GRAMM International Future Energy Challenge

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

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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

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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/
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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

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System Layout
http//www.freescale.com/webapp/sps/site/overview.
jsp?nodeId02nQXGrrlPglzQMszY
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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

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General Torque-Speed Characteristics
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Torque-Speed curve change from starting point
(30Nm) to 750 rpm
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Torque-Speed curve change from 8 pole (750 rpm)
to 4 pole (1500 rpm)
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Torque-Speed curve change from 4 pole 1500 rpm
to 2250 rpm
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Torque-Speed curve change from 4 pole 2250 rpm
to 3000 rpm
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Generalized frequency and speed operation of motor
Frequency-time Diagram
Speed-time Diagram
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BLOCK DIAGRAM
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Converter (Inverter/Rectifier)

• Converter must fulfill two functions
• Inverter operation during starting and motoring
  up to 3000rpm
• Rectifier operation during generating mode

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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

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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 _at_ 10 ADC maximum or
  at least deliver 1 kW to the battery at 200V with
  efficiency of 75

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Gate/Motor Drivers

• Provide fast change in current to drive the gates
  of all IGBT/MOSFET switches in the converter

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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

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BLOCK DIAGRAM
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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

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User Interface

• PC Master Software
• Serial port connection
• Later use RF/Bluetooth

http//www.freescale.com/files/product/doc/AN1948.
pdf
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PC Master Support

• Freescale
• 56F80x
• 56F82x
• 56F85x
• Possibly supported by
• MC68HC08 (MC68HC908MR32)
• MC68HC512
• MPC500

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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

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PC Master Windows
http//www.freescale.com/files/product/doc/AN1948.
pdf
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Other parts

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

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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
• Users Manual
• Micro-controller coding
• Technical manual compilation
• All
• Documentation
• Test/debug
• Wire-wrap prototyping

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GANTT CHART
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Budget
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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

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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

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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

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