Arctic Power System Intermediate Design Review

Arctic Power SystemIntermediate Design Review

Lisa Ferguson, Emily Davy, Dylan Schindler, Austin Sverdrup, Dee Dozier

Overview

• Product Structure• Subsystems

• Overview• Block Diagram• Schematics• Critical Components

• Microcontroller• APS Housing• Schedule

2Arctic Power System Intermediate Design Review

Product StructureDee Dozier


Product Structure DiagramRev. Doc Number:

T1 APS 065-0084-00

003-0084-00066-0084-00

366-0084-00

Software Assembly and Test Docs Hardware005-0084-00008-0084-00

Microprocessor Sensors Output Conversion AC Subsystem Hydrogen Subsystem Solar Subsystem Capacitor

200-0391-00 200-0392-00 200-0386-00 200-0387-00 200-0388-00 200-0389-00 200-0390-00


APS Subsystems

• Output Conversion• AC Conversion• Hydrogen Conversion• Solar Conversion• Arctic Power Microprocessor• Arctic Power Sensor


Power Inputs

• AC Input• Solar Panel Input• Hydrogen Fuel Cell Input

• 5V Line• 12V Line• 3.3V Line - Microcontroller

Power Outputs


Power InputsLisa Ferguson

Arctic Power System Intermediate Design Review 7

AC Input


Overview

• Input• 64 VRMS – 186 VRMS

• Regulated Output• 12 Volts• 2 Amps

• Surge Stopper• Load Switch• Protection Diode


Block Diagram

Grid Matched AC Power

AC/DC Converter Surge Stopper Load Switch

• USA or European mains wall power

• Wind turbine• Diesel generator

• 20 watt converter• 12 VDC / 1.67 A

regulated output• 3000 VAC isolation

voltage• Continuous short

circuit protection

• Surge Stopper• Circuit Breaker• Current Limit• Reverse Current

Blocking• Reverse Input

Protection• Reverse Output

Protection

• Input Voltage: 3 –20 Volts

• Constant Current: 2.3 Amps

• Surge Current: 10 Amp

• Controlled by Microcontroller

Protection Diode

• Schottky Diode• Maximum Voltage:

30 Volts• Maximum Current:

100 Amps• Voltage Drop:

400 µAmps @ 30V


SchematicsAC / DC Converter Load Switcher


Schematic – Surge Stopper


Critical Components

• RECOM 20W Single Output • RAC20-12SB

• Linear Technology Surge Stopper• LTC4364-1

• Fairchild Load Switch• FDC6330L

• Vishay Protection Diode• SSB43LHE3_A/I


Solar Panel Input


Overview

• Input• 3 – 20 Volts Input• 18 Volts – Optimal• 1.11 Amps – Optimal

• Regulated Output• 12 Volts• 1.67 Amps



Block Diagram

20 Watt Solar Panel

Buck / Boost Power

ArchitectureSurge Stopper Load Switch

• Optimal Voltage: 18 Volts DC

• Optimal Current: 1.11 Amps

• Operational Temperature Range: -40˚C - 80 ˚C

• Charge Controller Available

• TI LM25118 based Wide-Rage Buck Boost

• Input: 3 – 20 Volts DC

• Regulated Output: 12 Volts DC / 2 Amps

• Designed using TI Webench




Protection





Protection Diode




400 µAmps @ 30V


Schematic – Buck/Boost




Buck/Boost Architecture

• TI LM25118• Efficiency: 95%• Power Dissipated: .35 Watts• Power Output: 1.05 Watts – Maximum• Duty Cycle: 61%• Output Current: 20 A – Maximum• BOM Count: 38 components


Hydrogen Fuel Cell Input


Overview

• Input• 7.8 Volts – Optimal• 2.56 Amps – Optimal

• Regulated Output• 12 Volts• 2 Amps



Block Diagram

20 Watt Hydrogen Fuel Cell

Boost Power ArchitectureSurge Stopper Load Switch

• Optimal Voltage: 7.8 Volts DC

• Optimal Current: 2.6 Amps

• Provided power control line from APS

• Simulated for testing purposes

• TI TPS61088 based Boost

• Input: 3 –10 Volts DC

• Regulated Output: 12 Volts DC / 2 Amps





Protection


• Output Current: 2.3 Amps



Protection Diode




400 µAmps @ 30V


Schematic - Boost




Buck Architecture

• TI LM25118• Efficiency: 97.14%• Power Dissipated: .58 Watts• Power Output: 20 Watts – Maximum• Duty Cycle: 75.5%• Output Current: 20 A – Maximum• BOM Count: 21 components


