GRAMM International Future Energy Challenge ‘07 Geoff Sanders, Richard Tan, Ankit Tripathi, Maung...
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GRAMMInternational Future Energy Challenge ‘07
Geoff Sanders, Richard Tan, Ankit Tripathi, Maung Myat, and Marc Hesse
Versamachine
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OverviewPurposeSpecificationsSystem Description System Layout/BreakdownLabor DistributionFuture Schedule to meetMarketability/Impacts and SustainabilityChallengesRisks and ContingenciesQuestions/Suggestions and Comments
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PurposeElectric machine (motor):
Works both as a starter (motoring) and an alternator (generator)
Target: Electric Car, Hybrid Electric Car
Reasons:IFEC ’07 challengeSave SpaceDecrease Cost Increase Efficiency
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SpecificationsMust provide 30 Nm of Torque startup.Must motor up to 3000 rpm in 3-5 secondsMust generate 1 KW of powerMust be at least 75% efficientMust use NEMA frame 56, which is less than 7 inches in diameter
http://www.leeson.com/
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System DescriptionA two pole induction machine (motor)Inverter/RectifierMotor Drivers Gate Drivers (MOSFET DRIVER)Micro-controller (TI / Freescale)User Interface (using a CAN, RS 232 cable, PC Master)RF/Bluetooth Sensors (flux, torque, Hall, temperature, etc)Power Supply
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System Layout
http://www.freescale.com/webapp/sps/site/overview.jsp?nodeId=02nQXGrrlPglzQMszY
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Induction Machine (Motor)
Squirrel cage induction machine with Variable Frequency (V/f) Control
Will work on the principles of 1. Flux weakening/strengthening2. Pole changing3. Frequency Change
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General Torque-Speed Characteristics
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Torque-Speed curve change from starting point (30Nm) to 750 rpm
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Torque-Speed curve change from 8 pole (750 rpm) to 4 pole (1500 rpm)
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Torque-Speed curve change from 4 pole – 1500 rpm to 2250 rpm
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Torque-Speed curve change from 4 pole – 2250 rpm to 3000 rpm
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Generalized frequency and speed operation of motor
Frequency-time Diagram
Speed-time Diagram
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BLOCK DIAGRAM
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Converter (Inverter/Rectifier)
Converter must fulfill two functions:1) Inverter operation during starting and
motoring up to 3000rpm2) Rectifier operation during generating mode
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InverterPWM Inverter
Operates during both motoring and generating modes
Converts DC supply voltage to 3 phase AC Provides excitation current to stator windings Additional specifications of the Inverter1) Input dc voltage: VDC = 200V
2) Frequency range: 10-200 Hz3) Current at low frequency of 15 Hz: Iline = 30 Apeak
4) Output voltage as high as possible for given input voltage
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RectifierRectifier
Operates only during generating Converts AC current to DC in order to charge
battery Additional specification of the rectifier
Output voltage: VDC = 200V @ 10 ADC maximum or at least deliver 1 kW to the battery at 200V with efficiency of 75%
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Gate/Motor DriversProvide fast change in current to drive the gates of all IGBT/MOSFET switches in the converter
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Sensors, Switches & Power Supply
Sensors Operational sensors
Hall effect Temperature Position encoders
Testing Torque transducer Flux meter Universal Dynamometer
Switches winding switches
Pole changing N reduction
Power Supply 200 V DC
Motor
Motor DrivingPower
Converter
DSPOr
Micro-Controller
Memory
Hall EffectSensor
Encoder
Current Voltage
Sense
Current Voltage
Sense
Receiver
ADC
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BLOCK DIAGRAM
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DSP/Micro-Controller3 Primary functions Control switching of PWM inverter
IGBT/MOSFET switches Control winding switching
For pole changing To reduce windings by half during 4 pole
operation Interact with user interface to produce
desired operation
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User InterfacePC Master SoftwareSerial port connection Later use RF/Bluetooth
http://www.freescale.com/files/product/doc/AN1948.pdf
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PC Master Support
Freescale 56F80x 56F82x 56F85x Possibly supported by:
MC68HC08 (MC68HC908MR32) MC68HC512 MPC500
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PC Master Features
Control the motor Start-up/shut-down Speed control
Read/change variablesScope slower variablesRecord fast variablesStimulate variablesSend application commands with parametersDisplay help items (block diagrams, characteristics)Remote control of application through the internet
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PC Master Windows
http://www.freescale.com/files/product/doc/AN1948.pdf
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Other parts
Voltage regulatorsResistors, capacitors, and heat sinksVoltage shiftersRAM/ROMADC/DACRS232 serial portUARTClocks
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Task DistributionMaung/Richard
Part research and ordering Design inverter/rectifier Implement sensor circuits Circuit schematics and PCB design
Ankit/Geoff Motor design finalization and ordering User interface/system controller
Marc/Geoff User’s Manual Micro-controller coding Technical manual compilation
All Documentation Test/debug Wire-wrap prototyping
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GANTT CHART
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BudgetCategory Item Unit Cost Quantity Total Cost
Induction Motor $250 2 $500 Motor/Generator Custom Rotor Fabrication $1,000 1 $1,000
Stator Re-winding $500 1 $500 Power MOSFETs $20 6 $120
Motor Controller Gate Drive Board $20 1 $20 Aluminum Heat Sink $50 1 $50
Pole Changing Switches $5 6 $30 Micro-controller and Support $500 1 $500
System Controller Wireless Communication $200 1 $200 Various Sensors $100 1 $100
Flux Meter $380 1 $380 DC/AC Measurement Switch $40 1 $40
Testing and Measuring Equipment External Power Plug-in $30 1 $30 Torque Transducer $1,290 1 $1,290
Torque Sensor Cable $95 1 $95 TRD-S Position Encoder $81.50 1 $82
Other PCB fabrication $66 3 $198 Voltage regulator/resistors/caps $200 1 $200
Total $5,335
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MarketabilityAlmost all motor-vehicle manufacturers in the world can use it as it would Increases overall efficiency of vehicle Decreases overall cost Take up less space
Target Manufacturing cost of $100Possible Patent
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Challenges, Risks, and Contingencies
Challenges This has never been done effectively! What makes us think we will succeed where
many have failed?
Risks We could quite possibly fail to meet the IFEC
specifications with our first (capstone) design. We may be unable to make the machine
automatically shift speeds and windings
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Challenges, Risks, and Contingencies
Contingencies For expo we will have a motor controlled with
our controller that will run, although it may not meet the requirements dictated by IFEC. If this occurs a permanent magnet rotor
will be designed and used in place of the squirrel cage rotor in order to increase torque and efficiency
This is beyond the scope of capstone Will be able to run each characteristic for
testing using user interface to set frequency and manually switch windings
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Questions / Suggestions
http://www.smartquestion.com/images/sq_image.jpg