Hybrid Power Controller (HPC)

Mid-Semester PresentationSenior Design I

HPC Team MembersStephen Allard David Duke Brandon Kennedy Kevin Roberts

Dr. Mike Mazzola

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

Electrical Engineer• System Integration• Enclosure• Integration Research• Controller 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– Practical– Technical

• Approach– Components– Software

• Progress– Timeline

• Questions

Problem

• In the event of a power outage, people lose contact with the outside world and suffer the loss of everyday conveniences. Most people do not possess sufficient knowledge of electrical components that would allow them to effectively use multiple forms of hybrid power.

Solution• Design and build a controller that

autonomously manages a personal solar panel array, battery bank, and generator, and that optimizes the use of the solar panel array.

System Overview

Solar Array

MPPT Charger

DC Distribution

Panel

Battery Bank

Mobile Inverter/ Charger

AC Outlet (load)

Generator

Hybrid Power

Controller

MATE

MPPT Charger

Mobile Inverter

Grid-tie Inverter (unused)

AC Outlet (load)

Solar Panel Bus

DC Bus

Technical and Practical Constraints

Technical ConstraintsName Description

Accuracy The Hybrid Power Controller will need to have an accuracy of +/- 100 mV on inputs.

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

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

Sampling Rate The device must be able to take samples from Hybrid Power System components 3 times per second.

Supply Power The device should be able to accept 24 Volts DC for supply power.

Practical ConstraintsName Description

Economic The parts must cost less than $200.

Manufacturability The device must fit into an enclosure that measures 10’’x10’’x5’’.

Economic

Cost Considerations• Price of competition: $420 [1]• Estimated cost of parts for HPC: <$200• Choosing a microcontroller to meet Dr.

Mazzola’s future needs

Manufacturability

Size Limitation• Controller enclosure must fit inside

existing NEMA enclosure• Limited spacing around other

components, such as fuses and distribution panels

Manufacturability

Approach

Powering the Microcontroller

Regulator Cost Vin VoutThrough-

hole compatible?

Our Choice

LTM8048 [2] $38 3.1V-32V 2.5V-13V No

DE-SW033 [3] $15 Up to 30V 3.3V Yes

LTM8029 [4] $8 4.5V-36V 1.2V-18V No

The micro-controller must be powered from the 24VDC battery bank. A regulator is needed with an input of 20-28VDC, and an output of 3.0-3.6VDC. Due to the large difference between the input and output voltage, a linear regulator will not suffice, due to excess heat. A switching regulator will be needed.

Powering the Microcontroller

Regulator Cost Vin VoutThrough-

hole compatible?

Our Choice

LTM8048 [2] $38 3.1V-32V 2.5V-13V No

DE-SW033 [3] $15 Up to 30V 3.3V Yes ✓LTM8029 [4] $8 4.5V-36V 1.2V-18V No

The micro-controller must be powered from the 24VDC battery bank. A regulator is needed with an input of 20-28VDC, and an output of 3.0-3.6VDC. Due to the large difference between the input and output voltage, a linear regulator will not suffice, due to excess heat. A switching regulator will be needed.

Microcontroller

Micro Cost/per +1000 Familiarity

Potential for further

developmentADC Our

Choice

PIC24HJ32GP202 $2.90[5] Yes little 10/12-bit

“Piccolo” F28027 $1.85 [6] No much 12-bit

“Piccolo“ F28069 $4.95[6] No most 12-bit

Microcontroller

Micro Cost/per +1000 Familiarity

Potential for further

developmentADC Our

Choice

PIC24HJ32GP202 $2.90[5] Yes little 10/12-bit

“Piccolo” F28027 $1.85 [6] No much 12-bit

“Piccolo“ F28069 $4.95[6] No most 12-bit ✓

Software Approach

If Solar Power is < than Load

Turn on Generator

Battery Voltage Low

Wait time and check generator operation

Battery Voltage Stable

If generator producing

Check for Load and

Solar Power

If Solar Power is > than Load

If Generator not

producing

Cut off Load

Sample Battery Bank

Progress

Data

[7]

Data

[8]

Data

[8]

Data

[8]

Data

[8]

Data

[8]

Test Circuit

Test Circuit

Voltage Adjustment

Timeline August September October November December

Research of Hybrid Power System Components, Design of Test FixtureManufacture of Test Fixture, Finalize Design Constraints of ControllerConstruct Prototype of Controller, Testing of Prototype with Test FixtureComplete Testing, Debugging, Finalize Prototype

References[1] Outback Mate 3 System Control and Monitor. [2012, Sept. 12]. Available: http://www.solarhome.org/outbackmate3systemcontrolandmonitor.aspx

[2] Digi-Key Corporation: LTM8048MPY#PBF. [2012, Sept. 24]. Available: http://www.digikey.com/product-search/en?mpart=LTM8048MPY%23PBF&vendor=161

[3] Dimension Engineering: 3.3V 1A Switching voltage regulator. [2012, Sept. 24]. Available: http://www.dimensionengineering.com/products/de-sw033

[4] Digi-Key Corporation: LTM8029EY#PBF. [2012, Sept. 24]. Available:http://www.digikey.com/product-detail/en/LTM8029EY%23PBF/LTM8029EY%23PBF-ND/3306831

[5] Digi-Key Corporation. [2012, Sept. 24]. Available: http://www.digikey.com/product-detail/en/PIC24HJ32GP202-I%2FSP/PIC24HJ32GP202-I%2FSP-ND/1635696

[6] C2000 32 bit 28x Piccolo™ Series. [2012, Sept. 26]. Available: http://www.ti.com/mcu/docs/mcuproductcontentnp.tsp?sectionId=95&familyId=919&tabId=2883

[7]WattMetrics. [2012, Sept 26]. Available: http://www.wattmetrics.com/support/connectingtoinverters/OutBack.aspx

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

Questions?