LOW CARBON FOOTPRINT HYBRID BATTERY CHARGER FINAL PRESENTATION

Transcription

1 LOW CARBON FOOTPRINT HYBRID BATTERY CHARGER FINAL PRESENTATION Students: Blake Kennedy, Phil Thomas Advisors: Mr. Gutschlag, Dr. Huggins Date: May 1,

2 PRESENTATION OUTLINE Project Overview Design Buck-Boost Theory Design Iterations Closed Loop Control Lead Acid Fast Charge IC Results Future Recommendations Questions 2

3 INTRODUCTION Emphasize efficient energy collection Photovoltaic arrays Wind turbine Minimize utility A.C. energy Store renewable energy Charge a mobile battery for vehicular applications using renewable energy

4 PREVIOUS RESEARCH What has been created by others? What is new with our project? All systems combined to charge a vehicle battery Utilization of battery to battery charging How can this be done? 4

5 HIGH LEVEL SYSTEM BLOCK DIAGRAM Solar Energy Renewable Energy Wind Energy Voltage/Current sense leads Key: = Primary Objective = Extended Objective (if time permits) = Power Flow = Control Signal Stationary Battery Charger Stationary Battery Voltage/Current sense leads AC Energy Select Menu Keypad Max Battery Life (On/Off) Min. Charge Time (On/Off) Battery Charging (On/Off) Percent Battery Full AC to DC converter Emergency Charge Microcontroller System Time Remaining Liquid Crystal Display Mobile Battery Charger Power Control System 5 Mobile Battery Voltage/current sense leads

6 LOW LEVEL FLOWCHART 6

7 RENEWABLE ENERGY Photovoltaic (P.V.) Array BP 350J 50W, 17.5V, 2.9A at max power Provide sufficient energy to charge the mobile battery given worst case conditions 7

8 RENEWABLE ENERGY Mobile Battery Load = 648 kj BP 350J Efficiency = % Worst Case: sun hours per day Worst Case Solar Power Energy = 206,449 J/day Min Number of P.V. Arrays = 2.45 P.V. Arrays 8

9 RENEWABLE ENERGY Wind Energy 1.2 kwh/day average at 50m Simulated with D.C. power supply Southwest Wind Power Air-X Start up wind speed: 7 M.P.H. Rotor Diameter: 46 in. Max Power: 28 M.P.H Vout= 24VDC Competitive Cost 9

10 LOW LEVEL FLOWCHART 10

11 BUCK-BOOST THEORY 11

12 BUCK-BOOST VERIFICATION Simulated basic circuit using P-spice D V1 2 L1 DMBRF1045 1m R2.3 NDP4060/FAI M1 C1 500u 200 R3 100 R VB VS VCC COM LO U1 VDD HIN SD LIN VSS HO IR V2 V1 = 0 V2 = 15 TD = 0 TR = 1n TF = 1n PER = 20u PW = 10u V_BATT 15Vdc 0 12

13 BUCK-BOOST SCHEME Continuous mode- Inductor Current 13

14 BUCK BOOST PSPICE SIMULATIONS Minimum Input 6V with a 75% Duty Cycle 14

15 BUCK BOOST PSPICE SIMULATIONS Maximum Input 40V with a 25% Duty Cycle 15

16 BUCK-BOOST IMPLEMENTATION IR2113 Low-side Driver D V1 2 L1 DMBRF1045 1m R2.3 NDP4060/FAI M1 C1 500u 200 R3 100 R VB VS VCC COM LO U1 VDD HIN SD LIN VSS HO IR V2 V1 = 0 V2 = 15 TD = 0 TR = 1n TF = 1n PER = 20u PW = 10u V_BATT 15Vdc 0 16

17 BUCK-BOOST IMPLEMENTATION IR2113 High-side Driver D1 DMBRF V1 VB VS 1 2 L1 400u R2.3 M2 IRFP240 C1 220u R4 10 R3 100 V2 V1 = 0 V2 = 5.0 TD = 0 TR = 10n TF = 10n PW = 25u PER = 50u 5 V_BATT VDD HIN SD LIN VSS HO U1 IR2113 VB VS VCC COM LO VB VS R V_BATT 10Vdc 17

18 BUCK-BOOST IMPLEMENTATION HPCL-3120 High-side driver Vcc D1 DMBRF1045 L1 800u C1 220u VIN R2.02 M3 IRFP240 1 PWM 2-Anode BATT - 3-Cathode 4 R7 100 HCPL Vcc 7-Vo 6-Vo 5-Vee Vcc Vee 18 Vee

