Hybrid Power Controller (HPC)

Final PresentationSenior Design II

HPC Team MembersStephen AllardDavid Duke Brandon Kennedy Kevin Roberts

Dr. Mike Mazzola

Electrical Engineer• Website Design• System Integration• Testing• Generator Controller

Circuit

Electrical Engineer• System Integration• Enclosure• Integration Research• PCB Design

Electrical Engineer• Website Design• Programming• Controller Design• Component Research

Electrical Engineer• Programming• Test Circuit Design• Controller Design• Debugging

Advisor

Andy Lemmon, GRA

Co-Advisor

Outline• Problem• Solution• System Overview• Constraints

• Technical• Practical

• PCB Design• Enclosure• System Hardware• Testing• Questions

Problem

Existing residential backup power solutions are not adequate for long-term power

outages which follow large-scale natural disasters.

Solution

A hybrid power system that can address residential long-term power needs. This

system requires an autonomous controller which manages:

• solar panel array• tri-fuel generator• battery bank

"What does the HPC do?"

The HPC efficiently manages the Hybrid Power System to accomplish

the following objectives:

1- Keep the batteries healthy2- Supply the load when traditional backup power supplies cannot

System Overview

Solar Array

Battery Bank

Inverter

Load

Generator

Hybrid Power Controller

OEM

Device

Hybrid Power System

[1]

Technical and Practical Constraints

Technical ConstraintsName Description

Accuracy The Hybrid Power Controller must have an accuracy of +/- 100 mV on the battery bank voltage input and +/- 500 mA on the battery bank current input.

Input The Hybrid Power Controller must accept inputs up to 50 Volts DC.

Output The output of the device must provide signals to operate a 12 volt relay for start/stop generator operation.

Response Time The device must take samples from Hybrid Power System components and respond to changes within 1 second.

Supply Power The device must accept 24 Volts DC for supply power.

Practical ConstraintsName Description

Sustainability The device must be vibration resistant.

Manufacturability The device must fit into available space in the NEMA enclosure.

SustainabilityVibration Resistance

• Located within an enclosure mounted on a mobile trailer

• Need reliable connections

• Easy to connectSolution

• Use locking connectors[3]

Manufacturability

Size Limitation• Controller enclosure

must fit inside existing NEMA enclosure

• Limited spacing around other components, such as fuses and distribution panels

• The maximum available space is 10” x 10” x 5”

HPC

Manufacturability

Size Limitation• Controller enclosure

must fit inside existing NEMA enclosure

• Limited spacing around other components, such as fuses and distribution panels

• The maximum available space is 10” x 10” x 5”

PCB

DIMM 100 Breakout Board PCB Design

Prototype DIMM100 Breakout Board

DIMM 100 Breakout Board PCB Design

DIMM 100 Breakout Board PCB Design

Component PCB Design

Component PCB Design

Power Circuitry

Inputs and Voltage Dividers

Generator Output Circuit

Serial Data

Status LEDs

Enclosure

Finished Enclosure

Enclosure mounted in NEMA cabinet

System Hardware

Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.

Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.

Generator ModificationIn order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.

Current Sensing

Battery Current Hall Effect

Solar Array Hall Effect

Calculated an Offset and Conversion Factor in Software

System Assembled

After the necessary hardware was completed, we began to test each subsystem and our constraints

Testing

Test Plan - Overview

• Technical Constraints• Complete System Test

Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage

• Multi-meter: 24.365 V• HPC: 24.371• Accuracy: + 6 mV

Within +/- 100 mV

Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage

• Multi-meter: 24.365 V• HPC: 24.371• Accuracy: + 6 mV

Within +/- 100 mV

Technical Constraints -- Accuracy: +/- 500 mA on Battery Current

• Multi-meter(1mV = 1 A): -36.336 A

• HPC: -36.513• Accuracy: -177 mA

Within +/- 500 mA

Technical Constraints -- Accuracy: +/- 500 mA on Battery Current

• Multi-meter(1mV = 1 A): -36.336 A

• HPC: -36.513• Accuracy: -177 mA

Within +/- 500 mA

Technical Constraints -- Inputs -- HPC must accept up to 50 VDC

• HPC reads inputs up to 50 VDC using voltage divider circuits

Sensor Inputs up to 50 VDC

Technical Constraints -- Outputs

The output of the device must provide signals to operate a 12 volt relay for start/stop

generator operation.

Load Cutoff

[4]

• Send serial “FF” to OEM Interface to Drop load when Battery Voltage reaches critical level

• Send “OO” to reconnect load

Technical Constraints -- Response Time

• HPC must respond to system changes within 1 second: o Protects

Batterieso Increases

Runtime for customer

• HPC responds within allotted time

Technical Constraints -- Response Time

• HPC must respond to system changes within 1 second: o Protects

Batterieso Increases

Runtime for customer

• HPC responds within allotted time

Technical Constraints -- Supply Power -- Controller must accept 24 VDC for power

• 24 VDC is stepped to 5 VDC using switching regulator

• Controller is successfully powered by battery bank

• Board Power Indicator LED

Complete System Test

Usage Case Status

Generator Mode

UPS Mode

Critical Mode

Complete System Test

Usage Case Status

Generator Mode Fully Functional

UPS Mode

Critical Mode

Complete System Test

Usage Case Status

Generator Mode Fully Functional

UPS Mode Fully Functional

Critical Mode

Complete System Test

Usage Case Status

Generator Mode Fully Functional

UPS Mode Fully Functional

Critical Mode Fully Functional

Bill of Materials

References[1] Inverter Generator with CMD Triple-Fuel System. [2012, Nov. 28]. Avalable: http://www.generatorsales.com/order/Honda-EU3000iS-Tri-fuel.asp?page=EU3000iS_Tri_Fuel

[2] US Digital. [2012, Noc. 28]. Available: http://www.usdigital.com/products/cables-connectors/cables/5-pin/ca-fc5-sh-lc5

[3] Digi-Key Corporation. [2012, Nov. 28]. Available: http://www.digikey.com/product-detail/en/C091%2031W107%20100%202/361-1317-ND/1647574

[4] Mate Serial Communications Guide. Rev. 4.04., OutBack Power Systems, Arlington, WA, 2008.

[5] Owner’s Manual Generator EU3000is. Rev. 1.0., Honda Motor Co., Printed in Japan.

Questions?