lprds – cms – 2011
DESCRIPTION
LPRDS – CMS – 2011 . Per Cell Management Design. Presentation Outline. Introduction Project Goals One Board Per Pack ESS Controller Board System Communication Mechanical Design ATP / Requirements Analysis Budget Schedule. Presentation Outline. Introduction Project Goals - PowerPoint PPT PresentationTRANSCRIPT
LPRDS – CMS – 2011 Per Cell Management Design
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
3-year Senior Design Project2009 Legacy Work
2010 Legacy Work
2011 Projected Work
Lafayette Photovoltaic Research and Development System (LPRDS)
LCD Display
SCADA Interface Box (SIB)Fit PC
System Status Display
Filter Inverter Box (FIB)
Switch Controller / Energy Management Unit(SC / EMU)
Energy Storage System (ESS)
Transformer
Energy Storage System (ESS)
LPRDS-CMS-2011•Finish a per-cell
balancing scheme for the 64-cell LiFePO4 battery pack.
•Complete design so that energy storage system is capable of being utilized by the LPRDS system.
Plan of Work•Develop a “Slave Board” (OBPP PCB) which
will balance during charge/discharge a pack of 4 cells
•Develop a “Master Board” (ESSCB PCB) which will control the functioning of the OBPPs to charge/discharge/bypass a particular cell.
•Develop a “Stand-alone” mode for the OBPP in which a pack and OBPP together do not need the master to make decisions for bypassing during charge/discharge.
Aggregate Battery Stack with OBPP PCBs
Energy Storage System Master Controller Board (ESSCB PCB)
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
Project Goals•Develop a One Board Per Pack PCB which
can handle the balancing of a 4-cell battery pack.
•Modify previous ESS Controller Board which can control individual OBPP packs for total pack charging/discharging.
•Develop method of visually demonstrating operation of ESS.
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
One Board Per Pack (OBPP)
One Board Per Pack :: Key Features•Individual cell balancing capabilities•Two Modes of Operation (Slave & Stand-
alone)•Boots in Stand-alone Mode•LEDs indicating operational state of pack•LEDs indicating operation of bypass•Scalability•Temperature Fail-Safe System
One Board Per Pack :: Design
One Board Per Pack :: Design•Resistive burn-off bypass solution•Independent redundant temperature safety
system (RTSS)•Individually addressable packs for master-
slave configuration•Stand-alone operation with charge state
controlled open collector output•Implements I2C communication in master-
slave configuration•*Current sensing capability
Cell Balancing Design•Breakdown of design trade-offs
▫Active vs. Passive Balancing▫Level of Integration▫Delegation between Controller and OBPP
boards▫Scalability▫Layout Space▫Cost▫Manufacturability▫Availability
Active Vs. Passive Balancing•Active: Using capacitive or inductive
loads to shuttle charge from higher charged cells to lower charged cells.▫Is more efficient from a power perspective▫Has scalability issues▫OBPP boards are larger and handle more
work▫Manufacturability issues
Active Vs. Passive Balancing•Passive: Bypasses cells and burns off the
excess charge from the cell.
▫Better large-stack scaling
▫Burn off can be significant
▫Controller board handles decision-making
Bypass Design•Grounding the floating reference
•Choosing a resistor value
•Choosing a suitable transistor
Bypass Design – Resistor Choice
Bypass Design
Bypass Design – Transistor Simulation
These numbers give a maximum power dissipation of 2.122 * 1.5 = 6.74W, which is about 35 degree temp rise using the thermal resistance of the resistor alone.
Bypass – Final Thoughts•Only the most recent simulations•Several different iterations of components
and control schemes•Final design can reasonably bypass 1/5 C
at full charge•Limitations of the bypass circuit heavily
influenced the balancing algorithm
Critical Monitoring•Battery Voltages•Temperature
▫On board and RTSS•Current
▫Direction and Amplitude•Open-Drain Output
▫Optional Automatic Control•Fuse
Critical Monitoring - Voltage
Critical Monitoring - Voltage•Difference Amp to buffer and isolate
battery voltages
•Monitors for voltage thresholds that indicate a full or empty state
•Balancing algorithm requires them
Critical Monitoring - Temperature•RTSS discussed later
•Voltage output temperature sensors for non-critical temperature monitoring
Critical Monitoring - Current•A relatively new addition
•Gives a way to independently judge whether the pack is charging or discharging
•Required for the balancing algorithm
Critical Monitoring – Output Pin•Based entirely on OBPP calculations
•Allows the user to have a charging circuit that is autonomous
•An open drain output from the microcontroller
Critical Monitoring - Fuse•Another new addition
•Will protect the CMS from currents above 25A
Digital I/O•Master/OBPP communications will be
over I2C
▫OBPP will have a 4 bit switch addressing
•OBPP will transfer from Standalone to Slave when I2C becomes active
•Master commands override OBPP automated tasks
Redundant Temperature Safety System (RTSS)• Independent functionality to shut down system when
temperature exceeds 65°C
• Connection to each OBPP using AD22105 “Low Voltage, Resistor Programmable Thermostatic Switch” Integrated Circuit▫(Setpoint accuracy = 2°C)
• When any board exceeds the temperature limit, the switch within the safety loop is activated and the system shuts down.
