2007 International Future Energy Challenge Team Members

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Oscar Casey
6 years ago
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Geoff Sanders Gregory Martin Richard Moutoux Ankit

Tom Brown Dr. Robert Erickson Dr. Dragan Maksimovic Dr.

Gupta Aditya Bhatla Dhruv Vatsal Ekansh Aggarwal Ishita

1 2007 International Future Energy Challenge Team Members University of Colorado - Boulder Maung Myat Richard Tan Geoff Sanders Gregory Martin Richard Moutoux Ankit Tripathi Marc Hesse Dr. Frank Barnes Dr. Ewald Fuchs Prof. Tom Brown Dr. Robert Erickson Dr. Dragan Maksimovic Dr. Regan Zane Indian Institute of Technology - Delhi Megha Gupta Aditya Bhatla Dhruv Vatsal Ekansh Aggarwal Ishita Mukhopadhyay Parag Arora Vineesh Kumar Dr. Bhim Singh Dr. G. Bhuvaneshwari

Competition Test Results Design concepts and basic functionality demonstrated successfully No-load acceleration from 0 to over 2200 rpm in 4 seconds (0 to 2700 rpm in 4.

2 Competition Test Results Design concepts and basic functionality demonstrated successfully No-load acceleration from 0 to over 2200 rpm in 4 seconds (0 to 2700 rpm in 4.5 seconds achieved in CU lab) > 60% generating efficiency at 200 V DC Start-up torque of 10 Nm (22 Nm achieved in CU lab) Successful duration testing: 3 minutes at 1.2 kw generating 9 minutes at 600 W generating

3 ISG System Design Off-the-shelf induction machine has been customized for pole changing and winding switching capability. Off-the-shelf inverter and micro-controller are customized to provide v/f motor control and winding switching signals. Custom switch network reconfigures machine windings as shaft speed changes. induction machine micro-controller inverter rectifier switch network excitation capacitors Rectifier and excitation capacitors generate more than 1 kw at 200 Vdc.

4 Cost and Weight This is a very low cost solution; mass production costs are estimated at ~$ Simple, inexpensive induction machine: $60.00 Inexpensive, basic, portable control and switching electronics: $75.00 Prototype weight is not optimized (14 kg), however weight reductions of more than 6 kg are easily achievable. Aluminum housing Less back iron

5 Project Time-Line Summer 2006: Professor Fuchs suggests entering the competition. Professor Barnes begins to organize team with CU Boulder and IIT Delhi students. Undergraduate team assembled at CU and IIT Delhi. CU Boulder students to do Fall semester independent study on Topic B. September 2006: Proposal submitted for pole changing induction machine concept. Proposal accepted by IFEC committee. Fall 2006: Major design work completed on induction machine design and power inverter topology. Regular working meetings between CU and IIT ongoing, technical collaboration underway. Spring 2007: Fabrication work, including machine customization and procurement of inverter and switches. System assembled and demonstrated at student Capstone Design Expo at CU Boulder. Summer 2007: Maung Myat leads test and design improvements effort with Richard Tan, Geoff Sanders and Professor Fuchs to complete and test the system.

6 Future Work Eliminate excitation capacitors Integrate rectifier with inverter Custom stator core design Custom double squirrel cage rotor design Inverter that can handle high current transients Improve packaging for in-situ custom installation

7 Our team would like to thank Professor Ewald Fuchs 2007 IFEC Committee IEEE and PELS Acknowledgements Boulder Electric Motor Company Hybrids Plus Boundless Corporation Bernard Gordon Prize CU Power Lab (CoPEC) CU Engineering Excellence Fund and UROP Indian Institute of Technology Department of Electrical Engineering University of Colorado at Boulder Department of Electrical and Computer Engineering MPC Products Corp. for support of this project.

8 Back-Up Materials Machine Analysis and Simulation

9 Motoring Performance

10 Starter-Alternator Induction Machine Three Phase AC Squirrel Cage Rotor V E = 4.44 * f * N * Φ Pole Changing 8 pole to 4 pole Winding Switching N reduction by half T = (π/2) * (pole/2)* Φ * F mr * sin δ r Flux Control Volts per hertz

11 Torque-Speed Characteristics of Machine speed [rpm] GENERATION II MOTORING I operating point 3 characteristic 4 characteristic 3 characteristic 2 characteristic Torque [Nm] starting characteristic at 27.5 Hz and 24A line peak by increasing flux Torque curves for each characteristic Characteristic 1 (8-pole) Starting ~ 27Hz, Torque ~ 36Nm f->50hz, speed -> 750rpm Switch to 4-pole operation Characteristic 2 (4-pole) f->50hz, speed -> 1500rpm Characteristic 3 (4-pole) f->75hz, speed -> 2250rpm N reduction (N/2) f->100hz, speed -> 3000rpm Characteristic 4 (4-pole) Speed=3000rpm Generating

