life in the atacama, design review, december 19, 2003 carnegie mellon power system overview life in...
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Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power system overview
Life in the Atacama Design ReviewDecember 19, 2003
J. TezaCarnegie Mellon University
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power system - function
Sourcessolar panelshore power
Storagedaylight operation with reduced insolation night operations (science) hibernation
Control operation of subsystemspower distribution
Measurementengineering logginghealth monitoring
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power – Simplified Architecture
SolarArray
MPPT
Li PolymerBattery
DC/DCConverters
Amplifier/Motors
Main DC Bus
What is an appropriate battery?
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Simulation – effect of battery capacity
Battery capacity: 1500 Wh 1000 Wh 500 Wh
Input power Load profile
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery - requirements
Energy capacityat least 1000 Wh
Voltagewithin requirement of locomotion system
(75V < Vnominal < 90V)
Current capacitysufficient for obstacle climbing
Weightless than 15 kg
Thermal - operating range 0 to 40o C
ReliabilitySafety during operation and shippingCostSchedule
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – trade study
Technology Specific Energy W/kg
$/Wh Relative Cost/Wh(practical)
Eff % Life cycles Charge management
safety Can parallel?
Sealed lead acid
(AGM)
35-40 0.2-0.3 1 50–85,
70
200-500 CC, equalization; simple
Robust, H2 gas explosive
Not recommended
NiCd 30-60 0.5 2 72 1500 CC Burst, leakage no
NiMH 60-80 0.7 2.8
(7.5)
70 500 CC, thermal/pressure, dV, dT/dt; complex
Overcharge thermal runaway
No (?)
Li Ion 110 -135 4
(70)
96 500-1000 CC CV, voltage fire, leakage yes
Li polymer 170
(150 – 200)
1.15 3.6
(39)
98 150-200 CC CV, voltage Fairly safe,
No metallic Li
yes
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – trade
Sealed lead acidLow specific energy
simple, reliable, cheap
NiMH
Fair specific energy
Problems - charge control, cost, reliability, thermal, configuration
Li Ion
Good specific energy
Component and NRE costs, lead time, control, safety
Voltage required makes design complex
Li Ion Polymer
Good specific energy
Reliability / Risk (?)
Cost – limits spares, redundancy
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – implementation
Technology /
Vendor
Configuration /
Capacity
Battery Mass
Cost /
Lead time
Sealed lead acid
(Hawker - Genesis)
16 Ah x
84V
1.3 kWh
44 kg $350
days
(COTS)
Li Ion
(Saft)
31 Ah x 8 x
57 V
2 kWh
17 kg $28K + NRE (?)
2 - 6 months (?)
Li Polymer
(Worley)
3 Ah x 6 x
78 V
1.4 kWh
8 kg $7K / battery + $1.7K controller
6 to 8 weeks
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – implementation – Li polymerWorley
Li Polymer
Capacity: 1.4 kWh, 78 V (nominal)
Cost – $18K (two batteries, one controller)
Delivery – 6 (to 8) weeks
Vendor claims no shipping restrictions on assembled battery
Fabrication - Singapore
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – implementation – Li polymer3.30 Ah (rated) 3.7 V Li polymer cellSix cell parallel moduleModule size : 64 x 100 x 36 mm (approximate)21 modules in series Voltage: 63 to 88.2 V, 78V nominalCapacity: 19.8 Ah (rated)Maximum current: 35 A Battery dimensions:For example: 128 x 110 x 378 mm (2 x 1 x 11)
Volume: 0.0053 m3
Mass: 8.2 Kg, plus wiring, fuses, enclosure
One module
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – Li Polymer - Cell
Capacity dependent onCharge / discharge rate
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – Li Polymer - controller
Lithium battery safety unit – Worley LBSU-4-100Monitor individual cell voltages Monitor battery currentMonitor battery temperature
Shut off battery if out of limit condition occursAllows external reset of battery (circuit closure)Allows control of external battery relay
Serial (RS-232) communication voltage, current, temperature, fault condition reported every minute
Is this control sufficient?
One module
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Battery – Issues
Reliability
Components, vendor
Single string – no redundancy for computing load
Life cycle – limited (100 – 200 cycles)
Cost – limits redundancy, spares testing
Testing – limits life cycles
Spares – cold or hot?
Fall back / risk mitigation
Substitute other technology (SLA or ?)
Impact of change of technology• Reduction in capacity / increase in mass• Effect on Solar power tracker / solar array requirements (?)
