Transcript GRAMM International Future Energy Challenge ‘07 Geoff Sanders, Richard Tan, Ankit Tripathi, Maung Myat, and Marc Hesse.

GRAMM
International Future Energy Challenge ‘07
Geoff Sanders, Richard Tan, Ankit Tripathi,
Maung Myat, and Marc Hesse
Overview
Purpose & Specifications
System Description
Electric Machine
Power Converter
Controller Circuit
In-circuit Debugger
Other parts and purchases
Updated Labor Distribution
Updated detailed schedule
Questions/Suggestions and Comments
Purpose & Specifications
Electric machine (motor):
Works both as a starter (motoring) and an alternator (generator)
Must provide 30 Nm of Torque startup.
Must motor up to 3000 rpm in 3-5 seconds
Must generate 1 KW of power
Must be at least 75% efficient
Must use NEMA frame 56
Target:
Hybrid Electric Car
Reasons:
IFEC ’07 challenge
Save Space
Decrease Cost
Increase Efficiency
System Description
Starter-Alternator Unit (motor)
Pole Changing, ‘N’ winding reduction, Flux based design
Power Converter
Power Board (STEVAL-IHM009V1)
Inverter/Rectifier
Generator exciter
System Controller
Control Board (STEVAL-IHM001V1)
Chip (ST7FMC2)
Gate Drivers (MOSFET DRIVER)
User Interface (On-Off switch, emergency switch)
Indart series debugging board (INDART-STX/D)
ST7 Debugger Program
Control panel software (AK-ST7FMC)
Test Set-Up
dynamometer
(drive and brake)
dyno
control
belt drive
coupling
machine power
feeders
electric machine
(NEMA 56)
torque
measurement
system controller
power converter
shaft position
measurement
PC
200 VDC
Mock Set-up with already acquired
parts
Electric Machine Hardware
Received free 3-phase ¾ hp squirrel
cage induction machine
Measured parameters and weight
Determined that the slot count is 36
(we need 24 slots)
Allowed us to specify the exact
machine we need
Baldor M3155 3-phase squirrel
cage induction machine
2 hp (1.49 kW)
3450 rpm, 2 pole
24 slots, 12.4 in. long, 6.8 A max
NEMA 56 frame
Will test, then re-wind machine for
8-4 pole configuration
Torque-Speed Characteristics of Machine
Torque curves for each characteristic
4500
4000
GENERATION
MOTORING
II
I
Characteristic 1 (8-pole)
• Starting ~ 27Hz, Torque ~ 36Nm
• f->50Hz, speed -> 750rpm
• Switch to 4-pole operation
operating point 3
3500
characteristic 4
speed [rpm]
3000
2500
characteristic 3
Characteristic 2 (4-pole)
2000
characteristic 2
• f->50Hz, speed -> 1500rpm
1500
characteristic 1
1000
Characteristic 3 (4-pole)
500
0
-30
-20
-10
0
10
Torque [Nm]
20
30
starting characteristic
at 27.5 Hz and 24Aline peak
by increasing flux
V  E/f = 4.44 * N * 
T = (/2) * (pole/2)*  * Fmr * sin r
40
• f->75Hz, speed -> 2250rpm
• N reduction (N/2)
• f->100Hz, speed -> 3000rpm
Characteristic 4 (4-pole)
• Speed=3000rpm
• Generating
8 Pole Winding Configuration and MMF
8-pole configuration
Nrat turns per phase
 winding connection
4 Pole Winding Configuration and MMF
4-pole configuration
Nrat turns per phase
Y-Y winding connection
Winding Switching
4-pole configuration
Nrat /2 turns per phase
Y-Y winding connection
Power Converter Board
AC Induction Motor Control
Power board SEMITOP®3 3kW
(STEVAL-IHM009V1)
Power Converter:
Block Diagram
200V Power
Supply
HV Monitoring
Control Board
PWM Input
Power
Regulation
Three Phase
Inverter
(STG3P3M25N60)
BEMF
Temperature
Sensor
Tachometer
Brake Motor
AC Induction
Machine
STG3P3M25N60
3 Phase inverter
IGBT - SEMITOP®3 module
General features
N-channel very fast PowerMESH™ IGBT
Lower on-voltage drop (Vcesat)
Lower CRES / CIES ratio (no cross-conduction
susceptibility)
Very soft ultra fast recovery anti-parallel diode
High frequency operation up to 70 KHz
New generation products with tighter
Parameter distribution
One screw mounting
Compact design
Semitop®3 is a trademark of Semikron
VIPer12ADIP - E
Low Power OFF-Line SMPS Primary Switcher
Description
The VIPer12A combines a dedicated current mode PWM controller with a high voltage Power MOSFET
on the same silicon chip.
