200-300 orphans
and local community children Unreliable grid Primary Goals
Cheap operation Robust Simple
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Microgrid Background
Rise of renewable energy sources has increased the popularity and practicality of localized, grid-independent, and highly efficient power systems
Flexible power solutions to meet needs in many settings, including developing countries
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Societal Impacts
Increase the effectiveness and efficiency of small scale power systems
System concept able to supply steady power to facilities such as schools, medical facilities, and community centers in areas of expensive and/or unreliable grid connection
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SEND System
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Basic System Goals
Convert solar and grid power to single homogeneous energy carrier (DC bus)
Store energy in battery system for use when resources are unavailable
Delivery energy to both DC and AC loads
Monitor load usage and display to user through web interface
Ability to isolate system components for protection
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Reach Goals
Predictive load profiling System mode control by the user Optimum power point tracking for solar Weather solar resource prediction Add scalability
Allow for multiple source possibilities System architecture may be followed for
higher power applications Load prioritization and control
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Functional Decomposition
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Functional Decomposition
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Power Inputs
• Two control signals
• Variable DC output to bus/battery voltage
• AC constant voltage output to bus
• 2 Charge Controllers
• Bridge Rectifier
• Charge Controller
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Controller
• 3 control signal outputs, one control input from Linux Server
• Load data output to Linux Server
• Current and voltage measurements from AC Rectifier, solar converter
• State of charge and load monitoring input for decision making
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Load Monitoring
• Separate in-line SCRs for load control
• Monitoring hardware with output to controller
• Spec’d for max draw of 55W and up to 4 loads
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PV Array and Battery
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PV Array
Monocrystalline Most efficient Most expensive
Polycrystalline Less efficient than mono Less expensive
Thin Film Lowest efficiency and density Least expensive Potentially available from University
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Battery
Lead-acid for best emulation of large scale implementation
AGM deep-cycle Maximum safety Low self-discharge Low hydrogen emission High charge rate Maintenance free Deliverable by UPS
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Input Power Electronics
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Solar Energy Power Electronics
Responsible for drawing and converting power from the solar panel, outputting to power bus without overcharging battery
Solar Panel
Solar Converte
r / Charge
Controller
Battery
Variable DC
Power Bus
Battery Voltage DC
Battery Voltage DC
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Solar Energy Converter
Implemented as DC-DC switching converter Buck/boost to be determined by solar panel
voltages
Output voltage is controlled by the power bus Set by the battery voltage
This, duty cycle from controller, and converter M(D) set the PV operating point
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Solar Energy Charge Controller Prevent overcharging of battery with
charge controller
Solar panel may be producing power even though battery is at max capacity
Must also prevent power from flowing back into panel during times of no insolation
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Grid Energy Rectifier
Responsible for drawing energy from grid when deemed necessary, outputting to power bus without overcharging battery
AC GridGrid
Rectifier
Battery
120V 60Hz AC
Power Bus
Battery Voltage DC
Battery Voltage DC
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Grid Energy Rectifier
Implemented using a full-wave rectifier and switching (buck) regulator
Will receive an input from the controller dictating whether it is in operation
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Grid Energy Charge Controller
The grid rectifier must also make sure to not overcharge the battery using a charge controller
Design will be similar to the solar energy charge controller
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Charge Controller Implementation
System control should prevent excess power to battery, but a safety backup is needed
The two charge controllers must also make sure to not exceed the maximum charge rate of the battery with their combined output currents
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Testability
Design will keep testability in mind Allow for subcomponents to be tested on
their own
Ex: Converter will be capable of being tested without solar panel input or charge controller output for proper DC-DC conversion Verify small pieces of functionality
individually
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Part Tolerance
Design somewhat hinges on choice of solar panel Operating voltage range dictates
converter type
Currently some of most difficult / high risk components
Project hinges on success of this subsystem
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Controller
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Required functionality
Brain of operation Central controller
Controls the inputs to provide appropriate power to the loads and battery
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Inputs
Current and voltage measurements from the solar panel
Current readings from the grid connection
State of charge of the battery User inputs Web interface settings and readings Load monitoring measurements
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Outputs
Load control – on/off
Data to the web interface
Solar panel / converter control
Rectifier control (on/off)
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Basic Functionality
Calculating available power from input sources
Power point tracking (PPT) for solar panel(s)
Calculating required power to be delivered Controlling external hardware
AC grid connection Solar converter / power point tracking Includes turning off inputs with insufficient
power Reporting data to the web interface
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Goal Functionality
Change of operation based on user mode Load priority control Use predictive models as an input for a
higher efficiency system If it is going to be sunny all day, don’t use the
grid to charge the battery the night before If the grid is unreliable on Tuesdays, charge
the battery in advance Enable optimum power point tracking
when appropriate
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Control Logic Flow
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Options for implementation
GPIC – General Purpose Inverter Controller National Instruments power controller
board
Microcontroller and custom PCB
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GPIC-General
General Purpose Inverter Controller
Robust device for controlling grid tied and high power systems
Built in FPGA
Real time operating system
Power protocol support
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GPIC- Advantages/Disadvantages
Advantage Simplifies a lot of implementation
Disadvantage No design experience with a
microcontroller Far more robust than our product needs Unit cost would be high since the GPIC is
expensive
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Microcontroller - Analysis
Advantages More design experience▪ Board design▪ High power considerations▪ Choosing the right microcontroller
Much more cost effective implementation▪ Options we don’t need can be eliminated
Disadvantages Large added effort to the system design
and implementation
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Testability
Testing will be divided into each subsystem of control Example: power point tracking can be
tested by testing a closed loop converter circuit with bench top power supply
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Part Tolerance
There are no required parts for initial design
After PCB fabrication, packages must remain the same for easy integration
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Web Monitoring / Load Management
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Web Monitoring
Web interface does not require specialized software for access
Enables monitoring of load power consumption
Load Management (On / Off)
Load profiles, for automatic power management
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Load Management
Solid State Relays
Non-invasive current sensing
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Web Server
Beagle Bone
Arm Cortex A8
Has a webserver pre-installed, running on the Angstrom Linux distribution.
