Transcript Housing the DC/DC Converter - Illinois Institute of Technology

Solar Hydrogen Project
IPRO 397 – 301
Advisor: Dr. Said Al-Hallaj
Sponsors: BP, BP Solar, Proton Energy
Systems, ComEd & IL-DCEO
Team Members
Ariel Simons, Ronak Shah, Harsha
Pannala, Vesna Dodevski, Umar Rabbani,
Nishant Shah, Steven Peters, Ryad
Djerrouf, Elvir Kahrimanovic, Leonardo
Melo, Lyes Boundaoui, Adekunmi Keleko
(Team Leader).
Brian Kustwin (Consultant).
Overview
Project Objective
Project Schematics
Individual Group Approaches
Q&A.
Objective
The objective of this project is to design,
assemble and analyze a stand-alone
distributed power generation system that
utilizes solar energy through PV panels
and hydrogen storage and conversion to
power an LED sign.
Schematic
Solar Hydrogen System Block Diagram
PHASE - I
PV
PHASE - II
PV
Charge
Controller
DC/DC Converters
DC/AC Inverter
Auxillaries
Cell Stack
H2
Electrolyzer
Battery Bank
Fuel Cell Battery
Control
System
H2
Fuel Cell
Load
Hydrogen
Storage
Hydrogen
Storage
Approach
Teams Inspect project site, test DC/DC converter,
1&2
back engineer electrolyzer. Price
120AC/240AC converters, wire AC/AC
converter, price relays and switches
Team 3 Inspect electrolyzer and storage tank, price
fuel cell equipment.
Team 4 Summarize past data papers, look for data
acquisition hardware. Perform
experiments.
Team 5 Purchase cameras, de-bug website,
upload all documents onto website.
Teams 1&2
The DC/DC Converter
Converts PV output to a voltage usable by the
electrolyzer
Needs protection from dust and heat
Housing should be made of aluminum,
Plexiglas, or plastic
Commercial units not acceptable


Too expensive, provided outdoor protection
Too unprofessional, cheap
Teams 1&2
The DC/DC Converter
DC/DC Converter
Experimental Setup
Input terminals
PV
PHASE II
SYSTEM I
AREA I - V
Output terminals
+
+
-
-
Analog Port,
DB 15-P
HP6060B
Digital
Electronic
Load
HP6632A
System DC
Power Supply
The Transformer
Teams 1&2
Previous IPROs underestimated input voltage
to electrolyzer auxiliaries (240 Vac instead of
120 Vac)
Need 120V/240V step-up transformer to fix
this problem
Decided on 1kVA rating to be safe
http://phaseconverter.com/sptransformer.html
$150 before shipping
Project Goals
Team 3
Go to site and inspect electrolyzer and storage
tank.
Find out how to connect the fuel cell to the fourway valve for the hydrogen flow.
Find equipment and price that can be purchased
and used to connect the fuel cell to the four-way
valve
Find equipment and price for a back pressure
regulator (BPR) and steel tubing to connect the
fuel cell intake with the hydrogen tanks
Team 3
Electrolyzer and Storage Tank
The water storage tank and electrolyzer
are already installed .
The electrolyzer is currently inactive, the
water tank would needs to be periodically
refilled when the electrolyzer is active .
The pump needed to bring the water from
the tank to the electrolyzer was installed in
the storage tank stand.
Team 3
Steel Tubing / Back Pressure
Regulator (BPR)
To transfer hydrogen to the fuel cell the four way
valve needs to be connected to the fuel cell
intake.
Connected to the stainless steel tubing needs to
be a BPR.
BPR takes 250psi inlet hydrogen down to
approximately 30psi outlet hydrogen.
Stainless steel tubing, at least 0.25in thick, is
needed to prevent significant hydrogen diffusion.
Further Actions
Team 3
A BPR needs to be purchased before all of
the gas systems can be put up.
The primary problem in searching for a
suitable BPR involves finding an inline
BPR instead of the more prevalent panelmounted BPR.
Team 4
Data Acquisition (DAQ)
The data acquisition was done using
LabView which is designed to monitor the
Solar Hydrogen System. It measured
voltage, pressure, temperature, solar
insulation and mass flow of the system
elements we studied in this project.
Equipment
Team 4
HP6060B Digital Electronic Load
HP6632A System DC Power Supply
Battery Bank
DC / DC Converter.
Team 4
Data
DC Converter Test Data
RESISTANCE
VOLTAGE RANGE
(V)
VOLTAGE
STABILIZATION
CURRENT (A)
30
46 - 60
59.5
2
20
55 - 61
55
3
10
38 - 48
48
4
8
42
42
5
6
34
34
6
4
29
29
7
2
18
18
10
1
14
14
14
Team 4
Data
Constant Resistance Mode Data
RESISTANCE
VOLTAGE
RANGE (V)
VOLTAGE
STABILIZATION
CURRENT (A)
PANELS
10
27 – 31
28
2.8
AREA I
10
34 – 36
35
3.5
AREA I, II
10
34 – 36
35
3.5
AREA I, II, III
10
32 – 33
32
3.2
AREA I, II, III,
IV
Team 4
Data
Constant Current Mode Data
RESISTANCE
VOLTAGE
RANGE (V)
VOLTAGE
STABILIZATION
CURRENT (A)
PANELS
10
32 – 33
32
3.2
AREA I - V
10
48 – 55
50
2.8
AREA I - IV
10
34 – 36
35
3.5
AREA I - III
10
34 – 36
35
3.5
AREA I - II
Team 4
Analysis
Resistance vs. Current
Current vs. Resistance
16
14
Current
12
10
8
6
4
2
0
30
20
10
8
6
Resistance
4
2
1
Team 4
Analysis
Voltage vs.
Resistance
Voltage vs. Resistance
70
60
59.5
55
Voltage
50
48
42
40
34
30
29
20
18
14
10
0
30
20
10
8
6
Resistance
4
2
1
Signal Calculation
Team 4
Voltage (Volt): System voltage
Current (Amp): System voltage/ Shunt
resistance.
PV Power (Watt):


