GRAMM International Future Energy Challenge ‘07 Geoff Sanders, Richard Tan, Ankit Tripathi, Maung Myat, and Marc Hesse

Overview Purpose & Specifications System Description Electric Machine Power Converter Controller Circuit In-circuit Debugger Other parts and purchases Updated Labor Distribution Updated detailed schedule Questions/Suggestions and Comments

Purpose & Specifications Electric machine (motor): Works both as a starter (motoring) and an alternator (generator) Must provide 30 Nm of Torque startup. Must motor up to 3000 rpm in 3-5 seconds Must generate 1 KW of power Must be at least 75% efficient Must use NEMA frame 56 Target: Hybrid Electric Car Reasons: IFEC ’07 challenge Save Space Decrease Cost Increase Efficiency

System Description Starter-Alternator Unit (motor) Pole Changing, ‘N’ winding reduction, Flux based design Power Converter Power Board (STEVAL-IHM009V1) Inverter/Rectifier Generator exciter System Controller Control Board (STEVAL-IHM001V1) Chip (ST7FMC2) Gate Drivers (MOSFET DRIVER) User Interface (On-Off switch, emergency switch) Indart series debugging board (INDART-STX/D) ST7 Debugger Program Control panel software (AK-ST7FMC)

Test Set-Up dynamometer (drive and brake) torque measurement electric machine (NEMA 56) belt drive coupling dyno control shaft position measurement machine power feeders power converter system controller PC 200 V DC

Mock Set-up with already acquired parts

Electric Machine Hardware Received free 3-phase ¾ hp squirrel cage induction machine Measured parameters and weight Determined that the slot count is 36 (we need 24 slots) Allowed us to specify the exact machine we need Baldor M phase squirrel cage induction machine 2 hp (1.49 kW) 3450 rpm, 2 pole 24 slots, 12.4 in. long, 6.8 A max NEMA 56 frame Will test, then re-wind machine for 8-4 pole configuration

starting characteristic at 27.5 Hz and 24A line peak by increasing flux Torque [Nm] speed [rpm] characteristic 1 characteristic 2 characteristic 3 characteristic 4 operating point 3 GENERATIONMOTORING I II Torque-Speed Characteristics of Machine Characteristic 1 (8-pole) Starting ~ 27Hz, Torque ~ 36Nm f->50Hz, speed -> 750rpm Switch to 4-pole operation Characteristic 2 (4-pole) f->50Hz, speed -> 1500rpm Characteristic 3 (4-pole) f->75Hz, speed -> 2250rpm N reduction (N/2) f->100Hz, speed -> 3000rpm Characteristic 4 (4-pole) Speed=3000rpm Generating V  E/f = 4.44 * N *  T = (  /2) * (pole/2)*  * F mr * sin  r Torque curves for each characteristic

8 Pole Winding Configuration and MMF 8-pole configuration N rat turns per phase  winding connection

4 Pole Winding Configuration and MMF 4-pole configuration N rat turns per phase Y-Y winding connection

Winding Switching 4-pole configuration N rat /2 turns per phase Y-Y winding connection

AC Induction Motor Control Power board SEMITOP ® 3 3kW (STEVAL-IHM009V1) Power Converter Board

Power Converter: Block Diagram Control Board Three Phase Inverter (STG3P3M25N60) AC Induction Machine Temperature Sensor Tachometer 200V Power Supply Brake Motor PWM Input BEMF HV Monitoring Power Regulation

STG3P3M25N60 3 Phase inverter IGBT - SEMITOP®3 module N-channel very fast PowerMESH™ IGBT Lower on-voltage drop (Vcesat) Lower CRES / CIES ratio (no cross-conduction susceptibility) Very soft ultra fast recovery anti-parallel diode High frequency operation up to 70 KHz New generation products with tighter Parameter distribution One screw mounting Compact design Semitop®3 is a trademark of Semikron General features

VIPer12ADIP - E Low Power OFF-Line SMPS Primary Switcher Features Fixed 60kHZ Switching Frequency 9V to 38V Wide Range VDD Voltage Current Mode Control Auxiliary Under-voltage Lockout with Hysteresis High Voltage Start-up Current Source Over-temperature, Over-current and Over-voltage Protection with Auto-Restart Description The VIPer12A combines a dedicated current mode PWM controller with a high voltage Power MOSFET on the same silicon chip. The internal control circuit offers the following benefits: Large input voltage range on the VDD pin accommodates changes in auxiliary supply voltage. This feature is well adapted to battery charger adapter configurations. Automatic burst mode in low load condition. Over-voltage protection in HICCUP mode.

