Confidential / Copyright © SD Group 06 Spr‘12 Critical Review Project Specs & Challenges Group 6: Jean Pierre Jose Paredes Luigi Evalle Andres Escalante

Confidential / Copyright © SD Group 06 Spr‘12

Critical ReviewProject Specs & ChallengesGroup 6:Jean PierreJose ParedesLuigi EvalleAndres Escalante

May 25, 2012

Page 2 May 25, 2012

Escalante, Evalle, Paredes, Pierre

© SD Group 06 Spr‘12

Senior Design Group VIGroup Members

Jean Pierre

Computer Engineering, B.S. Grad: Summer ‘12

Picture

Luigi Evalle

Picture

Electrical Engineering, B.S. Grad: Summer ‘12

Jose Paredes

Picture

Electrical Engineering, B.S. Grad: Fall ‘12

Andres Escalante

Electrical Engineering, B.S. Grad: Fall ‘12

Picture

Page 3 May 25, 2012



Mechanical Aspect

Component Breakdown

2.

3.

Project Essentials1.

Milestones4.

Financials5.

Critical ReviewTable of Contents

Page 4 May 25, 2012



Project EssentialsMain Project Overview

-Solar Panel-Uses Max Power Point Tracking (MPPT) to increase efficiency-Feeds a battery-Goes through a DC to AC Inverter-Supports a Load-MCU Enables PV Panel to Track Energy Source

Maximizes available Solar Radiation

-Solar Panel-Uses Max Power Point Tracking (MPPT) to increase efficiency-Feeds a battery-Goes through a DC to AC Inverter-Supports a Load-MCU Enables PV Panel to Track Energy Source

Maximizes available Solar Radiation

Page 5 May 25, 2012



AC Output

Source Tracking

Project EssentialsGoals & Objectives

Source Tracking feature Will increase energy input at

small energy expense

Enhanced features: Complete Enclosure for ease of Portability AC Output for extended time load-bearing

Portability

Efficiency

MPPT Efficiency of at least 90% DC/AC Inverter Efficiency of at least 90%

Page 6 May 25, 2012



Project EssentialsBlock Diagram

Project Breakdown

Page 7 May 25, 2012



Mechanical Aspect

Component Breakdown

2.

3.


Milestones4.

Financials5.


Page 8 May 25, 2012



EnclosureProject Physical Specs

Rotating Chair Base

Light-Weight Aluminum PV Frame

Wooden Enclosure & Ckt Box

Page 9 May 25, 2012



Mechanical Aspect

Component Breakdown

2.

3.


Milestones4.

Financials5.


Page 10 May 25, 2012



Component InformationPhotovoltaic Panel

Luigi E.

Status: Acquired

Currently @ 60%

Component Info.

Page 11 May 25, 2012



Solar Panel TypesCrystaline v. Thin Film Technologies

Monocrysalline

Polycrystalline

Thin Film

Efficiency 22.5% 11-15% 9%

Weight 12.7 lbs 13 lbs 30.2 lbs

Dimensions 33.25 in x 21.5 in

30.2 in x 26.38 in

39 in x 39 in

Price (w/ shipping)

$129.00 $179.99 $143.52

Crystalline PV Panels

Thin Film

Higher power per area

Output is less affected by temperature

More Efficient Lower Cost per Watt

More available product options

More Shade tolerant

Page 12 May 25, 2012



Solar Panel TypesMonocrystaline

Monocrystalline:• -Cheaper, more efficient,

Light weight and Smallest Surface Area

• Specifications:• -Max Power: 60 W• -Max Power Voltage: 17.6

V• -Max Current: 3.41 A• -Size: 33.25 in x 21.5 in• -Weight: 12.76

Page 13 May 25, 2012



PV PanelIncidence Angle Calculation

Solar Angle of Incidence:• Solar panel's will more efficiently produce greater amounts of power when its

oritentation • is exactly perpendicular to the light source feeding it. • Optimal angle depends on the geographic location of the solar panel and the

current time of year.• The Solar panel will be adjusted to fixed angles depending on the season

(summer, spring, fall or winter)• Various solar angle calculators may be found online

”EnergyWorksUs.com calculator was used as reference for this project• Once the angle from the horizontal is set, the efficiency of the panels will be

further increased by utilizing solar tracking in order to have full exposure to the sunFixed Angle (from horizontal) for Solar Panel

in Central FL Area

Summer 13 degrees

Spring/Fall 28 degrees

Winter 43 degrees

Page 14 May 25, 2012



Component InformationBattery Component

Andres E.