19 BUCK-BOOST IMPLEMENTATION Topology Change 19 D4 1N4744A M3 IRF9520 C2 1n L1 800u 1 2 C1 220u 200 Neg_Vin D2 DMBRF1045 5V 0 R2.02 R6 1k 0 R7 520 VIN 31 D1 DMBRF1045 PWM 0 U1 IR VDD HIN SD LIN VSS HO VB VS VCC COM LO D3 1N C4 3300u 50 Pos_Vin Pos_Vin

20 BUCK-BOOST IMPLEMENTATION Optical Isolator with Linear Voltage Regulator Pos_Vin C2 22n R6 4.7 M3 IRF9520 D3 1N4748 R9 100 IRF9520 M4 R7 100 IRF640 M5 R8 100 PWM 0 HCPL Vcc 2-Anode 7-Vo 3-Cathode 6-Vo 4 5-Vee -15V 3 C7 1u LM C8 2.2u 0 31 VIN D u C4 1 2 L1 800u D1 STPS20120D C1 220u 200 R2.02 Neg_Vin 20 0

21 BUCK-BOOST IMPLEMENTATION UA78S40 Universal Switching Regulator Subsystem Provides PWM Closed Loop Control 21

22 BUCK-BOOST IMPLEMENTATION Inverting Configuration Vout = 1.25 RC1/(RC2+RC3) UA78S40 PWM C3 1 Diode Neg 2 Diode Pos 3 Emitter 4 OpAmp Out 5 OpAmp Vcc 6 OpAmp Pos 7 Opamp Neg 8 Vref Out SW C 16 Driver C 15 Ipk Sense 14 Vcc 13 Timing Cap 12 GND 11 Compare Neg 10 Compare Pos 9 Ct1 470pF 0 5V Vout RC1 110K 0 220uF RC3 1k RC2 10K 22

23 LOW LEVEL FLOWCHART 23

24 STATIONARY BATTERY Reduces mobile battery charge time Capacity needed determined by: What is practical from cost standpoint Stationary battery decay vs. mobile battery Must be at least 180Wh 24

25 STATIONARY BATTERY Optima D31T Lead Acid 75 Ah,12V Low cost No Memory Effect 25

26 STATIONARY BATTERY CHARGER Can accept max input values Voltage: 30V (from renewable energy) Current: 10A Charges to maximize life Provide over current / voltage protection to battery 26

27 STATIONARY BATTERY CHARGER BQ2031- Lead Acid Fast Charge IC Automatically detects low current and switches to trickle charge Temperature-compensated charging Automatically detects shorted, opened, or damaged cells Provides binary state of charge status PWM Control Two-Step Voltage Control 27

28 STATIONARY CHARGER SCHEME BQ2031 Two-Step Voltage Charge 28

29 STATIONARY CHARGER SCHEME BQ2031 Stationary battery specific configuration Switching frequency = 100KHz Will charge between 32 ⁰ F and 106 ⁰ F Over current protection = 10A Voltage regulation = 14.3 V 29

30 STATIONARY CHARGER SCHEME Pos_Vin C2 22n R6 4.7 M3 IRF9520 D3 1N4748 R9 100 IRF9520 M4 R7 100 IRF640 M5 R8 100 PWM 0 HCPL Vcc 2-Anode 7-Vo 3-Cathode 6-Vo 4 5-Vee -15V 3 C7 1u LM C8 2.2u 0 1 C6.33u LM C5.1u BATT - 31 VIN D u C4 1 2 L1 800u R2.02 D1 STPS20120D C1 220u 200 PWM C3 UA78S40 1 Diode Neg 2 Diode Pos 3 Emitter 4 OpAmp Out 5 OpAmp Vcc 6 OpAmp Pos 7 Opamp Neg 8 Vref Out SW C 16 Driver C 15 Ipk Sense 14 Vcc 13 Timing Cap 12 GND 11 Compare Neg 10 Compare Pos 9 Ct1 470pF 0 5V Vout RC1 110K Neg_Vin uF RC3 1k VCC 5V RC2 10K M2 IRFP240 BATT + BATT + PWM2 BATT - RB1 130k RB3 620k RB2 50k RT2 19.2k RT1 9.4k MTO-N.C. RT 10k- 110k DSEL= 0 for Mode 1 Display Output (resistor to GND) TSEL= 0 for Two-Step Voltage Charge (resistor to GND) QSEL=0 for Two-Step Voltage Charge (resistor to GND) IGSEL=0 for Imin= 1A MTO=24hrs Open Circuit for Max RT1, RT2= Charging stops when greater than 105F and restarts at 85F RB1, RB2, RB3= Float Voltage=13.3V; IMax=10A; Battery charges at 14V R4 LED LED k 3 14 PWM2 Pull-Down DSEL k COM COM 7 10 R3 LED1 8 9 LED1 BQ2031 Pull-Down TSEL 1k CT 10k 1n R5 LED3 LED3 Pull-Down QSEL 10k 1k BATT - 30

