1 / 48

Power Supply for a Remotely Operated Vehicle (May05-12)

Power Supply for a Remotely Operated Vehicle (May05-12). Team Members: Jonathan Gettler EE Tai Ong EE Adam White EE Wei Yau EE Client: Scott Morgan Stealth ISR Engineering St. Paul, Minnesota Faculty Advisor: Dr. Venkataramana Ajjarapu

alfonso-rivers
Download Presentation

Power Supply for a Remotely Operated Vehicle (May05-12)

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Power Supply for a Remotely Operated Vehicle (May05-12) Team Members: Jonathan Gettler EE Tai Ong EE Adam White EE Wei Yau EE Client: Scott Morgan Stealth ISR Engineering St. Paul, Minnesota Faculty Advisor: Dr. Venkataramana Ajjarapu Date: April 25th, 2005

  2. Presentation Outline • Adam • Research, Design and Implementation • Other Project Activities • Yau • Resources & Schedules • Closing Materials • Questions • Jonathan • Introduction • Assumptions and Limitations • End-Product • Tai • Team Accomplishments • Approaches and Considerations May05-12

  3. Project Introduction • Remote control plane hobbyists want on-board electronics • Existing power systems do not meet the power requirements • Design a power supply that meets the new needs of hobbyists

  4. Project History Summary • Mechanical and electrical projects in parallel • April 5th mechanical team was more successful than expected • Loosens electrical design constraints Mechanical Design Start End Product Electrical Design

  5. List of Definitions • AGM – Absorbed Glass Mat • PWM – Pulse Width Modulation • UAV – Unmanned Aerial Vehicle May05-12

  6. Acknowledgements • Thanks to Dr. Ajjarapu for investing research dollars into SimPower. • Thanks to Scott Morgan for the personal contributions to the project. May05-12

  7. Problem Statement Alternative electronics onboard UAVs Increased power requirements stress the system Onboard batteries are overcharged and overheated Options for power supplies are limited May05-12

  8. Approach Statement • Design a power supply for large electrical loads • Power supply must be versatile • Increase reliability and life of the batteries May05-12

  9. Operating Environment Extreme temperatures -37°F to 125°F Extreme vibration Shock May05-12

  10. Remote control hobbyists Any person who wants to generate electricity Intended Users May05-12

  11. Intended Uses Provide electric power to remotely operated vehicles Transform rotating mechanical energy into electrical energy May05-12

  12. Assumptions • The gasoline motor will operate between 2,500 RPM and 13,000 RPM • Total load will not draw more than 100 Watts • Rectified generator output voltage will be 3.5-13 Volts DC May05-12

  13. Power Limitations • Output • 3.3 Volts (+.1/-.05V) • 5 Volts (+.2/-.1V) • 12 Volts (+.4/-.2V) • Less than .05 Vrms noise in the output • Batteries must supply the full load for 15 minutes without generator power May05-12

  14. Physical Limitations • The power supply shall be less than 2 pounds • Physical size shall be less than 6”x4”x1” • Emissions shall conform to MIL-STD-704C • Costs shall not exceed $500 May05-12

  15. End Product and Other Deliverables • Prototype mobile power supply • Test results • Specifications manual • Final design report May05-12

  16. Present Accomplishments • Order Parts 100% (completed) • Design 100% (completed) • Research 100% (completed) • Testing 80% (completed) May05-12

  17. Three-phase generator Provided by the client AC to DC rectifier Two choices Construct from scratch Six diodes Circuit board Labor cost Purchase off the shelf Less cost Hobby Airplane Engine 3 Phase Generator 3 Phase Rectifier Boost Voltage Regulator Battery Charger 12V Buck Regulator 5V Buck Regulator Batteries Load Load 3.3V Buck Regulator Load Approaches Considered May05-12

  18. DC to DC step-up converter Switching voltage regulator Light Efficient Transformer Heavy Frequency issues Hobby Airplane Engine 3 Phase Generator 3 Phase Rectifier Boost Voltage Regulator Battery Charger 12V Buck Regulator 5V Buck Regulator Batteries Load Load 3.3V Buck Regulator Load Approaches Considered May05-12

  19. Hobby Airplane Engine 3 Phase Generator 3 Phase Rectifier Boost Voltage Regulator Battery Charger 12V Buck Regulator 5V Buck Regulator Batteries Load Load 3.3V Buck Regulator Load Approaches Considered • Battery charger • MAX1873TEE evaluation kit • Meets all project requirements with an upgrade • Other • No other chargers were capable of handling current requirements within design limitations May05-12

