Hybrid Power Controller (HPC) Final Presentation Senior Design II.
-
Upload
elizabeth-shaw -
Category
Documents
-
view
223 -
download
0
Transcript of Hybrid Power Controller (HPC) Final Presentation Senior Design II.
![Page 1: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/1.jpg)
Hybrid Power Controller (HPC)
Final PresentationSenior Design II
![Page 2: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/2.jpg)
HPC Team MembersStephen AllardDavid Duke Brandon Kennedy Kevin Roberts
Dr. Mike Mazzola
Electrical Engineer• Website Design• System Integration• Testing• Generator Controller
Circuit
Electrical Engineer• System Integration• Enclosure• Integration Research• PCB 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
![Page 3: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/3.jpg)
Outline• Problem• Solution• System Overview• Constraints
• Technical• Practical
• PCB Design• Enclosure• System Hardware• Testing• Questions
![Page 4: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/4.jpg)
Problem
Existing residential backup power solutions are not adequate for long-term power
outages which follow large-scale natural disasters.
![Page 5: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/5.jpg)
Solution
A hybrid power system that can address residential long-term power needs. This
system requires an autonomous controller which manages:
• solar panel array• tri-fuel generator• battery bank
![Page 6: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/6.jpg)
"What does the HPC do?"
The HPC efficiently manages the Hybrid Power System to accomplish
the following objectives:
1- Keep the batteries healthy2- Supply the load when traditional backup power supplies cannot
![Page 7: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/7.jpg)
System Overview
Solar Array
Battery Bank
Inverter
Load
Generator
Hybrid Power Controller
OEM
Device
![Page 8: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/8.jpg)
Hybrid Power System
[1]
![Page 9: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/9.jpg)
Technical and Practical Constraints
![Page 10: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/10.jpg)
Technical ConstraintsName Description
Accuracy The Hybrid Power Controller must have an accuracy of +/- 100 mV on the battery bank voltage input and +/- 500 mA on the battery bank current input.
Input The Hybrid Power Controller must accept inputs up to 50 Volts DC.
Output The output of the device must provide signals to operate a 12 volt relay for start/stop generator operation.
Response Time The device must take samples from Hybrid Power System components and respond to changes within 1 second.
Supply Power The device must accept 24 Volts DC for supply power.
![Page 11: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/11.jpg)
Practical ConstraintsName Description
Sustainability The device must be vibration resistant.
Manufacturability The device must fit into available space in the NEMA enclosure.
![Page 12: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/12.jpg)
SustainabilityVibration Resistance
• Located within an enclosure mounted on a mobile trailer
• Need reliable connections
• Easy to connectSolution
• Use locking connectors[3]
![Page 13: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/13.jpg)
Manufacturability
Size Limitation• Controller enclosure
must fit inside existing NEMA enclosure
• Limited spacing around other components, such as fuses and distribution panels
• The maximum available space is 10” x 10” x 5”
HPC
![Page 14: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/14.jpg)
Manufacturability
Size Limitation• Controller enclosure
must fit inside existing NEMA enclosure
• Limited spacing around other components, such as fuses and distribution panels
• The maximum available space is 10” x 10” x 5”
![Page 15: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/15.jpg)
PCB
![Page 16: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/16.jpg)
DIMM 100 Breakout Board PCB Design
Prototype DIMM100 Breakout Board
![Page 17: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/17.jpg)
DIMM 100 Breakout Board PCB Design
![Page 18: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/18.jpg)
DIMM 100 Breakout Board PCB Design
![Page 19: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/19.jpg)
Component PCB Design
![Page 20: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/20.jpg)
Component PCB Design
![Page 21: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/21.jpg)
Power Circuitry
![Page 22: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/22.jpg)
Inputs and Voltage Dividers
![Page 23: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/23.jpg)
Generator Output Circuit
![Page 24: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/24.jpg)
Serial Data
![Page 25: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/25.jpg)
Status LEDs
![Page 26: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/26.jpg)
Enclosure
![Page 27: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/27.jpg)
Finished Enclosure
![Page 28: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/28.jpg)
Enclosure mounted in NEMA cabinet
![Page 29: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/29.jpg)
System Hardware
![Page 30: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/30.jpg)
Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.
![Page 31: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/31.jpg)
Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.
![Page 32: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/32.jpg)
Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.
