low carbon footprint hybrid battery charger project proposal
TRANSCRIPT
LOW CARBON FOOTPRINT HYBRID
BATTERY CHARGER
FINAL PRESENTATION
Students: Blake Kennedy, Phil Thomas
Advisors: Mr. Gutschlag, Dr. Huggins
Date: May 1, 20081
PRESENTATION OUTLINE
Project Overview
Design
Buck-Boost
Theory
Design Iterations
Closed Loop Control
Lead Acid Fast Charge IC
Results
Future Recommendations
Questions
2
INTRODUCTION
Emphasize efficient energy collection
Photovoltaic arrays
Wind turbine
Minimize utility A.C. energy
Store renewable energy
Charge a mobile battery for vehicular
applications using renewable energy
PREVIOUS RESEARCH
What has been created by others?
What is new with our project?
All systems combined to charge a vehicle battery
Utilization of battery to battery charging
How can this be done?
4
AC Energy
Solar Energy Wind Energy
Max Battery Life
(On/Off)
Select Menu
Min. Charge Time
(On/Off)
Emergency
Charge
Battery Charging
(On/Off)
Percent Battery
Full
Time Remaining
Keypad
Liquid Crystal Display
Key:
= Primary Objective
= Extended Objective (if time permits)
= Power Flow
= Control Signal
Stationary Battery
Stationary Battery Charger
Mobile Battery Charger
Voltage/Current sense leads
Renewable Energy
AC to DC converter
Mobile Battery
Power Control System
Voltage/current sense leads
Microcontroller System
Voltage/Current sense leads
HIGH LEVEL SYSTEM BLOCK DIAGRAM
5
LOW LEVEL FLOWCHART
6
RENEWABLE ENERGY
7
Photovoltaic (P.V.) Array
BP 350J
50W, 17.5V, 2.9A at max power
Provide sufficient energy
to charge the mobile battery
given worst case conditions
RENEWABLE ENERGY
8
Mobile Battery Load = 648 kJ
BP 350J Efficiency = 13.22 %
Worst Case: 1.470 sun hours per day
Worst Case Solar Power Energy = 206,449 J/day
Min Number of P.V. Arrays = 2.45 P.V. Arrays
RENEWABLE ENERGY
Wind Energy
1.2 kWh/day average at 50m
Simulated with D.C. power supply
Southwest Wind Power Air-X
Start up wind speed: 7 M.P.H.
Rotor Diameter: 46 in.
Max Power: 400W @ 28 M.P.H
Vout= 24VDC
Competitive Cost
9
LOW LEVEL FLOWCHART
10
BUCK-BOOST THEORY
11
BUCK-BOOST VERIFICATION
Simulated basic circuit using P-spice
12
D1
DMBRF1045
V1
31
0
R4 100
C1
500u
200
V_BATT15Vdc
V2
TD = 0
TF = 1n
PW = 10uPER = 20u
V1 = 0
TR = 1n
V2 = 15
M1
NDP4060/FAI
U1
IR2113
123456
789
1011
VDDHINSDLIN
VSSHO
VBVSVCCCOMLO
L1
1m
1
2
R3
100
R2
.3
BUCK-BOOST SCHEME
13
Continuous mode- Inductor Current
BUCK BOOST PSPICE SIMULATIONS
Minimum Input 6V with a 75% Duty Cycle
14
BUCK BOOST PSPICE SIMULATIONS
Maximum Input 40V with a 25% Duty Cycle
15
BUCK-BOOST IMPLEMENTATION
IR2113 Low-side Driver
16
D1
DMBRF1045
V1
31
0
R4 100
C1
500u
200
V_BATT15Vdc
V2
TD = 0
TF = 1n
PW = 10uPER = 20u
V1 = 0
TR = 1n
V2 = 15
M1
NDP4060/FAI
U1
IR2113
123456
789
1011
VDDHINSDLIN
VSSHO
VBVSVCCCOMLO
L1
1m
1
2
R3
100
R2
.3
BUCK-BOOST IMPLEMENTATION
IR2113 High-side Driver
17
V_BATT15
V2
TD = 0
TF = 10nPW = 25uPER = 50u
V1 = 0
TR = 10n
V2 = 5.0
C1220u
VS
R3100
VBVSVS
D1DMBRF1045
R510000
V_BATT
10Vdc
VB
M2IRFP240