Capacitor Storage Bank


Overview

• Maxwell Technologies Supercapacitor• Capacitance: 58 Farad• Rated Voltage: 16.2 Volts DC• Maximum Voltage: 17 Volts DC• Operating Temperature: -40˚C - 65 ˚C• 10 Year operational lifespan• 4 years storage lifespan• Shock and Vibration rated

• Current draw from capacitor: ~2.7 Amps


Schematic – Capacitor Bank


Power OutputsEmily Davy


5V Output


Subsystem Overview

• Input• 3 Volts – Minimum• 17 Volts - Maximum

• Regulated Output• 5 Volts – Maximum• 4 Amps – Maximum

• Surge Stopper• Load Switch• Female USB-A Connector


Block Diagram

Capacitor Bank

Buck / Boost Power

Architecture

Surge Stopper Load Switch


• Provides “reaction time” for Microcontroller to react

• 6 minutes operation stored energy




Protection

• Input Voltage: 3 – 20 Volts




Crowbar Circuit

• Analog protection for external load

• Resettable fuses allow for operation after circuit trip


• Input: 3 – 17Volts DC

• Regulated Output: 5 Volts DC / 4 Amps Maximum


Output

• Female USB-A• No data

transmitted


Schematics – Buck/Boost




Schematic - Crowbar



• TI LM25118• Efficiency: 88.7%• Power Dissipated: 2.54 Watts• Power Output: 20 Watts – Maximum• Duty Cycle: 31.3%• Output Current: 20 A – Maximum• BOM Count: 31 components


12V Output


Overview


• Regulated Output• 12 Volts – Maximum• 1.67 Amps – Maximum

• Surge Stopper• Load Switch• Male Barrel Jack


Block Diagram

Capacitor Bank

Buck / Boost Power

Architecture

Surge Stopper Load Switch







Protection

• Input Voltage: 3 – 20 Volts




Crowbar Circuit

• Analog protection for external load

• Resettable fuses allow for operation after circuit trip



• Regulated Output: 12 Volts DC / 1.67 Amps Maximum


Output

• Male Barrel Jack

• Energized Center pin

• Grounded barrel






Schematic – Crowbar



• TI LM25118• Efficiency: 91.5%• Power Dissipated: .95 Watts• Power Output: 20 Watts – Maximum• Duty Cycle: 71.5%• Output Current: 20 A – Maximum• BOM Count: 38 components


3.3V Output


Overview


• Regulated Output• 3.3 Volts – Maximum• 460 mAmps – Maximum

• Surge Stopper


Block Diagram

Capacitor BankBuck / Boost

Power Architecture

Surge Stopper






• Regulated Output: 3.3 Volts DC / 460 mAmps





Protection

Microcontroller

• TI Delfino Family Microcontroller

• Maximum Voltage: 3.3 Volts

• Maximum Current: 360 mAmps

• Hibernate Current: 300 μAmps







• TI LM25118• Efficiency: 81.2%• Power Dissipated: .35 Watts• Power Output: 1.52 Watts – Maximum• Duty Cycle: 20.9%• Output Current: 20 A – Maximum• BOM Count: 28 components


MicrocontrollerDylan Schindler


Overview• Microcontroller• Current/Voltage Measurement Circuitry

• ADC modules for measurements • Comparator modules for detection

• Humidity/Temperature Sensor• Measure relative humidity/temperature • Provide alarm when certain humidity reached

• USB Interface• Export binary data files to external system • Allow external system to send commands to MCU

• Load Switching• MOSFET IC with GPIO pin control

Microcontroller - TMS320F2837xS Delfino

Microcontroller - TMS320F2837xS Delfino

• 1MB ECC-Protected Flash Memory• Windowed Watchdog Timer with two zero-pin 10-MHz Oscillators

