Precision variable frequency drive may 07 13
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Precision Variable Frequency Drive May 07-13. Client: Jim Walker Advisor: Dr. Ajjarapu Team Members: Matt Shriver Jason Kilzer Nick Nation Dave Reinhardt April 24, 2007. Presentation Outline. Introductory Materials (Nick) Project Approach & Design (Jason) Testing and Implementation (Matt)

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Precision Variable Frequency Drive May 07-13

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Precision variable frequency drive may 07 13

Precision Variable Frequency DriveMay 07-13

Client: Jim WalkerAdvisor: Dr. AjjarapuTeam Members:Matt ShriverJason KilzerNick NationDave ReinhardtApril 24, 2007


Presentation outline

Presentation Outline

  • Introductory Materials (Nick)

  • Project Approach & Design (Jason)

  • Testing and Implementation (Matt)

  • Closing Materials (Dave)


The prototype

The Prototype


List of definitions

List of Definitions

  • VFD: Variable Frequency Drive

  • PWM: Pulse Width Modulation

  • IGBT: Insulated Gate Bipolar Transistor


Acknowledgements

Acknowledgements

  • Faculty advisor Dr. Ajjarapu

  • Client Jim Walker

  • Graduate Students

    • Ryan Konopinski

    • Sheng Yang


General problem statement

General Problem Statement

  • The speed control of an AC synchronous motor.

  • The synchronous motor and the subsequent drive mechanism do not always keep the correct speed.

  • A method is needed to control the frequency that is delivered to the synchronous motor.


Solution

Solution

  • A precision variable frequency drive will allow the user to manually change the operating frequency.


Operating environment

Operating Environment

  • Indoors

  • No extreme conditions

  • Near power outlet


Intended use

Intended Use

  • As a drive for a low power AC synchronous electric motor.

  • This drive was not considered to be used on any other type of electric motor except for a synchronous design.

  • This drive shall not be used to power any control circuits.


Intended users

Intended Users

  • Anyone who desires precise control over a small AC synchronous motor.

  • An owner of a turntable who needs better control over the speed of their turntable.

  • No technical knowledge will be required to operate the Precision VFD.


Assumptions

Assumptions

  • Constant linkage –An increase in motor speed by a certain factor will result in an increase in the speed of the turntable by the same factor.

  • Plug – the power cord from the record player can plug into a standard three pronged outlet.


Limitations

Limitations

  • Minimum Power Output: 75 W

  • Output Frequency Range: 58-62 Hz

  • Frequency Precision: 0.001 Hz

  • Frequency Stability: < ± 0.01 %

  • 12” by 12” by 6” size limitation

  • Cost less than $350


Expected end product

Expected End Product

  • Precision variable frequency drive

  • Portable strobe system

  • One-page quick users guide

  • Circuit diagrams and parts list


Project approach

Project Approach


Present accomplishments

Present Accomplishments

  • Research technologies (100%)

  • Simulate entire system (100%)

  • Purchase components (100%)

  • Build components (85%)

  • Test components (70%)

  • Build entire system (70%)


Approaches considered

Approaches Considered


Project definition activities

Project Definition Activities

  • Develop a VFD that will provide a precise frequency that can be changed.

  • A strobe light will also be included to measure the RPM of the electric motor.


Research activities 1 of 2

Research Activities (1 of 2)

  • Pulse Width Modulation

    • Needs small signal variable frequency sine wave

    • Need small signal triangle wave

    • Comparator produce pulses from comparison of sine and triangle wave

    • PWM would create the control signals for the IGBT bridge


Research activities 2 of 2

Research Activities (2 of 2)

  • IGBT Bridge

    • Provides power separation between PWM circuits and power supply circuitry

    • Generates pulses


Precision variable frequency drive

Precision Variable Frequency Drive

  • Ready to use design

  • Delivers precise frequency control for low power AC synchronous motors

  • Strobe light included to measure RPM of motor


Design

Design

  • Pulse Width Modulation Circuits

  • IGBT Bridge and Filter Circuits

  • Power Supply Circuits


Overall block diagram 1 of 2

Overall Block Diagram (1 of 2)


Overall block diagram 2 of 2

Overall Block Diagram (2 of 2)


Pulse width modulation circuits

Pulse Width Modulation Circuits


Igbt bridge and low pass filter

IGBT Bridge and Low Pass Filter


Power supply components

Power Supply Components

  • Astrodyne Power Supply (PT-45C)

    • Input: 120 VAC

    • Outputs: +/-15V, +5V

  • Filament Transformer

    • Primary Winding: 117V

    • Secondary Winding: 8V


Testing and implementation

Testing and Implementation


Pwm circuits

PWM Circuits


Comparator input output waveforms

Comparator Input/Output Waveforms


Inverter input output waveforms

Inverter Input/Output Waveforms


Igbt bridge and low pass filter1

IGBT Bridge and Low Pass Filter


Filter input output waveforms

Filter Input/Output Waveforms

Input and Output Waveforms of the Low Pass Filter


Implementation and testing

Implementation and Testing

  • Function generator chips

  • Amplifiers

  • Comparator and Inverter

  • IGBT’s

  • Filter

  • Strobe light system


Sine triangle generator chips

Sine & Triangle Generator Chips

  • Built and tested on breadboard


Amplifiers comparator and inverter circuits

Amplifiers, Comparator, and Inverter Circuits

  • Built and tested on breadboard


Comparator testing

Comparator Testing

Comparator Chips

  • UA741 Op Amp

  • LM319N High Speed Comparator

    Sources

  • Lab Function Generators

  • Function Generator Chips


Igbt bridge

IGBT Bridge

  • build and test on breadboard


Igbt bridge testing

IGBT Bridge Testing

  • Design overlooked need for delay circuitry

  • Tried multiple timing circuits

    • NE555 Timer Circuit

    • UA741 Op Amp Circuit


Strobe light system

Strobe Light System

Strobe Light Schematic


Closing material

Closing Material


Resources

Resources


Schedule

Schedule

Detailed Gantt Chart


Deadline schedule

Deadline Schedule

Deadlines Schedule


Project evaluation 1 of 2

Project Evaluation (1 of 2)


Project evaluation 2 of 2

Project Evaluation (2 of 2)


Commercialization

Commercialization

  • Not produced for commercialization

  • Precision variable frequency drive could be implemented for much less than current market price (~$250)


Additional work

Additional Work

  • Resolve comparator issues

  • Resolve IGBT issues

  • Combine Precision VFD and strobe light system into one product

  • Include feedback loop for total autonomy


Lessons learned 1 of 2

Lessons Learned (1 of 2)

  • What went well

  • Design/Simulation of project

  • Testing

  • What did not go well

  • Problem definition and planning (needed a new plan when we started implementing)

  • Having everyone on the same page (team members, advisor, vendor)


Lessons learned 2 of 2

Lessons Learned (2 of 2)

  • Technical

  • Implement and test one component at a time

  • Keep it simple

  • Comparator troubleshooting

  • IGBT implementation

  • Non-technical

  • Should have planned a lot more time for implementation

  • Everyone must be on the same page

  • Have a good plan to start


Risk and risk management

Risk and Risk Management


Unanticipated risks

Unanticipated Risks


Closing summary

Closing Summary

  • An incomplete prototype was produced due to difficulties with the comparator and the IGBT bridge.

  • Estimated final product could be commercialized and sold for $250.


Demonstration and questions

Demonstration and Questions


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