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GRAMM International Future Energy Challenge ‘07

GRAMM International Future Energy Challenge ‘07. Versamachine. Geoff Sanders, Richard Tan, Ankit Tripathi, Maung Myat, and Marc Hesse. Overview. Purpose Specifications System Description System Layout/Breakdown Labor Distribution Future Schedule to meet

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GRAMM International Future Energy Challenge ‘07

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  1. GRAMMInternational Future Energy Challenge ‘07 Versamachine Geoff Sanders, Richard Tan, Ankit Tripathi, Maung Myat, and Marc Hesse

  2. Overview • Purpose • Specifications • System Description • System Layout/Breakdown • Labor Distribution • Future Schedule to meet • Marketability/Impacts and Sustainability • Challenges • Risks and Contingencies • Questions/Suggestions and Comments

  3. Purpose Electric machine (motor): Works both as a starter (motoring) and an alternator (generator) Target: Electric Car, Hybrid Electric Car Reasons: • IFEC ’07 challenge • Save Space • Decrease Cost • Increase Efficiency

  4. Specifications • 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, which is less than 7 inches in diameter http://www.leeson.com/

  5. System Description • A two pole induction machine (motor) • Inverter/Rectifier • Motor 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

  6. System Layout http://www.freescale.com/webapp/sps/site/overview.jsp?nodeId=02nQXGrrlPglzQMszY

  7. Induction Machine (Motor) Squirrel cage induction machine with Variable Frequency (V/f) Control Will work on the principles of • Flux weakening/strengthening • Pole changing • Frequency Change

  8. General Torque-Speed Characteristics

  9. Torque-Speed curve change from starting point (30Nm) to 750 rpm

  10. Torque-Speed curve change from 8 pole (750 rpm) to 4 pole (1500 rpm)

  11. Torque-Speed curve change from 4 pole – 1500 rpm to 2250 rpm

  12. Torque-Speed curve change from 4 pole – 2250 rpm to 3000 rpm

  13. Generalized frequency and speed operation of motor Frequency-time Diagram Speed-time Diagram

  14. BLOCK DIAGRAM

  15. Converter (Inverter/Rectifier) • Converter must fulfill two functions: • Inverter operation during starting and motoring up to 3000rpm • Rectifier operation during generating mode

  16. Inverter • PWM 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 Inverter • Input dc voltage: VDC = 200V • Frequency range: 10-200 Hz • Current at low frequency of 15 Hz: Iline = 30 Apeak • Output voltage as high as possible for given input voltage

  17. Rectifier • Rectifier • 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%

  18. Gate/Motor Drivers • Provide fast change in current to drive the gates of all IGBT/MOSFET switches in the converter

  19. 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

  20. BLOCK DIAGRAM

  21. DSP/Micro-Controller • 3 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

  22. User Interface • PC Master Software • Serial port connection • Later use RF/Bluetooth http://www.freescale.com/files/product/doc/AN1948.pdf

  23. PC Master Support • Freescale • 56F80x • 56F82x • 56F85x • Possibly supported by: • MC68HC08 (MC68HC908MR32) • MC68HC512 • MPC500

  24. PC Master Features • Control the motor • Start-up/shut-down • Speed control • Read/change variables • Scope slower variables • Record fast variables • Stimulate variables • Send application commands with parameters • Display help items (block diagrams, characteristics) • Remote control of application through the internet

  25. PC Master Windows http://www.freescale.com/files/product/doc/AN1948.pdf

  26. Other parts • Voltage regulators • Resistors, capacitors, and heat sinks • Voltage shifters • RAM/ROM • ADC/DAC • RS232 serial port • UART • Clocks

  27. Task Distribution • Maung/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

  28. GANTT CHART

  29. Budget

  30. Marketability • Almost 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 $100 • Possible Patent

  31. 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

  32. 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

  33. Questions / Suggestions http://www.smartquestion.com/images/sq_image.jpg

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