  20. Hobby Airplane Engine 3 Phase Generator 3 Phase Rectifier Boost Voltage Regulator Battery Charger 12V Buck Regulator 5V Buck Regulator Batteries Load Load 3.3V Buck Regulator Load Approaches Considered • Batteries • AGM lead acid • Heavy, not available in small sizes • Nickel Cadmium/Nickel Metal Hydride • Lower capacity than Lithium Ion • Lithium Ion • High capacity • Used for high power applications May05-12

  21. Project Definition Activities Used for small airplane Power on-board electronics May05-12

  22. Research Activities • Project components May05-12

  23. Research Activities: Generator • Experimental setup May05-12

  24. Research Activities: Generator • Voltage vs. generator RPM curve with three phase rectifier May05-12

  25. Research Activities: Step-up Converter • Research components to use in building a step-up switching converter May05-12

  26. Research Activities: Step-up Converter • Research commercially available step-up switching converter • After initially finding none that met the project’s demands, one was stumbled upon • DCDC12/24/160 from Zahn Electronics

  27. Research Activities: Batteries and Charger • Lithium Ion batteries to meet weight and capacity requirements • Maxim charger evaluation kit

  28. Research Activities: Step-down Converter • Linear regulator • Switching regulator May05-12

  29. Design Activities: Step-up Converter • Initially selected components to use in a step-up switching converter • TI, TL5001 PWM control circuit May05-12

  30. Design Activities: Step-up Converter • Later purchased a step-up converter May05-12

  31. #1 #2 #5 #4 #1 #3 Design Activities: Battery Charger • An evaluation kit in the prototype • Evaluation board needed special tweaking May05-12

  32. Design Activities: Step-down Converter • Client decided that only the 12V output was needed • A 12V step-down regulator was purchased May05-12

  33. Tested Vout vs. RPM using a high-speed rotary tool Tested step-up voltage converter Unable to test battery charger due to shipping and other supplier issues Tested ability of batteries to supply rated load Tested the step-down converter’s ability to power 12V load Testing and Modification Activities May05-12

  34. Other Significant Project Activities • Met with client in Eagan, MN • Phone calls • Sampled parts • PSpice simulations of circuit components May05-12

  35. Personal Effort May05-12

  36. Resource Cost May05-12

  37. Total Project Cost Parts and Materials: Without Labor With Labor Project Poster $50.00 $50.00 Project Parts: Generator * (donated by client) donated Rectifier/Booster parts $30.04 $30.04 Battery charger $61.32 $61.32 Batteries $91.80 $91.80 DC/DC boost converter $100.00 $100.00 12 volt regulator $100.00 $100.00 Subtotal $433.16 $433.16 Labor ($10.30 per hour): Gettler, Jonathan $0.00 $2472.00 Ong, Tai $0.00 $1977.60 White, Adam $0.00 $2863.40 Yau, Wei $0.00 $2307.20 Subtotal $0.00 $9620.20 Totals $433.16 $10053.36 May05-12

  38. Project Task Schedule Specification changes Additional lead time on parts May05-12

  39. Project Evaluation May05-12

  40. Commercialization • Potential market • Remote control hobbyists • Production cost $350 • Retail price $700 May05-12

  41. Complete testing of battery charger Increase load handling capability Size and weight reduction of prototype Recommendations for Future Work May05-12

  42. Went well • Team communication • Vision of final product • Desire to finish project • Did not go well • Difference between experimental and expected results of testing • Lack of circuit fabrication experience • Often behind schedule Lessons Learned May05-12

  43. Lessons Learned • Technical knowledge gained • Electrical characteristics of motors • Power electronics design and modeling • Operation of a gas engine for UAV • Datasheet implementation • Non-technical knowledge gained • Public speech • Improved formal documentation and communication skills May05-12

  44. Lessons Learned • What would be done differently • Further define project specifications • More work in the beginning stages • Order parts sooner • Clearly divide tasks among members May05-12

  45. Potential/Encountered risks • Lead time on ordered parts • Loss of stored data • Voltage drop when load is connected • Management of risks • Backup data on engineering storage drive • Increase generator output by changing gear ratio Risk and Risk Management May05-12

  46. Cascading system: generator, rectifier, booster, charger, batteries, and regulator. Provide required 12 volts and 75 watts at output An easy to install and use add-on for remotely operated vehicles that require on-board power electronics Upgrade UAV’s power capabilities, ground/air constant power source Closing Summary May05-12

  47. Questions/Feedback? May05-12

  48. Thanks for your time!

More Related