Serial UART, I2C, SPI
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Schedule Sept 25
Initial Requirements Specification and Use Case Models
Oct 16 Preliminary Design Review Present Functional Decomposition Level 0 and 1
Oct 23 Functional Decomposition Complete Functional Decomposition to Level 3
Nov 6 Proof-of-Concept Bench Testing Power Point Tracking- Optimum and Peak Switching - Converter Manipulation Apache Server for Web Interface Current Monitoring
Nov 15 Demonstration of major hardware and software
components and subsystems critical to major functions.
Web Interface Power Point Tracking Inverter, Converters, Rectifier
Dec 6 Critical Design Review (CDR)
Dec 13 Proof-of-Concept Open Lab Symposium
Jan 17 Final Architecture and Requirements Specification
Complete
Jan. 24 Detailed Design Draft Software Implementation design Order PCBs / Complete BOM
Feb 7 Bench Testing of Prototype Whole System
(Hardware and Software) Feb 21
Complete test analysis and report results Mar 7
Develop initial integration test plan Mar 14
Final integration test plan complete Mar 21
Complete integration testing Apr 11
Final Demonstration (EXPO) Testing Apr 25
EXPO - Demonstration for Public. May 2
Complete all technical documents
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Division of LaborTask Primary Secondary
Network Interface John Fischer Kit Corey
Load Monitoring Christopher Corey None
Controller H/W Kristine Thompson John Fischer
Solar Charge Controller Josh Crowley Kristine Thompson
Rectifier Charge Controller Tim Myers Neil Severson
Peak Power Point Tracking Tim Myers Josh Crowley
Controller S/W Architecture
Neil Severson Christopher Corey
Appendix II: Division of Labor
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Budget
Item Item Total
Implement Solar 660
Load Measure and Monitor 300
Controller Implementation 568
Rectifier, Converters, and Inverter Implementation (Each) 1236
Energy Storage 230
Web Interface Implementation 120
User Interface 390
Margin 300
Total 3804
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Risks and ContingenciesArea of Risk Contingency Plan
Controller processor not robust enough to handle software scheduling requirements
Controller selection will be based on robust software specification, code will be written with efficiency in mind
Five boards to be developed:• Scheduling constraints for
system integration• High cost of error
Extensive prototyping combined with major development focus will ensure efficacy
Subsystem implementation could prove to be infeasible
These could be implemented with retail products if absolutely necessary
Smart control algorithm development requires working implementation of hardware; can only be tested late in development cycle
High level algorithm development is easy to scale for implementation, modeling will allow code development to begin prior to full hardware completion
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Safety
High currents and voltages in use throughout design
Each board will use over-current protection
System will use “breaker box” to ensure modularity, provide additional protection
Safe usage practices will protect group members
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Additional Considerations
Component redundancy for critical blocks Batteries Solar panels
Efficiency of individual parts determines overall system efficiency Not critical for basic goals Critical for reach goals, overall system
efficacy
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Sustainability
Efficiency makes up for cost of implementation in time
System components will eventually fail
Boards can be re-spun– no relying on manufacturer supply availability
Disposability always a problem for PCBs and semiconductor materials
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System Overview
Fully utilize heterogeneous energy sources
Store energy intelligently Supply power to variable loads Smart control to increase total
system efficiency Adaptable to loss of individual power
sources User monitoring and control
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Project Overview
Most systems of this type cannot deal with multiple power sources simultaneously
A new and more effective implementation of popular technology
Energy independence with reliability Scalability and adaptability Use in developing countries
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Questions