Circuit Breaker CalibrationPhilip Simonin (EE)

Kyle Weber (EE)Louis Leblanc (EE)

Tyler Lyon (EE)Advisor: Ali Gokirmak

Sponsor: Carling Technologies

Outline

1. Design objective and approach2. Hardware specification

1. Circuit Breakers2. PSoC3. Stepper Motor4. Pneumatic rig5. Relays6. Load bank

3. Circuit Design Diagram4. Alternative Design Possibilities5. Budget6. Timeline

Objective

• Design and create functioning circuit calibration unit• Comprised of pneumatic press, stepper motor,

PSoC, load bank, relays• Breakers of 5, 10, 15, or 20 Amperes must be

brought to proper trip point• PSoC will be the microcontroller

Problems To Address

Calibration currently done manually

Introduces unwanted human error

+/- 30% error

Effects manufacturing production

rate

Makes testing difficult for technicians

Our Solution

• Reduce margin of Error to +/- 10% (goal)

• Can be integratable into mass production

• More reliable product delivered to customer

• Simplified testing for engineers and

technicians

What is Being Calibrated?

• The spring attached to the actuation arm• Controls magnetic flux in the plunger• Alters current let-through and trip-point

Adjusts spring force onactuation arm

Applications

• Minimizes inaccuracies between products

• Allows engineers and technicians to test

products and achieve a repeatable

threshold

• Allows for testing of breakers before

shipment

• Modifiable for other product lines

• Can be applied to multiple poles potentially

Specifications

Circuit Breaker Specifications:

•A-Series Circuit Breakers• 5, 10, 15, 20A rated breakers• Max Voltage Current Rating: 80

VDC• Resistance values from Line to Load

Terminal• Single Pole• 10,000 ON/OFF operations @ 6 per

min.• Trip free

Breaker Architecture

Adjustment screw

Magnetic Sensing Coil

PSoC

• PSoC® 4 CY8CKIT-049 4200• C code programmable, via USB• Monitors current• Signals relays and stepper (bidirectional)• Conducts calibration adjustments• Automates system• Complete in 30 seconds or less

Top Design and Control

• Clock can be adjusted to speed of stepper motor

• ADC with follower input configuration from op-amp and protected by Zener.by Zener, looks for contact open/close

• Provisions for breaker in position are TBD

• Outputs kept at low level current and drive optocouplers and LEDs

PSoC Pinout

• Approximately 35 pins for I/O

• Data paths available

• Easy to program

PSoC MiniProg

• PSoC programmer via USB• 5 pin docking and programs in

seconds• Alternate ten pin or direct USB

available

Stepper Motor

Nema 11 Motor

• Step angle: 1.8°± 5% • Two Phase• Bidirectional

Holding

Torque

Current /

Phase

Voltage /

Phase

Phase

Resistance

Phase

Inductance

(1KHz)

0.6 Kg*cm 0.67 A 3.8 V 5.6 Ω± 10% 4.2 mH± 20%

Stepper Motor

Physical Dimensions:

• Bi-polar Microstepping Driver

• 2A/Phase Max

• 1.4-1.7A/Phase w/o Heatsink

• Max Motor Drive Voltage: 30V

• On-board 5V/3.3V Regulation

Motor Driver

opto

opto

opto

opto

opto

opto

opto

opto

a

bc

d

++

+ +

Pneumatic Press/Rig

• Pneumatic activated to contain breaker vertically (50 psi)

• Spring loaded compress for horizontalcontainment

Yellow: Stepper MotorRed: ArmatureBlue: Adjustment screwGreen: Horizontal SupportOrange: Connectors to breakerNot shown: Solenoid to interrupt trip

Power Relay

• Coil Voltage: 6-600V• Current Max: 40A• Response Time: 30 ms• Average Power Dissipation: 4 W

Optocoupler – 4N26

Input Parameters

Reverse Voltage 5 V

Forward Current 60 mA

Surge Current 3 A < 10µs

Power Dissipation 100 mW

Output

Collector Emitter Breakdown Voltage

70 V

Emitter Base Breakdown Voltage 7 V

Collector Current 50 mA (100 mA < 1ms)

Power Dissipation 150 mW

Load Bank

Taps:• One tap for 200% Current• Another for 115% Current

(for calibration)

Breaker Test Diagram

PSoC Operating

• Red – on for 10 seconds during200% load

• Clear LED – indicates activated relay, calibration commence

• Yellow – flashes indicatingpower to motor

• Green – Alive pin• Blue – Test done

Alternative Designs

• In place of the PSoC, use an Arduino, PLC or FPGA

• Construct our own mechanical unit in place of the rig provide by Carling Technologies

Budget

Quantity Item Model Specifics Cost

(1) Programming Unit for PSoC

CYPRESS – CY8CKIT-002 PSoC® MiniProg3 Program and Debug Kit

$82.43

(1) Stepper Motor Model – NEMA-17, product code: RB-Ada-138

$14.00

(1) Alternative Stepper Motor

Model NEMA-11, product code: 11HS12

$16.99

(1) USB oscilloscope From Analog Discovery, to be used with LabVIEW

$159.00

(1) Analog Parts Kit $49.99 (w/ academic discount)

Budget Continued

Quantity Item Model Specifics Cost

(1) NI Multisim & NI Ultiboard

NI Circuit Design Suite $9.95 (w/ academic discount)

(1) Analog Discovery BNC Adapter Board

$19.99

(1) BNC Oscilloscope Probes (pair)

$19.99

(1) Mini "Grabber" test hooks

$14.99

(1) Project Box + StickerSheet

$7.00

(2) Relay Schneider Electric/Magnecraft Model 119DBX-3

$37.70

Quantity Item Model Specifics Cost

(3) Signal Relays Kemet EE2-5NU-L, 3.75 V

$1.81

(3) Signal Relays Kemet EC2-12NU, 9 V $1.97

(6) Optocouplers Part number: 4N26 $0.59

Total: $484.61

Budget Continued

Timeline of Project

Questions?