Page 1 International Future Energy Challenge Integrated starter/alternator topic IFEC ‘07.

International Future Energy Challenge Integrated starter/alternator topic

IFEC ‘07

Encourage development of technologies to bring Encourage development of technologies to bring dramatic improvements to low-cost 4-Q ASMD for dramatic improvements to low-cost 4-Q ASMD for integrated S/A application.integrated S/A application.

Incorporate practicality, manufacturability, Incorporate practicality, manufacturability, affordability into competition processaffordability into competition process

Improve undergraduate education through Improve undergraduate education through development of innovative team-based solutions to development of innovative team-based solutions to complex problemscomplex problems

Program VisionProgram Vision

Technical GoalsTechnical Goals

Machine Under Test(MUT) 4-Q Dynamometertext

A

BL

MUT Controller A

BL

Dynamometer Controller

A

BL

DC Power Source

Figure 1. Functional Block Diagram of Test Set up


It is very important to have proper mounting and accurate alignment for safe operation of the whole set up. MUT mounting dimension should be in accordance with NEMA 56 frame size for foot mounting configuration. MPC test set up shall have matching dimensions to couple MUT confirming NEMA 56 frame size with foot mounting configuration. It is very important to observe these dimensions and verify that MUT dimensions match NEMA 56 frame size because any deviation may cause the MUT not to mount on MPC test set up. Such a situation may lead to being unable to test the MUT.

Mechanical Interface


Figure 2. Electrical Interfacing

A

BL

MUT Controller

A

BL

Dynamometer Controller A

BL

DC Power Source(+) DC Bus

(-) DC Bus

A

B

C

Student Team Hardware

Dynamic Braking Resistor


Assuming screw type terminal strips on prototype , these connections will be flying leads without any termination with appropriate cable size suitable to the power ratings. Please notify us immediately if competition specifications are otherwise for these electrical interfacing. DC bus voltage monitoring and control and brake IGBT/MOSFET are part of the prototype. . Input power supply shall have a current limit set to 20 ampere in order to protect against higher current under any adverse situation.

Electrical Interface:


Time

Speed

1 Second 5 Second

0 RPM

3000 RPM

Region - 1 Region - 2 Region - 3

Drawing Not to Scale

2500 RPM

300 RPM

Speed profile for testing


Test Methodology

There are three key areas of qualitative assessments:

• Capability to start under 30 Nm load as starter• Reach the speed up to 3000 RPM as starter• Smoothly transition from starter to generator and charge the batteries at 3000 rpm


Durability Test

At the end of the day, all qualified hardware will be tested for durability. Fan blades may be mounted on the shaft to provide a nominal load. The motor will start from rest. The set up will be observed for 10 minutes to ensure safety and then will be left to run for about 30 minutes at the least. There will be no measurements/data acquisition/monitoring of these systems during durability test. The only protection to the set up will be the individual circuit breaker on the input power supply to each UUT. Finalists are recommended to verify their set up for such continuous run during their trials to ensure everything runs as planned at the time of final competition.

JudgingJudging

Judges will be experts from machine/drive Judges will be experts from machine/drive industryindustry

Design, operating documentation, test results, Design, operating documentation, test results, presentation, final report (including cost analysis) presentation, final report (including cost analysis) all consideredall considered

Development of point structure requires team Development of point structure requires team participationparticipation

Rule IssuesRule Issues

Repair or maintenance work on hardware on site Repair or maintenance work on hardware on site must be approved by judgesmust be approved by judges

Units with major failures or obvious severe Units with major failures or obvious severe shipping damage may not be approved for testingshipping damage may not be approved for testing

Once at MPC, hardware may not be taken off siteOnce at MPC, hardware may not be taken off site

Appeals of rulings can be made to full judging Appeals of rulings can be made to full judging committee – their decisions are finalcommittee – their decisions are final

Teams must follow safety regulations established Teams must follow safety regulations established by MPC and IFEC.by MPC and IFEC.

Prizes Prizes

Highest in team scoring will have detailed cost Highest in team scoring will have detailed cost evaluation by industry expertsevaluation by industry experts

Expected prizes include $10k grand prize, and Expected prizes include $10k grand prize, and several category prizes ($5k/prize). several category prizes ($5k/prize).

There is an design innovation award for creativityThere is an design innovation award for creativity

in design and control of ASMD. This award will be in design and control of ASMD. This award will be presented at IECON 2009 (Portugal).presented at IECON 2009 (Portugal).

A Few Points to RememberA Few Points to Remember

Suggested Policy Points:Suggested Policy Points:

Students to work at least Students to work at least in pairsin pairs..

When full ac wall potential is in use, a faculty When full ac wall potential is in use, a faculty member or TA must be present. At least two member or TA must be present. At least two people must be present.people must be present.

No food or drink at lab benches.No food or drink at lab benches.


Shock hazards exist in any labs.Shock hazards exist in any labs.

Most likely problems are with spilled drinks or Most likely problems are with spilled drinks or careless wiring.careless wiring.

Loose clothing and neckties are a problem when Loose clothing and neckties are a problem when motors are used.motors are used.

It only takes a watt to make small parts hot.It only takes a watt to make small parts hot.

Often metal cases are live.Often metal cases are live.


Serious power electronics work –Serious power electronics work –

Safety glassesSafety glasses

Fire extinguishersFire extinguishers

A safety plan, to include circuit protectionA safety plan, to include circuit protection


– Turn power off when making circuit changes.Turn power off when making circuit changes.– Keep a tight, neat setup. (It is safer, easier to debug, and Keep a tight, neat setup. (It is safer, easier to debug, and

just plain works better.)just plain works better.)– Treat part cases as live or hot.Treat part cases as live or hot.– When in doubt, shut power off.When in doubt, shut power off.– If it doesn’t work, it probably isn’t the instrument.If it doesn’t work, it probably isn’t the instrument.


Equipment damage is a common safety issue.Equipment damage is a common safety issue.

Problem areas:Problem areas:– GroundingGrounding. Students often don’t understand limitations of . Students often don’t understand limitations of

grounded probes or sources.grounded probes or sources.– Ratings. Do instrument ratings match the signal?Ratings. Do instrument ratings match the signal?

Page 1 International Future Energy Challenge Integrated starter/alternator topic IFEC ‘07.

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