Stat: Not Acquired

Currently @ 50%

Component Info.

Page 15 May 25, 2012



Specifications

6 cells per unit, 12V total output30Ah capabilityMin charge current 1 Amp400A Maximum discharge Surge current (~5 sec) Battery life ~90,000 hours

Convenience

Battery ComponentEATON 12V 120 W Sealed Lead Acid Battery (PWHR12120W3FR)

Sealed construction. Flame-retardant design. Compact and low weight per avg. lead acid

battery designs (23.6lbs, 4.9”x6.5”x6.9). Wide range of operating temperatures

(5°F~104°F).

*Calculations per cell; 6 cells per unit

Page 16 May 25, 2012



Component InformationMax Power Point Tracker (MPPT) Unit

Luigi E

Status: PCB On Order

Currently @ 40%

Component Info.

Page 17 May 25, 2012



MPPT ComponentMaximum Power Point Tracking:

-Important because the voltage and current produced from the solar panel is variable depending on the amount of sun exposure to the solar panel.- The battery charges most efficiently 12V and 3 A. - purpose is to obtain the largest amount of voltage vs. current from a solar array. -voltage from solar panel goes to dc/dc converter which is parallel to MCU and battery-MCU chooses the maximum point at which the voltage and current will create the maximum power output as depicted by the equation P = IV.-Our goal: MPPT is to obtain efficiency of 90%

-Important because the voltage and current produced from the solar panel is variable depending on the amount of sun exposure to the solar panel.- The battery charges most efficiently 12V and 3 A. - purpose is to obtain the largest amount of voltage vs. current from a solar array. -voltage from solar panel goes to dc/dc converter which is parallel to MCU and battery-MCU chooses the maximum point at which the voltage and current will create the maximum power output as depicted by the equation P = IV.-Our goal: MPPT is to obtain efficiency of 90%

Page 18 May 25, 2012



MPPT Component PIC16F88

Microcontroller used:-Use the PIC16f88 microcontroller from Microchip-Program Memory: 7168 bytes Flash, 4096 Single Word Instructions-Data Memory: 368 bytes SRAM, 256 EEPROM bytes-16 I/o Pin-1 CCP (PWM)-2 Comparators-10-bit A/D-Timers 8/16 bit: 2/1

Page 19 May 25, 2012



MPPT Component MPPT Schematic

Page 20 May 25, 2012



Component InformationDC/AC Inverter

Jose P.

Status: Designed and Prototype.

Currently @ 55%

Component Info.

Page 21 May 25, 2012



DC/AC InverterSpecs

-100 watt.-Uses a pic16f628a microcontroller

pic assembly lang-60 hertz produced by two waves from

microcontroller.-Stp55nf06l logic mosfet, 50 amps max current.-Transformer wired backwards to attain high

voltage.-PCB space is 6 inches, 4 inches.-Any AC load, no more than 2 amps.

-100 watt.-Uses a pic16f628a microcontroller

pic assembly lang-60 hertz produced by two waves from

microcontroller.-Stp55nf06l logic mosfet, 50 amps max current.-Transformer wired backwards to attain high

voltage.-PCB space is 6 inches, 4 inches.-Any AC load, no more than 2 amps.

Page 22 May 25, 2012



• Pic of switching regulator

Page 23 May 25, 2012



DC/AC InverterSchematics

U1

PIC16F84A

RA21

RA32

RA4T0CKI3

MCLR4

VSS5

RB0INT 6

RB1 7

RB2 8

RB3 9

RB4 10

RB5 11

RB6 12

RB7 13

VDD 14

OSC2CLKOUT 15

OSC1CLKIN16

RA017

RA118

U2LM7805CT

LINEVREG

COMMON

VOLTAGE R1

47Ω

C11000µF

C2.22µF

C3.1µF

C4100µF

R2

10kΩ

R3

10kΩ

R4

470Ω

R5

470Ω

R622kΩ

R7

22kΩ

STP55N06L

STP55N06

F1

10_AMP

T1

TS_POWER_25_TO_1

V112 V

Design will be replaced

Page 24 May 25, 2012



DC/AC InverterPrototype

Page 25 May 25, 2012



Component InformationPV Panel Output Monitoring Unit

Luigi E.