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
DC bus
nominal – 78V
Typical range - 75.6 to 79.8 V
Maximum range - 63 to 88 V
Issues
Maximum too close to amplifier limit
Switching – light weight components limited
Fusing – circuit breakers (?) or fuses - reliability
Control – solid state relays (typical failure mode for MOSFET is to fail open)
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
DC sub buses
Typical bus voltages:5,12, 24 Vothers: 3.3, +/- 12, +/- 15 V
DC / DC convertersImplementation:Vicor – input 55 to 100V (72V nominal)High efficiency25 to 200 W units, Mega-modules, VI-200 or VI-J00 series-10 to 40 C temperature, can be paralleledVI-200 have over-temp and over-current protectionCan be shut down with gate control
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power - Architecture
SolarArray
MPPT
Li PolymerBattery
BatteryController
DC/DCConverters
Amplifier/Motors
PMADController
DC/DCConverter
Li ionBattery
Main DC Bus 78V (63 to 88 V)
Sub DC Buses
…
(5, 12, …, 24V)
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power – Architecture – Shore power
CC/CVDC supply
Li PolymerBattery
BatteryController
DC/DCConverters
Amplifier/Motors
PMADController
DC/DCConverter
Li ionBattery
Main DC Bus 78V (63 to 88 V)
ShorePower
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power - Architecture – split solar array
DC/DCConverters
Amplifier/Motors
PMADController
DC/DCConverter
Li ionBattery
SolarArray
MPPT
Li PolymerBattery
BatteryController
Main DC bus
SolarArray
MPPT
Reduce effect of shadowing and single point failure
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power – Architecture – battery redundancy
DC/DCConverters
Amplifier/Motors
SolarArray
MPPT
Li PolymerBattery
BatteryController
PMADController
DC/DCConverter
Li ionBattery
OR diodes drive main DC bus
Li PolymerBattery
BatteryController
SolarPanels
MPPT
Reduces chance of systemfault due to a battery fault
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
PMAD controller - requirements
Controls Hibernation of main computerPower for subsystems – computing, sensors, instrumentsBattery controller – reads status and internal values (cell voltage and temps), reset via serial interfaceSolar MPPT – via CAN bus interface
Acquires system measurements:Solar panel, bus voltages and currentstemperatures
Logging on main computer or internally when main computer is off lineCommunicates via main computer or external serial portHas own battery backupProvides status display on exterior panel of robot
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power – Architecture – PMAD
SolarPanels
MPPT
Li PolymerBattery
BatteryController
DC/DCConverters
Amplifier/Motors
PMADController
DC/DCConverter
Li ionBattery
Main DC Bus 78V (63 to 88 V)
V, I
V, I
CAN bus
RS-232
digital
analog
analog
PMAD controland data acquisition
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
PMAD controller requirements
I/O required
CAN bus
Serial – three ports
Digital - input / output• opto-isolated• number - TBD
Analog input – range, number TBD
LCD display driver
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
PMAD controller - implementation
PC104Low power CPUCompact flashReal time clockWatchdog timerBattery backup Can bus, Digital and analog I/O, serial portsOperating system - Linux (w/ minimal kernel)Example system:Arcom Viper, AIM104-CAN, AIM104-ADC16/IN8, ViperUSPTotal power 4.5W @ 5V with battery backup for 1 hr in full power mode or 18 hr in low power modeProvision for LCD display
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Exterior display / control panel
Displays:Battery status: charge, discharge, on/off line, fault condition, voltage, current, maximum temperatureMain system state – hibernation, normal, faultPlanner system state – on/off
Controls:Main power control (manual switch)Manual reset of battery controllerManual rest of PMAD controllerReset / halt of motion controllerJoystick inputE-Stop control
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Mechanical - thermal
Ebox – compartmentalizationBatteryVentilation, isolation, battery change out
Power distribution and locomotionPMAD (core CPU), MPPT, distribution buses, fusesLocomotion - Amplifier, motion controller I/O
ComputingAutonomy, planner, motion controller CPU, science computer (?)
Science – provide mechanical support, power, communication for:Chlorophyll detectorFluorescence cameraVisNIR spectrometerAdditional instruments
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Mechanical – thermal - issues
Thermal – ventilation not feasible
Maximize conduction dissipation
Layout - packaging
Cabling
Fabrication and field access
Carnegie MellonLife in the Atacama, Design Review, December 19, 2003
Power – requirements – load
LocomotionMotion controller – 9WMotors -
ComputingMain – 20 W Planning – 30 W Core (PMAD and hibernation) – 5 W
CommunicationsEthernet - 6.3 WLow BW - ?
SensingNav pair – 3WSPI pair – 3WLocalization – FOG 3W, SBC 2.2WCrossbow Tilt sensor – 0.24W Pan/tilt – 18W (operating)Workspace cams – ?Sick laser – 17WNovatel GPS – 12W
ScienceChlorophyll - ?VisNIR – 50W ?Plowing - ?