The internal control circuit offers the following benefits:
Large input voltage range on the VDD pin accommodates changes in auxiliary supply voltage.
This feature is well adapted to battery charger adapter configurations.
Automatic burst mode in low load condition.
Over-voltage protection in HICCUP mode.
Features
Fixed 60kHZ Switching Frequency
9V to 38V Wide Range VDD Voltage
Current Mode Control
Auxiliary Under-voltage Lockout with Hysteresis
High Voltage Start-up Current Source
Over-temperature, Over-current and
Over-voltage Protection with Auto-Restart
L78L05ACZ
POSITIVE VOLTAGE REGULATOR
OUTPUT CURRENT UP TO 100 mA
OUTPUT VOLTAGE OF 5V
THERMAL OVERLOAD PROTECTION
SHORT CIRCUIT PROTECTION
NO EXTERNAL COMPONENTS ARE REQUIRED
AVAILABLE IN EITHER ±5% (AC) OR ±10% (C)
SELECTION
Silicon Avalanche Diodes (P6KE Series)
600 Watt Axial Leaded Transient Voltage Suppressors
FEATURES
RoHS Compliant
6.8 to 550 Volts
Uni-directional and Bi-directional
Glass passivated chip junction in DO-15 Package
600W surge capability at 10/1000μs wave form
Excellent clamping capability
Low zener impedance
Fast response time: typically less than 1.0ps from 0 Volts to BV min.
Typical IR less than 1μA above 10V
Power converter’s schematic
System controller Board
AC Induction Motor Control
Control Board
STEVAL-IHM001V1
ST7MC2 44-Pin LQFP Package Pin-outs
System controller’s schematic
System Controller:
Block Diagram
Potentiometers
Connector
SPI
EEPROM
(M95040)
ICC
Interface
A/D
Converters
PWM
Generator
Bridge
Drivers
(L6386)
SPI
Interface
ST7FMC2
Feedback
Switches
16 KB
FLASH
Memory
768 Bytes
RAM
LEDs
16 MHz
Oscillator
Power Board
Debug
Board
ICC
PWM Timing
MCMP0 Register
Phase U Preload
Register
Phase V Preload
Register
Phase W Preload
Register
Phase U
Waveform
Phase V
Waveform
Phase W
Waveform
System Controller Flowchart
Initialize
Peripherals
Main Loop
Check State
Send System
Data (RS232)
Interrupts
Event U
Idle
Start
Run
Reload PWM
Duty Cycle
Event R or Z
Stop
Update LEDs
Brake
Wait
Fault
Check for
Errors
Event C or D
Tachometry
Emergency
Stop
Stop Motor
ART Reset
Update
Counters
SCI
Send Data
External
User Interface/Debugger
Testing the Control/Power board
Why use inDart-STX?
Real time code execution without Probes
In-Circuit debugging
Hardware and software testing in real time
Built in FLASH programmer (Data Blaze Programming utility)
Visual Debug user interface (with integrated C compiler and assembler
and source level symbolic debugging)
Hardware self diagnostic test
Working frequency as high as the microcontroller itself
Allows for programming the content of FLASH when chip already is
in the circuit
Uses ICC (In circuit communication to interface the programming tool
like inDART) with the microcontroller we have
User Interface/Debugger
inDart-STX
Pin out for inDART
ST7 Debugger Program
PC Interface Controller
Control panel software (AK-ST7FMC)
Other Parts Purchased for Testing
Safety
Face shield
Safety shield
Distribution of Work
Geoff
Custom Motor
Programming the micro-controller
Richard
Custom Motor
Calculation and simulation with the actual motor parameters
Maung
Custom Motor
PCB layout for the 64 pins controller
Ankit
Custom Motor
Permanent motor design/ Programming the micro-controller
Marc
Programming the micro-controller
Documentation
Gantt Chart
Milestone 1
Test system using regular induction machine
With 64 pin controller board (1st revision)
Should work the same as purchased 44 pin
controller board
Custom machine nearly finished
Switching circuit complete (wire wrap)
Milestone 2
Complete system test with:
Custom machine finished
Completed switching circuit PCB
Pole changing ability confirmed
Final Open-Lab Expo
Complete closed-loop operation of:
Custom pole changing induction machine
implementing N reduction
Meeting the basic IFEC requirements
Documentation complete
Thank you!
Questions / Comments
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