• Support for external clock reference• Various Low-Power Modes• Two I2C Interfaces• Four 12-Bit ADC Modules (24 external channels)• Eight 12-Bit Windowed Analog Comparators• Peripheral Interrupt Controller• Launchpad available

Block Diagram-Power/Signal

Block Diagram-Voltage/Current Measurement

Voltage/Current Measurements

• 7 Voltage/ 9 Current• 12-Bit ADC module

• Read voltage as needed• Use known resistor value ahead of pin to calculate current

• 12-Bit Windowed Comparator• Provide interrupt• Used with Surge Stoppers• Detect No-Load, Voltage/Current Surges, faults within the system

Voltage/Current Measurements - Circuitry

TransorbOp-Amp

1Op-Amp

2

ADCINA1

ADCINA2

0 –

20 V

0 – 20 V 0 – 20 V -3.3 – 0V

3.3 – 0V

3.3 – 0V

R

Voltage/Current Spike

• Use comparators for interrupts• Voltage < 3V• First three measurement systems

• Check Surge Stopper fault pin• Use pin to determine type of spike

• Reset Surge Stopper

Block Diagram-Humidity/ Temperature

Humidity/Temperature

• Honeywell Humdicon HIH6031-021• 14-Bit I2C output• +/- 4.5 %RH & +/- 1.0 °C accuracy• Alarm High/Low for %RH

USB Interface

• Native USB 2.0 PHY support• Full-Speed (12 Mbps) and Low-Speed (1.5 Mbps)

• Transfer Types: Control, Interrupt, Bulk• Can operate as device or host• 4KB dedicated endpoint memory• Internal Oscillator doesn’t meet standards

• Use external 20MHz crystal oscillator with 10ppm (~15 min/year drift)

Schematic – Microcontroller Pin-Out

APS HousingAustin Sverdrup


Boundary Shielding

Weatherproof Shielding for :• Power inputs

• Connected and disconnected• Power outputs

• Connected and disconnected• Hydrogen control line

• Connected and disconnected

Environmental Shielding

• Precipitation• Particulates• Relative Humidity• Ambient Internal Temperature• Ambient External Temperature

APS Access

• The system housing shall allow access to the internal APS• Annual Maintenance

• Shall provide a means of accessing the stored APS data logs without exposing the APS to the environment

• Shall provide a means of accessing the APS GPIO control lines without exposing the APS to the environment

Nonfunctional Requirements• Minimum Volume

• 50 x 50 x 50 cm

• Weight• No more than 10 kg

• Mechanical Shock• Shall withstand a fall from 1 m onto a hard, flat surface

• Vibration• Shall withstand a sinusoidal vibration sweep from 10 Hz to 500 Hz

• External Ambient Temperature• Shall operate between -40°C to 40°C

APS ScheduleDee Dozier


Updated Schedule


Week-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Task 25-Jan 1-Feb 8-Feb 15-Feb 22-Feb 29-Feb 7-Mar 14-Mar 21-Mar 28-Mar 4-Apr 11-Apr 18-Apr 25-Apr 2-May

A Preiminary Design Review 5

H System Design 5

O PCB Design 3

N Component Research and Selection 2

P Virtual Simulation Verification 3B Intermediate Design Review 0

Z1 Order 1st Prototype Parts 0

Q Finalize Bill of Materials 1D Finalize and Release Specification Sheet 1

K Poster 1

R Software Design 1

I Assemble PCB -1 0

S Power Simulation Testing (Prototype 1) 3 3

T Coding 2 2 1M Write Assembly Procedures 2

U Subsystem Software Testing 2

Z2 Order 2nd Protoype Parts 0G Write Acceptance Test Procedures 2

F Write User Manual 2

J Prototype-2 Testing 4

C Critical Design Review 0

V Full System Environmental Testing 5

L Demonstration (Discovery + Graded) 0

Critical Path

Spring Break

Float

Suggested Time

* Numbers in bar indicate manpower

Thank YouQuestions and Comments


Arctic Power System Intermediate Design Review

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