Pin = Vpr*Area (PV)/ Cal
PV Power Out (Watt): V*Current
Signal Calculation
Team 4
Solar Radiation Power (Watt/m2): Psr =
Vpr/Cal
Total Power, Ptotal: Voltage*Current (of
Pv1+Pv2)
Efficiency (%) = Ptotal/Pin*100
Battery Power (Watt): Vbat*Current.
Team 4
Hydrogen System
The power available at given time of year.
(2.7kW Array)
14.0
Power (kW-h/day)
12.0
10.0
8.0
6.0
4.0
2.0
0.0
1
2
3
4
5
6
7
8
9
Month
Avg Power
Min Power
Max Power
10
11
12
Hydrogen System
Team 4
The time needed to fill tanks at time of
year.
2.0
1.8
1.6
Time (days)
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
1
2
3
4
5
6
7
8
9
Month
Avg Power
Min Power
Max Power
10
11
12
Calculations
Team 4
Tank and Electrolyzer Calculations
Power for MSX
5.99Kw-h/day
Power for Millennia
21.16Kw-h/day
Power for BP
13.67Kw-h/day
Total Power to stack
8.98Kw-h/day
H2 Production Rate
38ft3/h @200psi
Energy Consumption
7.00Kw-Hour
Daily insulation data
4.1Kw-h/m2/day
Number of Days Needed to fill
the tanks
0.780Days
Calculations
Team 4
Fuel Cell Calculations
Load
Running Time
250Watts
24hrs
Mass of H2 Required
288.00grams
Mass of H2 in Tanks
1307.51grams
Time Fuel Cell Can
Run on Full Tanks
69.73hrs
Upgraded Camera
DVMR 80/CDN 12
Hardware Features:
It comes with four high quality
digital camera input
All weather Indoor/Outdoor
Rated CDD Cameras
Provides Sony True CCD
Color Quality
Automatic switch to infrared
in Total Darkness up to 30
feet
Has a reusable (record over)
80 gig hard drive
Team 5
Team 5
New Upgraded Camera
Software
Features:
Allows viewing of all cameras
live and recorded video via
internet
Has user name and
password option for security
Has split screen option
Has ability to ZOOM
120 fps (frame per second)
capacity
Order in progress
System Installed
Team 5
Ability to run LabView at all times to
record and store data
Share folders, directories with existing
system.
To be networked wirelessly to the World
Wide Web.
Performed complete diagnostics to
improve its efficiency and latest drivers
installed.
Website
Team 5
Newer accurate documents/pictures
uploaded and linked.
New design/layout applied to the website
to reflect modern design.
The End
Any Questions?