12 Winding Switching

13 Power Converter Inverter V/F evolving to DTC (from microcontroller) PWM Controlled MOSFET switches Rectifier/Exciter For battery charging at 200 Vdc and 5 Adc (1kW) Provide exciter current for generating mode Pole Changing Switches Mechanical relays and later electronic switches Winding Switches Mechanical relays and later electronic switches ST Microelectronic Power Board received

14 Micro-controller System Controller ST Microcontroller received Pole and Winding changing switch control User Interface Monitoring and data-logging Debugger mode

15 Alternative Concept - PM Rotor Parallel concept is to use a Variable Flux PM rotor Can be de and re-magnetized with short pulses of stator current. The air gap flux is controllable. More studies and simulations to be performed.

16 Speed-Torque Curves: Characteristic 1

17 Speed-Torque Curves: Characteristic GENERATION II MOTORING I speed [rpm] characteristic 2 at 50Hz and p 2 =4 poles, YY connection characteristic 1 at 50 Hz and p 1 =8 poles, Δ connection Torque [Nm]

18 Speed-Torque Curves: Characteristic GENERATION II characteristic 3 at 75Hz MOTORING I Hz speed [rpm] Hz 60Hz 55Hz characteristic 2 at 50Hz Torque [Nm]

19 Speed-Torque Curves: Characteristic GENERATION II MOTORING I speed [rpm] characteristic 4 at 100 Hz operating point Hz 90 Hz Hz 2000 characteristic 3 at 75 Hz Torque [Nm]

20 Equivalent Circuits: Characteristic 1 R s =4.9Ω X sl =7.72Ω Line + V Δ L L = V Δ " = ( 70 3! 0 )V Line - phrat X rl =6.47Ω Istart X m =62.64Ω (R r /s)=(8.14/s)ω Equivalent circuit of natural characteristic #1 (8 poles) at f rat =50 Hz, n ms =750 rpm, ω ms =78.5 rad/s, delta configuration R s =1.63Ω X sl =2.57Ω X rl =2.16Ω (R r /s)=(2.71/s)ω Line + V phrat = ( 70! 0 )V X m =20.88Ω Neutral - Equivalent circuit of natural characteristic #1 (8 poles) in equivalent Y connection at f rat =50 Hz, n ms =750 rpm, ω ms =78.5 rad/s, using Δ /Y transformation.

21 Equivalent Circuits: Characteristic 1 & 2 Line + R TH =1.274Ω X TH =1.4214Ω X rl =2.16Ω (R r /s)=(2.71/s)ω V phrat = ( 70! 0 )V Neutral - I start Equivalent circuit of natural characteristic #1 (8 poles) in Thévenin (TH) equivalent Y connection at f rat =50 Hz, n ms =750 rpm, ω ms =78.5 rad/s. R s =6.06Ω X sl =3.62Ω X rl =1.81Ω (R r /s)=(1.27/s)ω Line + V phrat = ( 70! 0 )V X m =39.94Ω Neutral - Equivalent circuit of natural characteristic #2 (4 poles) at f rat =50 Hz, n ms =1500 rpm, ω ms =157 rad/s, double Y configuration

22 Equivalent Circuits: Characteristic 3 & 4 R s =3.03Ω X sl =1.36Ω X rl =0.34Ω (R r /s)=(0.31/s)ω Line + V phrat = ( 70! 0 )V X m =15.69Ω Neutral - Equivalent circuit of natural characteristic #3 (4 poles) f rat =75 Hz, n ms =2250 rpm, ω ms =236 rad/s, double Y configuration, reduced # of turns from N rat to N rat /2 R s =3.03Ω X sl =1.81Ω X rl =0.45Ω (R r /s)=(0.31/s)ω Line + V phrat = ( 70! 0 )V X m =21.34Ω Neutral - Equivalent circuit of natural characteristic #4 (4 poles) f rat =100 Hz, n ms =3000 rpm, ω ms =314 rad/s, double Y configuration with N rat /2

23 8 Pole Winding Configuration and MMF 8-pole configuration N rat turns per phase Δ winding connection

24 4 Pole Winding Configuration and MMF 4-pole configuration N rat turns per phase Y-Y winding connection

25 Inverter Simulation in Pspice Starting currents obtained from PSpice simulations based on P-control at 50 Hz PSpice result operating at 27.5 Hz

26 Inverter Simulation in Matlab Matlab result of characteristic 1 with frat=50 Hz Matlab result of characteristic 1 with frat=27.5 Hz

An Integrated Starter-Alternator System Using Induction Machine Winding Reconfiguration

2007 International Future Energy Challenge Invited Paper: An Integrated Starter-Alternator System Using Induction Machine Winding Reconfiguration Richard Moutoux Gregory Martin Richard Tan Maung Myat Geoff