Status: Acquired; Awaiting Testing

Currently @ 55%

Component Info.

Page 26 May 25, 2012



Monitoring the Solar PanelSpecifications

U5

TLV2302

1234 5

678

U1ACS714

1 2 3 45678

SOLARPANEL12 V

C1

1µF C2

1nF

R15kΩ

R222kΩ

D11N4729A

VCC5V

DATA OUT

DATA OUT

Why is it important:-Efficiency calculations when comparing the efficiency of the MPPT.-Observe the effect of temperature on the solar panel's performance

Voltage Coming from Solar Panel:-A voltage divider circuit will be used to calculate the voltage produced by the solar panel

Why is it important:-Efficiency calculations when comparing the efficiency of the MPPT.-Observe the effect of temperature on the solar panel's performance

Voltage Coming from Solar Panel:-A voltage divider circuit will be used to calculate the voltage produced by the solar panel

Current Coming from Solar Panel:-ACS714 a hall effect-based linear current sensor which will be surface mounted to the main PCB. Chosen because it is accurate for low current readings which range up to 5 A.

Specifications:-Size: 0.7" x 0.8"-Weight: 1.3 g-Current Sensitivity: 0.185V/A-Max Logic Voltage: 4.5 - 5.5V-VCC: 5 V-Current input: -5A - 5A

Current Coming from Solar Panel:-ACS714 a hall effect-based linear current sensor which will be surface mounted to the main PCB. Chosen because it is accurate for low current readings which range up to 5 A.

Specifications:-Size: 0.7" x 0.8"-Weight: 1.3 g-Current Sensitivity: 0.185V/A-Max Logic Voltage: 4.5 - 5.5V-VCC: 5 V-Current input: -5A - 5A

Page 27 May 25, 2012



Component InformationMicroController Unit

Jean P.

Status: Acquired

Currently @ 60%

Component Info.

Page 28 May 25, 2012



Microcontroller Development Board Comparison ChartDevelopment Board Chip used

Comes with Chip?

Power jack w/ Voltage Regulator

USB Or Serial Interface

Programming Language Price

Arduino UNO - R3 ATMEGA328P YES YES USB C $29.95

Parallax Board of Education Development Board Basic Stamp 2 NO YES USB Basic $60.00

MSP430 Launchpad MSP430Fxx2 YES YES USB C $4.30

PICKit 2 Debug Express PIC16F887 YES NO USB

C/Assembly/Basic $49.99

Arduino Mega 2560 ATmega2560 YES YES USB C $53.95

40 Pin PIC Deveopment Board PIC18F4550 YES YES Serial/USB C/Assembly $37.95

MCU ComponentMCU Development Board Comparison Chart

Page 29 May 25, 2012



•Comes with PICkit 2 Development Programmer/Debugger

Needed to program PIC microcontrollers in our program.

• 44-pin Demo board with PIC16F887 Midrange PIC microcontroller• Has 12 lessons on assembly programming to cover I/O, A/D converters, timers, interrupts, etc.• Several lessons on using C language to program microcontrollers

•Comes with PICkit 2 Development Programmer/Debugger

Needed to program PIC microcontrollers in our program.

• 44-pin Demo board with PIC16F887 Midrange PIC microcontroller• Has 12 lessons on assembly programming to cover I/O, A/D converters, timers, interrupts, etc.• Several lessons on using C language to program microcontrollers

MCU ComponentMicrochip PICkit 2 Debug Express

Page 30 May 25, 2012



MCU Component Microcontroller ATmega328P

•Operating Voltage: 5V•Input Voltage (recommended): 7-12V•Input Voltage (limits): 6-20V•Digital I/O: 14 (of which 6 provide PWM output)•Analog Input Pins: 6•DC Current per I/O: Pin40 mA•DC Current for 3.3V: Pin50 mA•Flash Memory: 32 KB of which 0.5 KB used by bootloader•SRAM: 2 KB(Atmega328p)•EEPROM: 1 KB(ATmega328p)•Clock Speed: 16 MHz

•Operating Voltage: 5V•Input Voltage (recommended): 7-12V•Input Voltage (limits): 6-20V•Digital I/O: 14 (of which 6 provide PWM output)•Analog Input Pins: 6•DC Current per I/O: Pin40 mA•DC Current for 3.3V: Pin50 mA•Flash Memory: 32 KB of which 0.5 KB used by bootloader•SRAM: 2 KB(Atmega328p)•EEPROM: 1 KB(ATmega328p)•Clock Speed: 16 MHz

Page 31 May 25, 2012



Component InformationTracking Component (Photoresistor)

Jean P.

