Gramm international future energy challenge 07
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GRAMM International Future Energy Challenge ‘07. Geoff Sanders, Richard Tan, Ankit Tripathi, Maung Myat, and Marc Hesse. Overview. Purpose & Specifications System Description Electric Machine Power Converter Controller Circuit In-circuit Debugger Other parts and purchases

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GRAMM International Future Energy Challenge ‘07

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Gramm international future energy challenge 07

GRAMMInternational Future Energy Challenge ‘07

Geoff Sanders, Richard Tan, Ankit Tripathi, Maung Myat, and Marc Hesse


Overview

Overview

Purpose & Specifications

System Description

Electric Machine

Power Converter

Controller Circuit

In-circuit Debugger

Other parts and purchases

Updated Labor Distribution

Updated detailed schedule

Questions/Suggestions and Comments


Purpose specifications

Purpose & Specifications

Electric machine (motor):

Works both as a starter (motoring) and an alternator (generator)

Must provide 30 Nm of Torque startup.

Must motor up to 3000 rpm in 3-5 seconds

Must generate 1 KW of power

Must be at least 75% efficient

Must use NEMA frame 56

Target:

Hybrid Electric Car

Reasons:

IFEC ’07 challenge

Save Space

Decrease Cost

Increase Efficiency


System description

System Description

Starter-Alternator Unit (motor)

Pole Changing, ‘N’ winding reduction, Flux based design

Power Converter

Power Board (STEVAL-IHM009V1)

Inverter/Rectifier

Generator exciter

System Controller

Control Board (STEVAL-IHM001V1)

Chip (ST7FMC2)

Gate Drivers (MOSFET DRIVER)

User Interface (On-Off switch, emergency switch)

Indart series debugging board (INDART-STX/D)

ST7 Debugger Program

Control panel software (AK-ST7FMC)


Test set up

Test Set-Up

dynamometer (drive and brake)

belt drive coupling

machine power feeders

system controller

dyno control

electric machine (NEMA 56)

power converter

torque measurement

shaft position measurement

PC

200 VDC


Mock set up with already acquired parts

Mock Set-up with already acquired parts


Gramm international future energy challenge 07 1276797

Electric Machine Hardware

  • Received free 3-phase ¾ hp squirrel cage induction machine

  • Measured parameters and weight

  • Determined that the slot count is 36 (we need 24 slots)

  • Allowed us to specify the exact machine we need

  • Baldor M3155 3-phase squirrel cage induction machine

  • 2 hp (1.49 kW)

  • 3450 rpm, 2 pole

  • 24 slots, 12.4 in. long, 6.8 A max

  • NEMA 56 frame

  • Will test, then re-wind machine for 8-4 pole configuration


Torque speed characteristics of machine

Characteristic 1 (8-pole)

Starting ~ 27Hz, Torque ~ 36Nm

f->50Hz, speed -> 750rpm

Switch to 4-pole operation

Characteristic 2 (4-pole)

f->50Hz, speed -> 1500rpm

Characteristic 3 (4-pole)

f->75Hz, speed -> 2250rpm

N reduction (N/2)

f->100Hz, speed -> 3000rpm

Characteristic 4 (4-pole)

Speed=3000rpm

Generating

4500

GENERATION

MOTORING

II

I

4000

operating point 3

3500

characteristic 4

3000

2500

characteristic 3

speed[rpm]

2000

characteristic 2

1500

characteristic 1

1000

500

starting characteristic

at 27.5 Hz and 24Aline peak by increasing flux

0

-30

-20

-10

0

10

20

30

40

Torque [Nm]

Torque-Speed Characteristics of Machine

  • Torque curves for each characteristic

V  E/f = 4.44 * N * 

T = (/2) * (pole/2)*  * Fmr * sin r


8 pole winding configuration and mmf

8 Pole Winding Configuration and MMF

  • 8-pole configuration

  • Nrat turns per phase

  •  winding connection


4 pole winding configuration and mmf

4 Pole Winding Configuration and MMF

  • 4-pole configuration

  • Nrat turns per phase

  • Y-Y winding connection


Winding switching

  • 4-pole configuration

  • Nrat /2turns per phase

  • Y-Y winding connection

Winding Switching


Gramm international future energy challenge 07 1276797

Power Converter Board

  • AC Induction Motor ControlPower board SEMITOP®3 3kW(STEVAL-IHM009V1)


Power converter block diagram

Power Converter:Block Diagram

200V Power Supply

Control Board

HV Monitoring

Power Regulation

Three Phase Inverter

(STG3P3M25N60)

PWM Input

AC Induction Machine

BEMF

Temperature Sensor

Tachometer

Brake Motor


Stg3p3m25n60 3 phase inverter igbt semitop 3 module

STG3P3M25N603 Phase inverterIGBT - SEMITOP®3 module

  • General features

  • N-channel very fast PowerMESH™ IGBT

  • Lower on-voltage drop (Vcesat)

  • Lower CRES / CIES ratio (no cross-conduction

  • susceptibility)

  • Very soft ultra fast recovery anti-parallel diode

  • High frequency operation up to 70 KHz

  • New generation products with tighter

  • Parameter distribution

  • One screw mounting

  • Compact design

  • Semitop®3 is a trademark of Semikron


Viper12adip e low power off line smps primary switcher

VIPer12ADIP - ELow Power OFF-Line SMPS Primary Switcher

  • Description

  • The VIPer12A combines a dedicated current mode PWM controller with a high voltage Power MOSFET on the same silicon chip.