![Page 33: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/33.jpg)
Current Sensing
Battery Current Hall Effect
Solar Array Hall Effect
Calculated an Offset and Conversion Factor in Software
![Page 34: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/34.jpg)
System Assembled
After the necessary hardware was completed, we began to test each subsystem and our constraints
![Page 35: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/35.jpg)
Testing
![Page 36: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/36.jpg)
Test Plan - Overview
• Technical Constraints• Complete System Test
![Page 37: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/37.jpg)
Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage
• Multi-meter: 24.365 V• HPC: 24.371• Accuracy: + 6 mV
Within +/- 100 mV
![Page 38: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/38.jpg)
Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage
• Multi-meter: 24.365 V• HPC: 24.371• Accuracy: + 6 mV
Within +/- 100 mV
![Page 39: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/39.jpg)
Technical Constraints -- Accuracy: +/- 500 mA on Battery Current
• Multi-meter(1mV = 1 A): -36.336 A
• HPC: -36.513• Accuracy: -177 mA
Within +/- 500 mA
![Page 40: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/40.jpg)
Technical Constraints -- Accuracy: +/- 500 mA on Battery Current
• Multi-meter(1mV = 1 A): -36.336 A
• HPC: -36.513• Accuracy: -177 mA
Within +/- 500 mA
![Page 41: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/41.jpg)
Technical Constraints -- Inputs -- HPC must accept up to 50 VDC
• HPC reads inputs up to 50 VDC using voltage divider circuits
Sensor Inputs up to 50 VDC
![Page 42: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/42.jpg)
Technical Constraints -- Outputs
The output of the device must provide signals to operate a 12 volt relay for start/stop
generator operation.
![Page 43: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/43.jpg)
![Page 44: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/44.jpg)
Load Cutoff
[4]
• Send serial “FF” to OEM Interface to Drop load when Battery Voltage reaches critical level
• Send “OO” to reconnect load
![Page 45: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/45.jpg)
Technical Constraints -- Response Time
• HPC must respond to system changes within 1 second: o Protects
Batterieso Increases
Runtime for customer
• HPC responds within allotted time
![Page 46: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/46.jpg)
Technical Constraints -- Response Time
• HPC must respond to system changes within 1 second: o Protects
Batterieso Increases
Runtime for customer
• HPC responds within allotted time
![Page 47: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/47.jpg)
Technical Constraints -- Supply Power -- Controller must accept 24 VDC for power
• 24 VDC is stepped to 5 VDC using switching regulator
• Controller is successfully powered by battery bank
• Board Power Indicator LED
![Page 48: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/48.jpg)
Complete System Test
Usage Case Status
Generator Mode
UPS Mode
Critical Mode
![Page 49: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/49.jpg)
Complete System Test
Usage Case Status
Generator Mode Fully Functional
UPS Mode
Critical Mode
![Page 50: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/50.jpg)
Complete System Test
Usage Case Status
Generator Mode Fully Functional
UPS Mode Fully Functional
Critical Mode
![Page 51: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/51.jpg)
Complete System Test
Usage Case Status
Generator Mode Fully Functional
UPS Mode Fully Functional
Critical Mode Fully Functional
![Page 52: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/52.jpg)
Bill of Materials
![Page 53: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/53.jpg)
References[1] Inverter Generator with CMD Triple-Fuel System. [2012, Nov. 28]. Avalable: http://www.generatorsales.com/order/Honda-EU3000iS-Tri-fuel.asp?page=EU3000iS_Tri_Fuel
[2] US Digital. [2012, Noc. 28]. Available: http://www.usdigital.com/products/cables-connectors/cables/5-pin/ca-fc5-sh-lc5
[3] Digi-Key Corporation. [2012, Nov. 28]. Available: http://www.digikey.com/product-detail/en/C091%2031W107%20100%202/361-1317-ND/1647574
[4] Mate Serial Communications Guide. Rev. 4.04., OutBack Power Systems, Arlington, WA, 2008.
[5] Owner’s Manual Generator EU3000is. Rev. 1.0., Honda Motor Co., Printed in Japan.
![Page 54: Hybrid Power Controller (HPC) Final Presentation Senior Design II.](https://reader036.fdocuments.in/reader036/viewer/2022062423/5697bfd51a28abf838cad930/html5/thumbnails/54.jpg)
Questions?