Compact DC/AC Power Inverter Design Day - Fall 2014 Philip Beard - - PowerPoint PPT Presentation

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Compact DC/AC Power Inverter Design Day - Fall 2014 Philip Beard - - PowerPoint PPT Presentation

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Compact DC/AC Power Inverter Design Day - Fall 2014 Philip Beard Jacob Brettrager Jack Grundemann Stanley Karas Travis Meade Team 7 - Compact DC/AC Power Inverter 12 -05-14 Outline Introduction to Power Inverters Motivation and

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Team 7 - Compact DC/AC Power Inverter • 12-05-14

Compact DC/AC Power Inverter Design Day - Fall 2014

Philip Beard Jacob Brettrager Jack Grundemann Stanley Karas Travis Meade

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Outline

  • Introduction to Power Inverters
  • Motivation and Goals
  • Design Specifications

○ Little Box Challenge ○ Chosen Parameters

  • Final Design

○ Self Assessment

  • Future Suggestions
  • Demonstration and Questions

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Introduction to Power Inverters

  • Convert DC to AC

○ Power devices ○ Supplement grid

  • Variety of sizes & applications

○ Solar, portable power, etc.

  • Design constraints:

○ Size, efficiency, power density

Team 7 - Compact DC/AC Power Inverter • 12-05-14

http://en.wikipedia.org/wiki/Power_inverter

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Motivation and Goals

  • Opportunities from Industry
  • What could a new design mean?

○ Better stand alone systems ○ Greater efficiencies ○ Solar power generation

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Motivation and Goals (cont.)

  • Falling panel prices, stagnant inverter prices
  • Easy to find room for tissue box sized device
  • Modified sine waves are “sloppy”

Team 7 - Compact DC/AC Power Inverter • 12-05-14

http://www.theengineeringprojects.com/wp-content/uploads/2012/11/Pure-Sine-wave-Inverter-With- Code3.jpg

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Motivation and Goals (cont.)

  • New technologies provide more design choices

○ Silicon Carbide ○ Gallium Nitride

  • Inexpensive, open-source availability

○ Free Libraries ○ Extensive Support

Team 7 - Compact DC/AC Power Inverter • 12-05-14

http://www.cree.com/power/littleboxchallenge

Chosen MOSFET

http://arduino.cc/en/Trademark/CommunityLogo

Arduino Logo

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SLIDE 7

Design Specifications

Parameter Requirement (Nominal) Maximum Load 2 kVA Power Density > 50 W/in3 Volume < 40 in3 Voltage Input 450 V DC Voltage Output 240 V RMS AC Frequency Output 60 Hz Maximum Outer Temperature < 60 °C Electromagnetic Compliance FCC Part 15 B

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Design Specifications (cont.)

Parameter Requirement (Nominal) Maximum Load 1 kVA Power Density > 25 W/in3 Volume < 40 in3 Voltage Input 200 V DC Voltage Output 120 V RMS AC Frequency Output 60 Hz Maximum Outer Temperature < 60 °C Electromagnetic Compliance FCC Part 15 B

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Final Design

Team 7 - Compact DC/AC Power Inverter • 12-05-14 DC-DC Conversion

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Final Design (cont.)

Team 7 - Compact DC/AC Power Inverter • 12-05-14 Pulse Width Modulation

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Final Design (cont.)

Team 7 - Compact DC/AC Power Inverter • 12-05-14 H Bridge

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Final Design (cont.)

Team 7 - Compact DC/AC Power Inverter • 12-05-14

Final Printed Circuit Board Layout 3” x 3.3”

  • Board Size
  • Trace widths
  • Vias
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Final Design (cont.)

Team 7 - Compact DC/AC Power Inverter • 12-05-14

Initial Enclosure Layout

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Final Design (cont.)

Team 7 - Compact DC/AC Power Inverter • 12-05-14

Inductor Enclosure Final Layout

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Budget

Team 7 - Compact DC/AC Power Inverter • 12-05-14

Item Price Quantity Total Description

C2M0025120D $71.99 4 $287.96 Silicon Carbide MOSFETs FAN7382 $3.75 2 $7.50 600 Volt Gate Driver DC-DC Converters $2.02 2 $4.04 Supply Rail for Micro Controller LM2940 $1.65 1 $1.65 5V Regulator Enclosure $24.37 1 $24.37 Aluminum Enclosure ATMega328 $4.95 1 $4.95 Arduino Microcontroller PCB $0.00 1 $0.00 Printed Circuit Board from ECE Shop

TOTAL: $330.47

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Future Suggestions - Heat Design

  • Better materials

○ Heat sinks ○ Plating

  • Milled Enclosure

○ PCB Guides ○ Dissipation fins

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Future Suggestions - Printed Circuit Board

  • Contain H Bridge, filter, processor, and DC/DC converter
  • n same PCB
  • Use surface mount over DIP components

○ Smaller, contain multiple parts

  • Port placement

○ Transistor closer to edge

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Future Suggestions - Filtering

  • Current filter designed for smaller loads (~ 400W)
  • 1 capacitor over capacitor bank

○ High voltage

  • Increase inductor wire diameter
  • Isolation transformer

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Conclusion

  • Education

○ The process ○ Technical integration

  • Self Assessment

○ Shortcomings ○ Successes

  • Thank you

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Demonstration and Questions

Now, time for a video demonstration...

Team 7 - Compact DC/AC Power Inverter • 12-05-14

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Questions

Questions?

Team 7 - Compact DC/AC Power Inverter • 12-05-14