Status: Construction phase

Currently @ 45%

Component Info.

Page 32 May 25, 2012



Tracking ComponentPHOTORESISTOR

• Size: 5.00x4.00mm• Resistance on light: 5k-20k ohm• Resistance in darkness: 1M ohm• Max Voltage: 150V (DC)• Peak Sensitivity: 560nm• Sensitivity Range: CdS cells respond to light between 400nm (violet) and 600nm (orange) wavelengths, peaking at about 520nm (green).• Power Supply: use less than 1mA for up to 100V (depending on power supply)• Max power consumption: 100mW• Operating temperature: -30 to +70°C

• Size: 5.00x4.00mm• Resistance on light: 5k-20k ohm• Resistance in darkness: 1M ohm• Max Voltage: 150V (DC)• Peak Sensitivity: 560nm• Sensitivity Range: CdS cells respond to light between 400nm (violet) and 600nm (orange) wavelengths, peaking at about 520nm (green).• Power Supply: use less than 1mA for up to 100V (depending on power supply)• Max power consumption: 100mW• Operating temperature: -30 to +70°C

Page 33 May 25, 2012



Component InformationLoad Control Monitoring Unit

Jean P.

Stat: Design Phase

Currently @ 15%

Component Info.

Page 34 May 25, 2012



With MCU, we will display:• Current being consumed by the load•Current out of PV panel• Temperature of PV panel• Voltage output of PV panel

With MCU, we will display:• Current being consumed by the load•Current out of PV panel• Temperature of PV panel• Voltage output of PV panel

Load Control MonitoringPorpuse

Page 35 May 25, 2012



Component InformationMotor Controller

Jean P.

Status: Acquired

Currently @ 65%

Component Info.

Page 36 May 25, 2012



Motor ControllerStepper Motor

-- Designed by Brian Schmalzhaus-- from Sparkfun.comSpecification:• Bi-polar Micro stepping Driver use for Bi-Polar Stepper Motors• Drive motor up to 2A/Phase Max• Max Motor Drive Voltage: 35V• On-board 5V/3.3V Regulation to use for Microcontroller• Board can drive motor in Full Step, Half-Step, Quarter-Step, 1/8th –Step, 1/16th –Step• Motor with 200 steps per revolution, require 3200 steps/rev for full revolution• Comes with Eagle board files and schematic

-- Designed by Brian Schmalzhaus-- from Sparkfun.comSpecification:• Bi-polar Micro stepping Driver use for Bi-Polar Stepper Motors• Drive motor up to 2A/Phase Max• Max Motor Drive Voltage: 35V• On-board 5V/3.3V Regulation to use for Microcontroller• Board can drive motor in Full Step, Half-Step, Quarter-Step, 1/8th –Step, 1/16th –Step• Motor with 200 steps per revolution, require 3200 steps/rev for full revolution• Comes with Eagle board files and schematic

Big Easy Driver: Bi-Polar Stepper

Motor Driver

Page 37 May 25, 2012



Component InformationMotor Component

Jean P.

Status: Acquired

Currently @ 65%

Component Info.

Page 38 May 25, 2012



Stepper Motors Comparison ChartStepper Motor TYPE

WebsiteManufacturer ID

Holding Torque Oz-in

VoltageCurrent Rating A/phase

Type Weight kg Cost

Nema 23 Ebay57BYGH41-601B

55.00 12 Vdc 1.00 SIZE 23 0.47 $30.11

Nema 23 Ebay57BYGH41-401B

76.00 12 Vdc 2.80 SIZE 23 0.47 $30.11

Nema 23 Ebay57BYGH56-401A

175.00 12 Vdc 2.80 SIZE 23 0.71 $37.99

Lin Engineering

Alltronics.com

5718M-05E-04 124.21 12 Vdc 2.00 SIZE 23 N/A $19.95

NI NEMA 23National Instrument

780073-01 180.00 12 Vdc 0.40 SIZE 23 N/A $139.00

Nema 23 Ebay 23HS6410-02A 212.00 12 Vdc 1.00 SIZE 23 0.85 $45.00

AMCI AMCI.com SM23 240.00 12 Vdc 2.00 SIZE 23 0.99 N/A

Motor ComponentComparison

Page 39 May 25, 2012



Stepper Motor Specifications:

