AC ACTIVE LOAD FINAL PRESENTATION

Presented by:Mark Fraysier

Richard Jennings11/28/2012

Recap: What is the AC Active Load?

Testing equipment device for three-phase devices

Analyzes how efficiently machines operate using desired, created load.

Done by manipulating the power triangle

How we left EE 480Part # # Used Price for 1 of each ($) Price*#

Piccolo Experimenter Kit TMDSDOCK28035 1 130 130Heat Sink (DC Chopper) 530002B02500G 1 1.71 1.71Heat Sinks (Converter) RA-T2X-51E-ND 6 2.55 15.3Switch (DC Chopper) AOT12N60 1 1.52 1.52Switches (Converter) IXFH30N50Q3 6 10.33 61.98Input Filter Inductor Core T650-26 3 30 90Input Filter Capacitor B32794D3126K 3 6.02 18.06AC Metering (Input Filter) CS5463 3 1.97 5.91Display Module NHD0420D3ZNSWBBW 1 18 18Drivers (all MOSFETs) FAN73711MXCT-ND 7 1.29 9.03PCB 1 1 100 100PCB 2 1 100 100PCB 3 1 100 100PCB 4 1 100 100Power Dump TMC50-.25-ND 80 3.66 292.8Heat Sinks (Power Dump) 091 Feet of Copper Wire (10 ga) 3 28.21 84.63Minor Component Estimation 1 1200 1200

GRAND TOTAL 2328.94

Summer Contributions

Research of cost reduction Communication between group members

Reassured what our efforts would be during the beginning of EE 481

The Beginning of EE 481

The Reaction

We met with Dr. Famouri Dr. Famouri suggested us to get rid of all

systems except AC Switches DC Chopper Microprocessor Drive Circuits Zero Crossing Detector Filters

This dramatically reduced the costs and complexity of the project

The New Parts ListPart # # Used Price for 1 of each ($) Price $

Microprocessor 296-31062-ND (DigiKey) 1 82.03 82.03 Note: This is the F28027 Experimenter KitHeat Sink (DC Chopper) 530002B02500G 1 1.71 1.71Heat Sinks (Converter) RA-T2X-51E-ND 6 2.55 15.3Switches (Converter) IXFH30N50Q3 8 10.33 82.64Input Filter Capacitor B32794D3126K 3 6.02 18.06DC Chopper Filter Capacitor P13837-ND (digikey) 10 2.74 27.40.8 mH Inductor CMT1-0.8-12L 3 0 0 Free Sample1.4 mH Inductor CMT1-1.4-12L 3 0 0 Free Sample2.5 mH Inductor CMT3-2.5-15L 1 0 0 Free Sample3 mH Inductor CMT3-3-12L 1 0 0 Free SampleDiodes (Drivers) 596-1352-5-ND 7 1.95 13.65Diodes (Zero-Crossing) DFLS130LDICT-ND 3 0.49 1.47Drivers (all MOSFETs) FAN73711MXCT-ND 7 1.29 9.038-pin Surfboard 6808CA-ND 1 2.34 2.34Pinless Surfboard 9081CA-ND 7 1.49 10.43Bread Board Sheet 438-1021-ND 1 45 45Thermostats 317-1014-ND 3 6.56 19.68Knobs 987-1276-ND 2 0.76 1.52Transformer 595-1206-ND 1 10.12 10.12Resistors: (ohm)

16500 RNF14FTD16K5CT 1 0.15 0.1568 7 0 0 Acquired in Lab

1.1 7 0 0 Acquired in Lab1000 3 0 0 Acquired in Lab

1.20E+06 7 0 0 Acquired in LabCapacitors:

0.1 uF BC2665CT-ND 6 0.37 2.221 uF BC2668CT-ND 1 0.94 0.94

22 uF 490-5387-ND 7 1.81 12.67Anti-corrosive goo 2 3.02 6.04Screws and Bolts Lowe's - 15 EstimatedAluminium Sheets Lowe's 2 20Wires 0 Taken from Various Supplies

TOTAL 362.4

Zero Detection Circuit

Drive Circuits

Bi-directional Converter

Input Filter

DC Chopper

Entire System Schematic

Software Design

(See Microsoft Word Document)

Construction Process

Printed Circuit Boards were removed from our design

This drastically increased the amount of labor to construct the hardware Surfboards Assembly

Design Achievements

We completed nearly all hardware construction of the system as designed With + or – 10% tolerance

The seven drive circuits were tested and operated correctly

We ran out of time to do the software

Demonstration of AC Active Load

We will attempt to manually generate our own pulse width modulation using lab supplies No microprocessor No zero crossing circuit No knobs

Software Simulation

Simulation Parameters

FSW=5 kHz

NOTE The simulation was done for maximum load

power with unity power factor

Simulation Results

Simulation Conclusions

From the graph we determine that this load would work well with the generator

However, the simulation does not include the effects of switching losses

We must build the hardware to demonstrate switching losses

Still, the simulation provides useful information about the system

Drive Circuits Test Results

The Drive Circuits functioned properly during independent testing.

However, the turn-on rate for the MOSFETs appears to be insufficient for proper operation at 10 kHz.

This may be remedied by adjusting component values in the Drive Circuits

Safety Precautions

An external housing would greatly improve the safety of the system.

Proper design of the system makes failure unlikely, however operator misuse could result in injury or death due to electrocution.

Reflections

Lack of proper communication with our mentor resulted in a lot of wasted time

Wasted time resulted in our failure to have software operational

We will test the system over the next several days using our own created PWM

We won’t know the final results of the entire system performance until then

Advice for Future AC Active Load Senior Design Endeavors

Have 4 group members 2 Electrical Engineers 1 Computer Engineer 1 Computer Scientist

The computer engineer and computer scientist work on the software while the electrical engineers work on the hardware

Include the automatic feedback and include a simple user friendly GUI

Potential Development of Project

Incorporate externalized elements to create independently functional device Meters Display Power supply Power dump

Add canceled features back into the system Computer interface Battery back-up Internal memory

Any Questions?