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Fuel Cell Converter

Fuel Cell Converter. For Residential Application. Brian Mathis: BSEE, May 2001 Nick Schroeder: BSEE, May 2001 JasonWoodard: BSEE, May 2001. 2001 Future Energy Challenge Objectives. Input: 48-72 VDC Output: 120 VAC 60 Hz 1.5KW Supply: Chemical Fuel Cell

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Fuel Cell Converter

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  1. Fuel Cell Converter For Residential Application Brian Mathis: BSEE, May 2001 Nick Schroeder: BSEE, May 2001 JasonWoodard: BSEE, May 2001

  2. 2001 Future Energy Challenge Objectives • Input: 48-72 VDC • Output: 120 VAC 60 Hz 1.5KW • Supply: Chemical Fuel Cell • Use: Residential back-up power at low cost

  3. Design Goals • Sustain continuous 1.5 KW output • Operating efficiency of 90 % • Less than 5% total harmonic distortion • Modular design for a wide range of power needs • Protection against over current, over temperature, shorts, over/under Voltage and loss of power source • Easily and safely used by non-technical personnel

  4. What is a “Fuel Cell” • Converts Hydrogen to electricity using a chemical process with no combustion. • Can be used in a variety of applications. 1) Used by NASA since the 60’s. 2) Transportation : Auto, Air, Train. 3) Industrial/Residential Use.

  5. Advantages of Fuel Cells • Independent power supply. • Environmental friendly, low to zero emissions. • Customized to individual needs. • Can use a variety of fuels, hydrogen, diesel, biomass etc.

  6. Power Conversion Process DC to DC DC to AC Fuel Cell 48-72VDC Battery Bank 72 VDC Transformer Residential Applications

  7. DC to DC BOOST CIRCUIT • Takes a variable 48 to 72 volt DC input from the fuel cell. • The boost circuit raises the DC voltage from the fuel cell to that of the battery bank. • Uses adjustable duty ratio signal to control boost circuit. • The feedback controlled duty ratio maintains the output of the circuit at a steady 72+ volts DC.

  8. DC to DC Process

  9. DC to DC Gate Drive Control

  10. Output Ripple

  11. Output Ripple

  12. Efficiency and Duty Ratio

  13. Complications • Converter components capable of handling 30+ amps • PSpice simulation • Data sheets • High voltage to drive the gate • Feedback control

  14. DC to AC INVERTER • Takes a 72+ volt DC input. • Uses Pulse Width Modulation to drive inverter circuitry. • Inverter takes a DC input and converts to a 60hz 60 volt AC output. • 1:2 transformer increases voltage to 120 volt AC for residential use.

  15. DC to AC Process

  16. PWM Concept

  17. Signal Inversion Process

  18. PWM Comparator Signals

  19. PWM Output

  20. Dead Time control circuit

  21. DC to AC Gate Drive Circuit

  22. Complications YES

  23. Complications • Dead time - RC • MOSFET Driver overheating • Used both P and N type MOSFETS • Signal generation • Circuit output signal noisy – led to inverter malfunction

  24. Fuel Cell Converter Circuitry

  25. Further Improvements • Project is an ongoing success • Use voltage regulators • Isolated sources to independent gate circuits • Improved snubber circuit on MOSFET to improve efficiency • Decrease voltage ripple on DC to DC output • Voltage equalizers between batteries • Scaleable up to 10kW

  26. Learned Lessons • Division of labor, diverse tasks • Plan ahead, always order extra parts • Always have backup schemes • Time Management • Design before building • Communication

  27. Questions?

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