R410
U1IR2113
123456
7891011
VDDHINSDLINVSSHO
VBVS
VCCCOM
LO
V1
20
0
R2
.3
L1
400u
1
2
BUCK-BOOST IMPLEMENTATION
HPCL-3120 High-side driver
18
VIN
31
6-Vo
5-Vee
3-Cathode
0
2-Anode
Vcc
1
R7100 HCPL3120
M3IRFP240
L1
800u
1
2
PWM
Vee
C1
220u
200
BATT -
R2
.02
8-Vcc
D1DMBRF1045
Vcc
4
7-Vo
Vee
BUCK-BOOST IMPLEMENTATION
Topology Change
19
D41N4744A
12
0
0
M3IRF9520
C2
1n
L1
800u
1
2
C1
220u
200
Neg_Vin
D2DMBRF1045
5V
0
R2
.02
R61k
0
R7520
VIN
31
D1DMBRF1045
PWM
0
U1
IR2113
123456
789
1011
VDDHINSDLIN
VSSHO
VBVSVCCCOMLO
D31N270
12
0
C4
3300u
50
Pos_VinPos_Vin
BUCK-BOOST IMPLEMENTATION
Optical Isolator with Linear Voltage Regulator
20
M5IRF640
8-Vcc
C1
220u
200
4
C71u
L1
800u
1
2
C82.2u
Pos_Vin
7-Vo
6-Vo
M4IRF9520
R2
.02
3
5-Vee
2
3-Cathode
Neg_Vin
VIN
31
D31N4748
1
0
2-AnodeLM7915
C4
3300u
50
1
PWM
HCPL3120
C2
22n
R64.7
M3IRF9520
D2691120
R9100
-15V
D1STPS20120D
0
R7100
0
R8100
BUCK-BOOST IMPLEMENTATION
UA78S40
Universal Switching Regulator Subsystem
Provides PWM Closed Loop Control
21
BUCK-BOOST IMPLEMENTATION
Inverting Configuration
Vout = 1.25 RC1/(RC2+RC3)
22
Ipk Sense 14Driver C 15
4 OpAmp Out
GND 11
3 Emitter
0
2 Diode Pos
UA78S40
PWMCt1470pF
0
RC210K
RC1110K
RC31k
Compare Neg 10
1 Diode Neg
Timing Cap 12
8 Vref OutC3
220uF
Vout
7 Opamp NegCompare Pos 9
6 OpAmp Pos
Vcc 135 OpAmp Vcc
5VSW C 16
LOW LEVEL FLOWCHART
23
STATIONARY BATTERY
Reduces mobile battery charge time
Capacity needed determined by:
What is practical from cost standpoint
Stationary battery decay vs. mobile battery
Must be at least 180Wh
24
STATIONARY BATTERY
25
Optima D31T
Lead Acid
75 Ah,12V
Low cost
No Memory Effect
STATIONARY BATTERY CHARGER
Can accept max input values
Voltage: 30V (from renewable energy)
Current: 10A
Charges to maximize life
Provide over current / voltage protection to battery
26
STATIONARY BATTERY CHARGER
BQ2031- Lead Acid Fast Charge IC
Automatically detects low current and switches
to trickle charge
Temperature-compensated charging
Automatically detects shorted, opened, or
damaged cells
Provides binary state of charge status
PWM Control
Two-Step Voltage Control
27
STATIONARY CHARGER SCHEME
BQ2031
Two-Step Voltage Charge
28
STATIONARY CHARGER SCHEME
BQ2031
Stationary battery specific configuration
Switching frequency = 100KHz
Will charge between 32 ⁰ F and 106 ⁰ F
Over current protection = 10A
Voltage regulation = 14.3 V
29
STATIONARY CHARGER SCHEME
30
R5
1k
M5IRF640
Ipk Sense 14
RB250k
PWM2
8-Vcc
Driver C 15
C1
220u
200
4 OpAmp Out
Pull-Down DSEL10k
16
4
C71u
GND 11
3 Emitter
L1
800u
1
2
C82.2u
0
Pos_Vin
8
7-Vo
2 Diode Pos
UA78S40
PWM
4
6-Vo
M4IRF9520
DSEL= 0 for Mode 1 Display Output (resistor to GND)
TSEL= 0 for Two-Step Voltage Charge (resistor to GND)
QSEL=0 for Two-Step Voltage Charge (resistor to GND)
IGSEL=0 for Imin= 1A
MTO=24hrs Open Circuit for Max
RT1, RT2= Charging stops when greater than 105F and restarts at 85F
RB1, RB2, RB3= Float Voltage=13.3V; IMax=10A; Battery charges at 14V
LED2
R2
.02
CT1n
3
Ct1470pF
MTO-N.C.