Size: Nema 23 Step Angle: 1.8 deg Voltage: 7.5 VDC Current/Phase: 1.0 Amp/phase Resistance/phase: 20.0 mH/ phase Holding Torque: 212 oz-in

150 N-cm Detent Torque: 7.0 oz-in

5.0 N-cm Rotor Inertia: 2.08 on-in2

380 g-cm2 Weight: 1.87 lbs

0.85 kg Available step Modes:

Full, Half, Quarter, 1/8th and 1/16th Step

Stepper Motor Specifications:

Size: Nema 23 Step Angle: 1.8 deg Voltage: 7.5 VDC Current/Phase: 1.0 Amp/phase Resistance/phase: 20.0 mH/ phase Holding Torque: 212 oz-in

150 N-cm Detent Torque: 7.0 oz-in

5.0 N-cm Rotor Inertia: 2.08 on-in2

380 g-cm2 Weight: 1.87 lbs

0.85 kg Available step Modes:

Full, Half, Quarter, 1/8th and 1/16th Step

Motor ComponentSpecs

Page 40 May 25, 2012



Motor ComponentStepper Motor Schematic

Page 41 May 25, 2012



Motor ComponentStepper Motor Tracking Algorithm

Page 42 May 25, 2012



Component InformationLiquid Crystal Display

Andres E.

Status: Acquired

Currently @ 70%

Component Info.

Page 43 May 25, 2012



LCD specs:• Module Size(W×H×T): 98.0×60.0×14.0mm• Viewing Area(W×H): 76.0×26.0 mm• Character Size(W×H): 2.94×4.74• Dot Size(W×H): 0.54×0.54mm• Operating Voltage: 4.5 – 5.5 V• Operating Current: 1.0 – 2.2 mA• Can run in 4-bit or 8-bit mode.• Easily interface with Arduino using LiquidCrystal library.• Sturdy enough for outside use

LCD specs:• Module Size(W×H×T): 98.0×60.0×14.0mm• Viewing Area(W×H): 76.0×26.0 mm• Character Size(W×H): 2.94×4.74• Dot Size(W×H): 0.54×0.54mm• Operating Voltage: 4.5 – 5.5 V• Operating Current: 1.0 – 2.2 mA• Can run in 4-bit or 8-bit mode.• Easily interface with Arduino using LiquidCrystal library.• Sturdy enough for outside use

HD44780 2004 20x4 LCD Module W/ Blue backlightHD44780 2004 20x4 LCD Module W/ Blue backlight

Liquid Crystal DisplaySpecs

Page 44 May 25, 2012



U1

GND

VCCCV

RSRW

E

D0D1D2D3D4D5D6D7

V15 V Battery

R1

10kΩKey=A

50%

GND

GND

MicrocontrollerArduino

Liquid Crystal DisplayPin Schematic of 20X4 LCD Module

Page 45 May 25, 2012



Mechanical Aspect

Component Breakdown

2.

3.


Milestones4.

Financials5.


Page 46 May 25, 2012



Milestone SchedulePer Semester

Page 47 May 25, 2012



Progress By ComponentPercent Completion

Page 48 May 25, 2012



Mechanical Aspect

Component Breakdown

2.

3.


Milestones4.

Financials5.


Page 49 May 25, 2012



BudgetPivot Table of Actuals vs. Forecast

Page 50 May 25, 2012



Points of ConcernPossible Technical Problems to Come

Stepper Motor torque output

DC/AC transformer efficiency

MPPT actual efficiency

Page 51 May 25, 2012



Thank you for your attention!

…Any Questions?

Page 52 May 25, 2012



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Equator

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Incidense Angles v. Earth Rotational StatesPhase4

Documents

Confidential / Copyright © SD Group 06 Spr‘12 Critical Review Project Specs & Challenges Group 6: Jean Pierre Jose Paredes Luigi Evalle Andres Escalante