31 LOW LEVEL FLOWCHART 31

32 MOBILE BATTERY CHARGER Accepts energy from stationary battery Must be capable of outputting Voltage: 14.9V Current: 4.8A The mobile battery charger shall be capable of charging the mobile battery within at least 12 hours 32

33 MOBILE BATTERY Panasonic LC-RA1212P for Gaucho 12V lead-acid battery Rated capacity: 12Ah Minimal charge time 2 hours 39 minutes Maximum battery life 2-8 years charge cycles Constant Voltage Charge 33

34 USER INTERFACE Keypad input User selects mode of charge L.C.D. output Battery charging indicator Battery charge percentage indicator Time remaining until battery charged indicator 34

35 ACTUAL RESULTS Buck boost topology, gate drivers, and regulation works 35

36 ACTUAL RESULTS Buck- Boost Results with feedback 36

37 ACTUAL RESULTS BQ2031 Indicates it passes qualification tests Still need to implement gate driver and FET 37

38 POTENTIAL IMPROVEMENTS Implement Mobile Battery Charger Microcontroller Feedback Use switching voltage regulators instead of linear N-channel MOSFET with floating gate drive on buck-boost Clean up noise in voltage regulation Create more protection circuitry 38

39 QUESTIONS? 39

40 STATIONARY BATTERY Possible battery choices Optima Li-Ion Ni-CD Ni-MH Sealed Lead Acid Lead Acid Temperature Range (C) 130 to to to to to -40 Calendar Life (years)? 2 to 5 2 to 5 2 to 5 2 to 8 Max Charge Cycles to to to 500 Discharge Profile Flat Slope Flat Flat Flat Self Discharge 20C (% /mo) Very Low 2 15 to to 25 4 to 8 Memory Effect No No Yes Yes No Ability to Trickle Charge Yes No Yes Yes Yes Charging Characteristic 2 stage Deep Discharge Yes Yes Yes Yes No Relatively Quick Charge Yes Yes Yes Yes No Constant Voltage Or Voltage Voltage Current Current Voltage Current Charge Relative Expense/ Capacity Cheap Expensive Moderate Moderate Cheap Approx Expense (dollars) 150 <

41 STATIONARY CHARGER SCHEME BQ2031 Configuring Charging Algorithm 41

42 STATIONARY CHARGER SCHEME BQ2031 Voltage and Current Monitoring 42

43 STATIONARY CHARGER SCHEME BQ2031 Voltage and Current Monitoring N=6 cells Vflt=13.3V Vblk=14.0V Imax=10A Using Equations RB1=130KΩ RB2=50KΩ RB3=620KΩ 43

44 STATIONARY CHARGER SCHEME BQ2031 Fast Charge cutoff to Trickle Charge IGSEL = 0 Imin = Imax/10 = 10A/10 = 1A 44

45 STATIONARY CHARGER SCHEME BQ2031 Temperature Sensing 45

46 STATIONARY CHARGER SCHEME BQ2031 Setting Charging Maximum Timeout Tmto=24hours R=24hrs/(.5*.1uF) = 480GΩ Use largest resistance possible or open circuit 46

47 STATIONARY CHARGER SCHEME BQ2031 Set switching frequency Fpwm=100KHz 47

48 MICROCONTROLLER REQUIREMENTS Microcontroller switches IC charging mode Feedback loop handled by IC Keypad user input 1 port needed LCD user output 1 port needed Port pin IC input 3 pins needed for status Port pin IC output 1 pin needed for switching modes 48

49 BUCK-BOOST IMPLEMENTATION IR2113 High and Low Side Driver Ability to operate at 100KHz Separate logic supply range from 3.3V to 20V LO = Vdd = Vbatt = V 49