L78L05ACZ POSITIVE VOLTAGE REGULATOR OUTPUT CURRENT UP TO 100 mA OUTPUT VOLTAGE OF 5V THERMAL OVERLOAD PROTECTION SHORT CIRCUIT PROTECTION NO EXTERNAL COMPONENTS ARE REQUIRED AVAILABLE IN EITHER ±5% (AC) OR ±10% (C) SELECTION

Silicon Avalanche Diodes (P6KE Series) 600 Watt Axial Leaded Transient Voltage Suppressors FEATURES RoHS Compliant 6.8 to 550 Volts Uni-directional and Bi-directional Glass passivated chip junction in DO-15 Package 600W surge capability at 10/1000μs wave form Excellent clamping capability Low zener impedance Fast response time: typically less than 1.0ps from 0 Volts to BV min. Typical IR less than 1μA above 10V

Power converter’s schematic

System controller Board AC Induction Motor Control Control Board STEVAL-IHM001V1

ST7MC2 44-Pin LQFP Package Pin-outs

System controller’s schematic

System Controller: Block Diagram ST7FMC2 A/D Converters Bridge Drivers (L6386) PWM Generator LEDs Power Board Feedback Potentiometers Debug Board ICC Interface ICC Connector Switches SPI Interface 16 MHz Oscillator SPI EEPROM (M95040) 16 KB FLASH Memory 768 Bytes RAM

PWM Timing MCMP0 Register Phase U Preload Register Phase V Preload Register Phase W Preload Register Phase W Waveform Phase V Waveform Phase U Waveform

System Controller Flowchart Initialize Peripherals Main Loop Check State Check for Errors Update LEDs Send System Data (RS232) Idle Start Run Stop Brake Wait Fault Interrupts Event U Reload PWM Duty Cycle Event R or Z Event C or D Tachometry Emergency Stop Stop Motor ART Reset Update Counters SCI Send Data External

User Interface/Debugger Testing the Control/Power board

Why use inDart-STX? Real time code execution without Probes In-Circuit debugging Hardware and software testing in real time Built in FLASH programmer (Data Blaze Programming utility) Visual Debug user interface (with integrated C compiler and assembler and source level symbolic debugging) Hardware self diagnostic test Working frequency as high as the microcontroller itself Allows for programming the content of FLASH when chip already is in the circuit Uses ICC (In circuit communication to interface the programming tool like inDART) with the microcontroller we have

User Interface/Debugger inDart-STX

Pin out for inDART

ST7 Debugger Program

PC Interface Controller Control panel software (AK-ST7FMC)

Other Parts Purchased for Testing

Safety Safety shield Face shield

Distribution of Work Geoff Custom Motor Programming the micro-controller Richard Custom Motor Calculation and simulation with the actual motor parameters Maung Custom Motor PCB layout for the 64 pins controller Ankit Custom Motor Permanent motor design/ Programming the micro-controller Marc Programming the micro-controller Documentation

Gantt Chart

Milestone 1 Test system using regular induction machine With 64 pin controller board (1 st revision) Should work the same as purchased 44 pin controller board Custom machine nearly finished Switching circuit complete (wire wrap)

Milestone 2 Complete system test with: Custom machine finished Completed switching circuit PCB Pole changing ability confirmed

Final Open-Lab Expo Complete closed-loop operation of: Custom pole changing induction machine implementing N reduction Meeting the basic IFEC requirements Documentation complete

Questions / Comments Thank you!