  • The internal control circuit offers the following benefits:

  • Large input voltage range on the VDD pin accommodates changes in auxiliary supply voltage.

  • This feature is well adapted to battery charger adapter configurations.

  • Automatic burst mode in low load condition.

  • Over-voltage protection in HICCUP mode.

  • Features

  • Fixed 60kHZ Switching Frequency

  • 9V to 38V Wide Range VDD Voltage

  • Current Mode Control

  • Auxiliary Under-voltage Lockout with Hysteresis

  • High Voltage Start-up Current Source

  • Over-temperature, Over-current and

  • Over-voltage Protection with Auto-Restart


L78l05acz positive voltage regulator

L78L05ACZPOSITIVE VOLTAGE REGULATOR

  • OUTPUT CURRENT UP TO 100 mA

  • OUTPUT VOLTAGE OF 5V

  • THERMAL OVERLOAD PROTECTION

  • SHORT CIRCUIT PROTECTION

  • NO EXTERNAL COMPONENTS ARE REQUIRED

  • AVAILABLE IN EITHER ±5% (AC) OR ±10% (C) SELECTION


Silicon avalanche diodes p6ke series 600 watt axial leaded transient voltage suppressors

Silicon Avalanche Diodes (P6KE Series)600 Watt Axial Leaded Transient Voltage Suppressors

  • FEATURES

  • RoHS Compliant

  • 6.8 to 550 Volts

  • Uni-directional and Bi-directional

  • Glass passivated chip junction in DO-15 Package

  • 600W surge capability at 10/1000μs wave form

  • Excellent clamping capability

  • Low zener impedance

  • Fast response time: typically less than 1.0ps from 0 Volts to BV min.

  • Typical IR less than 1μA above 10V


Power converter s schematic

Power converter’s schematic


System controller board

System controller Board

  • AC Induction Motor ControlControl BoardSTEVAL-IHM001V1


St7mc2 44 pin lqfp package pin outs

ST7MC2 44-Pin LQFP Package Pin-outs


System controller s schematic

System controller’s schematic


System controller block diagram

System Controller:Block Diagram

Potentiometers

ST7FMC2

ICC Interface

A/D Converters

PWM Generator

Debug Board

ICC Connector

Bridge Drivers (L6386)

Power Board

SPI Interface

SPI EEPROM(M95040)

Feedback

Switches

16 KB

FLASH Memory

768 Bytes RAM

LEDs

16 MHz Oscillator


Pwm timing

MCMP0 Register

Phase U Preload Register

Phase V Preload Register

Phase W Preload Register

Phase U Waveform

Phase V Waveform

Phase W Waveform

PWM Timing


System controller flowchart

Idle

Start

Run

Stop

Brake

Wait

Fault

System Controller Flowchart

Initialize Peripherals

Main Loop

Interrupts

Check State

Event U

Reload PWM Duty Cycle

Emergency Stop

Stop Motor

Send System Data (RS232)

Event R or Z

ART Reset

Update Counters

Update LEDs

Event C or D

Tachometry

SCI

Send Data

Check for Errors

External


User interface debugger

User Interface/Debugger

Testing the Control/Power board


Why use indart stx

Why use inDart-STX?

  • Real time code execution without Probes

  • In-Circuit debugging

  • Hardware and software testing in real time

  • Built in FLASH programmer (Data Blaze Programming utility)

  • Visual Debug user interface (with integrated C compiler and assembler and source level symbolic debugging)

  • Hardware self diagnostic test

  • Working frequency as high as the microcontroller itself

  • Allows for programming the content of FLASH when chip already is

    in the circuit

  • Uses ICC (In circuit communication to interface the programming tool

    like inDART) with the microcontroller we have


User interface debugger1

User Interface/Debugger

inDart-STX


Pin out for indart

Pin out for inDART


Gramm international future energy challenge 07 1276797

ST7 Debugger Program


Pc interface controller

PC Interface Controller

Control panel software (AK-ST7FMC)


Other parts purchased for testing

Other Parts Purchased for Testing


Safety

Safety

Face shield

Safety shield


Distribution of work

Distribution of Work

  • Geoff

    • Custom Motor

    • Programming the micro-controller

  • Richard

    • Custom Motor

    • Calculation and simulation with the actual motor parameters

  • Maung

    • Custom Motor

    • PCB layout for the 64 pins controller

  • Ankit

    • Custom Motor

    • Permanent motor design/ Programming the micro-controller

  • Marc

    • Programming the micro-controller

    • Documentation


Gantt chart

Gantt Chart


Milestone 1

Milestone 1

  • Test system using regular induction machine

    • With 64 pin controller board (1st revision)

    • Should work the same as purchased 44 pin controller board

  • Custom machine nearly finished

  • Switching circuit complete (wire wrap)


Milestone 2

Milestone 2

  • Complete system test with:

    • Custom machine finished

    • Completed switching circuit PCB

    • Pole changing ability confirmed


Final open lab expo

Final Open-Lab Expo

  • Complete closed-loop operation of:

    • Custom pole changing induction machine implementing N reduction

  • Meeting the basic IFEC requirements

  • Documentation complete


Questions comments

Questions / Comments

Thank you!

http://www.smartquestion.com/images/sq_image.jpg


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