Team HydroFly: Fuel Cell

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1 Team HydroFly: Fuel Cell Team Members: Adam Lint Chris Cockrell Dan Hubbard Sponsors: Dr. Herb Hess Dr. Brian Johnson Overview Project Purpose Project Objective Background (Fuel Cell and AMPS) Basic Design Description Additional Design Considerations Schedule and Budgeting Purpose: Why are we interfacing the fuel cell to the Analog Model Power System? Objective: Interface the Fuel Cell to the Analog Model Power System Alternative Energy Source Flexibility for the AMPS?

What is a Hydrogen Fuel Cell? Different Types Phosphoric Acid Proton exchange membrane (PEM) Solid Oxide (SOFC) Molten Carbonate (MCFC) Alkaline What is a Hydrogen Fuel Cell?

Emissions (water and heat) Portable Capacity of up to 10KW Avista SR-12 PEM Hydrogen Fuel Cell Donated by Genesis FuelTech in 2003 500W Peak Power output (23V - 43V) 12 Fuel Cell Cartridges Spare

2 What is a Hydrogen Fuel Cell? Different Types Phosphoric Acid Proton exchange membrane (PEM) Solid Oxide (SOFC) Molten Carbonate (MCFC) Alkaline What is a Hydrogen Fuel Cell? Operation of a PEM fuel cell Chemical reaction similar to a battery Does not need to be charged as long as hydrogen is supplied Proton exchange membrane (PEM) Low temperature Low Noise Zero Harmful Emissions (water and heat) Portable Capacity of up to 10KW Avista SR-12 PEM Hydrogen Fuel Cell Donated by Genesis FuelTech in W Peak Power output (23V - 43V) 12 Fuel Cell Cartridges Spare Parts Available 80 C Operating Temp. Added Features: Analog Model Power System Acquired from Idaho Power in the mid 1990 s Models a typical power transmission system 1. A fault matrix in which three faults can be placed on the system, either simultaneously or in an evolving manner. 2. The ability to load impedance faults onto the system. 3. SEL (Schweitzer Engineering Labs) relays into the system.

to Converter 23-43V 12V/24V / Converter Purpose: Regulate output voltage from fuel cell to a constant voltage Requirements Input Voltage: 23-43 V (min) Input Current: 25 A (min) Power Rating: 500 W

3 to Converter 23-43V 12V/24V / Converter Purpose: Regulate output voltage from fuel cell to a constant voltage Requirements Input Voltage: V (min) Input Current: 25 A (min) Power Rating: 500 W (min) Output Voltage: 12/24 V / Converter / Converter Wide Input Range (20-45 V) 600 W Power Rating 12 V Output Audible/Visual Indicators MajorVTC / Voltage Converter MajorVTC / Voltage Converter

4 to AC Converter to AC Converter Purchase from Tier Electronics in Oconomowoc, WI 23-43V 12V 12V AC 3-phase AC Specifications: Input Voltage: 12 V +/- 0.5 V Input Current: 50 A Continuous/ 55 A Peak Power Rating: 500 W Output Voltage: 12 VAC 60 Hz to AC Converter Mini Universal Power Converter (UPC) from Tier Electronics Features: 40MHz Re-Programmable TI-2400 series DSP 24KHz PWM Switching frequency (offers greater control) Communication Module for asynchronous serial communication Expansion capabilities for monitoring and controlling external signals Filtering Why? Distortion on the 3-phase AC voltage y( x) x Corrected by using a simple LC Filter

5 Transformer: 12V to 208V AC 12V 12V AC 3-phase 12:208 AC Transformer 208V AC 3-phase Transformer 3 Phase Delta to Delta Configuration Input: 12 Volts AC Output: 208 Volts AC 23-43V : BLOCK DIAGRAM Synchronization 12V 208V AC 3-phase 12V AC 3-phase 12:208 To correctly provide supplemental power to AMPS, our AC signal must be in phase with the system 23-43V AC Transformer Synchronous Signals Voltage/Current Readings : Why? If the two signals are out of phase when connected to each other, massive current spikes will appear and it will take longer for the signal to stabilize.

Synchronization Microprocessor Phase-Lock Loop Fast Response Will accurately correct any error Zero-Point Crossings Sample Rate Frequency 3-Phase Timings TI 2400 Series DSP 16-bit data Fixed-Point

6 Synchronization Microprocessor Phase-Lock Loop Fast Response Will accurately correct any error Zero-Point Crossings Sample Rate Frequency 3-Phase Timings TI 2400 Series DSP 16-bit data Fixed-Point MIPS On-Chip Flash Memory Other Features: A/D Converter, CAN Module, SCI, SPI, Device Protection Schedule Protect from what? Incorrect power flow Exceeding component rating How to protect it? Switches (Control) Fuses Initial Design for Prototypes Project Briefings (w eekly - Semester 1) Design Review Simulation: Interfacing Components to AMPS Ordering Voltage Inverter and Buck Converter Demonstrate Working Simulation Project Report and Notebook Due (Semester 1) Summer Break Project Briefings (w eekly - Semester 2) Interface Fuel Cell Components to AMPS Revise Voltage Control System Finalize Protection Circuitry Complete/Debug Interfacing to AMPS Final Product Demonstration/Release/Final Report 1/31/2005 2/28/2005 3/28/2005 4/25/2005 5/23/2005 6/20/2005 7/18/2005 8/15/2005 9/12/ /10/ /7/ /5/2005 1/2/2006

7 Budget Item Price / Converter $800 /3-Phase AC Converter $2,000 Transformer $125 Hydrogen $45 Design Poster/Report Binding* $15 Project Display Costs* $35 Protection Circuitry $100 Filtering $50 Miscellaneous $300 Total $3,470 Questions? *Cost divided evenly between Fuel Cell and Flywheel Groups

Final Design Review Outline

ydrofly: Fuel Cell Project Final Design Review Outline Group Members: -Adam Lint -Chris Cockrell -Dan ubbard ponsors: -Dr. erb ess -Dr. Brian Johnson Project Objectives Project Introduction Project tatus