C6.33u
BATT +
7
5-Vee
0
10
LED2
RT10k- 110k
2
RC210K
6 COM
BATT -
3-Cathode
1
Neg_Vin
9
VIN
31
D31N4748
LED1
1
0
5
Pull-Down TSEL10k
2-Anode
RT219.2k
11
0
LM7915
COM
PWM2
RC1110K
BATT -
3
C4
3300u
50
13
3
R3
1k
RC31k
2
R4
1k
M2IRFP240
Compare Neg 10
VCC 5V
15
1
2
1 Diode Neg
1
PWM
Timing Cap 12
12
HCPL3120
C2
22n
BATT +
R64.7
8 Vref Out
LED3
C3
220uF
M3IRF9520
D2691120
Vout
R9100
7 Opamp Neg
-15V
RT1
9.4k
Compare Pos 9
BQ2031
14
D1STPS20120D
C5.1u
RB3620k
0
R7100
6 OpAmp Pos
Vcc 13
BATT -
0
Pull-Down QSEL10k
R8100
LED3
LED1
5 OpAmp Vcc
5VSW C 16
LM7805
RB1130k
LOW LEVEL FLOWCHART
31
MOBILE BATTERY CHARGER
Accepts energy from stationary battery
Must be capable of outputting
Voltage: 14.9V
Current: 4.8A
The mobile battery charger shall be capable of
charging the mobile battery within at least
12 hours
32
MOBILE BATTERY
Panasonic LC-RA1212P for Gaucho 12V lead-acid battery
Rated capacity: 12Ah
Minimal charge time
2 hours 39 minutes
Maximum battery life
2-8 years
250-500 charge cycles
Constant Voltage Charge
33
USER INTERFACE
Keypad input
User selects mode of charge
L.C.D. output
Battery charging indicator
Battery charge percentage indicator
Time remaining until battery charged indicator
34
ACTUAL RESULTS
Buck boost topology, gate drivers, and regulation
works
35
ACTUAL RESULTS
Buck- Boost Results with feedback
36
ACTUAL RESULTS
BQ2031 Indicates it passes qualification tests
Still need to implement gate driver and FET
37
POTENTIAL IMPROVEMENTS
Implement
Mobile Battery Charger
Microcontroller Feedback
Use switching voltage regulators instead of linear
N-channel MOSFET with floating gate drive on buck-boost
Clean up noise in voltage regulation
Create more protection circuitry
38
QUESTIONS?
39
STATIONARY BATTERY
Possible battery choicesOptima
Lead AcidLi-Ion Ni-CD Ni-MH
Sealed Lead Acid
Temperature Range (C) 130 to -30 50 to -20 45 to -40 50 to -20 60 to -40
Calendar Life (years) ? 2 to 5 2 to 5 2 to 5 2 to 8
Max Charge Cycles 300+ 1000+ 300 to 700 300 to 600 250 to 500
Discharge Profile Flat Slope Flat Flat FlatSelf Discharge Rate @ 20C (% /mo) Very Low 2 15 to 20 15 to 25 4 to 8
Memory Effect No No Yes Yes NoAbility to Trickle Charge Yes No Yes Yes Yes
Charging Characteristic 2 stageDeep Discharge Yes Yes Yes Yes NoRelatively Quick Charge Yes Yes Yes Yes No
Constant Voltage Or Current Charge
Voltage Voltage Current Current Voltage
Relative Expense/ Capacity Cheap Expensive Moderate Moderate CheapApprox Expense (dollars) 150 < 600 300 350 80
40
STATIONARY CHARGER SCHEME
BQ2031
Configuring Charging Algorithm
41
STATIONARY CHARGER SCHEME
BQ2031
Voltage and Current Monitoring
42
STATIONARY CHARGER SCHEME
BQ2031
Voltage and Current Monitoring
N=6 cells
Vflt=13.3V
Vblk=14.0V
Imax=10A
Using Equations
RB1=130KΩ
RB2=50KΩ
RB3=620KΩ
43
STATIONARY CHARGER SCHEME
BQ2031
Fast Charge cutoff to Trickle Charge
IGSEL = 0
Imin = Imax/10 = 10A/10 = 1A
44
STATIONARY CHARGER SCHEME
BQ2031
Temperature Sensing
45
STATIONARY CHARGER SCHEME
BQ2031
Setting Charging Maximum Timeout
Tmto=24hours
R=24hrs/(.5*.1uF)
= 480GΩ
Use largest resistance
possible or open circuit
46
STATIONARY CHARGER SCHEME
BQ2031
Set switching frequency
Fpwm=100KHz
47
MICROCONTROLLER REQUIREMENTS
Microcontroller switches IC charging mode
Feedback loop handled by IC
Keypad user input
1 port needed
LCD user output
1 port needed
Port pin IC input
3 pins needed for status
Port pin IC output
1 pin needed for switching modes
48
BUCK-BOOST IMPLEMENTATION
IR2113
High and Low Side Driver
Ability to operate at 100KHz
Separate logic supply range from 3.3V to 20V
LO = Vdd = Vbatt = 12-13.5V
49