Overall RTSS
•Does not work as stand-alone pack
•Must be connected to ESSCB Safety Loop
RTSS parts on OBPP
To other OBPPs
OBPP Connection to Safety Loop
to OBPPs
OBPP Thermal Analysis (Charging/Discharging)
Aluminum
CopperFR4 (Circuit board)
Lithium Iron Phosphate (Aluminum)
Acrylic Plastic
OBPP Thermal Analysis (Bypass Scenario)
Aluminum
CopperFR4 (Circuit board)
Lithium Iron Phosphate (Aluminum)
Acrylic Plastic
Stationary Analysis (1 cell heating)
Stationary Analysis (4 cells heating)
Stationary Analysis (Conductive slabs)
Stationary Analysis (Bypass scenario)
Time Dependent (1 cell)
Time dependent (Bypass Scenario)
OBPP Operational Verification•Bypass LEDs to indicate resistive
bypassing
•LEDs to indicate charge/discharge and mode of operationSolid –
ChargedBlink –
Charging
Solid – Discharged
Blink – Discharging
Solid – SlaveBlink – Stand-
aloneSolid – Bypassing
OBPP Additional Notes•Multiple levels of electrical isolation
▫Microcontroller/bypass loop
▫I2C on OBPP and Master board
▫RTSS isolated as well
OBPP Firmware•Stand-alone Mode
•Slave Mode
•Cell Balancing Algorithm
OBPP Firmware - Standalone•Begins after a reset or losing the I2C
clock signal
•Watches for voltage thresholds
•Cell balancing is enabled
•Waits for I2C connection
•First firmware development milestone
OBPP Firmware – Slave•Many of the same responsibilities
•If no explicit instructions from the master, very similar to Standalone
•Master commands are executed first and prioritized
OBPP FirmwareStand-alone Mode
Dis-chargin
g
Slave Mode
Charging
Check
Status
Bypass
Bypass
Sleep
Dis-chargin
gChargin
g
Check
Status
Bypass
Bypass
Sleep
•Type- Lithium Iron Phosphate (LiFePO4) •Nominal Voltage - 3.2 V •Capacity – 10 A-h
Cell Specifications
Cell Behavioral Simulation
Cell Behavioral Simulation
Cell Behavioral Simulation
Average Slope (V/min) 0.00208
• Charging▫ If the voltage of any cell in a pack of 4 is greater than
any of the other 3 cells by more than 40mV, then that cell will go into bypass for 20 minutes.
▫ During charge, a green LED on the OBPP will blink▫ If the voltage of any cell exceeds 3.8V, then the pack will
be considered fully charged, and the CMS will notify the user to discontinue charging (this must happen regardless of whether the cell is in bypass or not)
▫ If the temperature of any cell exceeds 40° above ambient, then the CMS will notify the user to discontinue charging (this must happen regardless of whether the cell is in bypass or not)
Cell Balancing Algorithm (1 Cell)
• Discharging▫ If the voltage of any cell in a pack of 4 is less than any of
the other 3 cells by more than 40mV, then all other cells will go into bypass for 20 minutes.
▫ During discharge, a Red LED on the OBPP will blink▫ If the voltage of any cell drops below 2.8V, then the pack
will be considered fully discharged, and the CMS will notify the user to discontinue discharging (this must happen regardless of whether the cell is in bypass or not)
▫ If the temperature of any cell exceeds 40° above ambient, then the CMS will notify the user to discontinue discharging (this must happen regardless of whether the cell is in bypass or not)
Cell Balancing Algorithm (1 Cell)
•OFF▫If the CMS is in the OFF state, either a
Solid Red LED will indicate that the pack is fully discharged, or a Solid Green LED will indicate that the pack is fully charged
▫If the CMS is in the OFF state, no cells will be in bypass
▫If the CMS is in the OFF state, all time differentials will be set to zero
Cell Balancing Algorithm (1 Cell)
•Bypass▫If a cell is in bypass, a Solid Red LED in
parallel with the Bypass resistor will be lit
Cell Balancing Algorithm (1 Cell)
Cell Balancing Algorithm (1 Cell)
Check Status ChargingBlink Green LED
Bypass CellBypass LED
Blink Green LED
OFFSolid Red/Green
DischargingBlink Red LED
Bypass CellsNot in This StateBlink Green LED
Time < 20 min
Always
Time < 20 min
Temp > 60°C || V < 2.8V
V < (V of any Cell – 40mV)
ELSE
V > (40mV + V of any Cell) || V > 3.5V
ELSE
isCharging
isDischarging
Reset || Change in Status
Temp > 60°C || V > 3.8V
Any Other Cell is in OFF State
3/9/2011Cell Balancing Algorithm
State DiagramJustin Bunnell
LPRDS-CMS-2011
Temp > 60°C || V > 3.8V
Temp > 60°C || V < 2.8V
Cell Balancing Simulations
Cell Balancing Simulations
Cell Balancing Simulations
Cell Balancing Simulations
Cell Balancing Simulations
Cell Balancing Simulations
Cell Balancing Simulations
Cell Balancing Simulations
Power dissipation across power resistor
Time
Pow
er D
issi
patio
n (W
)
Cell Balancing Algorithm Pros•Cell Balancing within 10 charge/discharge
cycles•Ability to be done in Standalone Mode•Relative Simplicity•Strict conditions to keep cell within safe
ranges•Bypass current does not scale at same
rate as charge current
Cell Balancing Algorithm Cons•Cell Characteristic Differences•State of Health of Cell•High State Of Charge Mismatch•Power Losses to Bypass Resistor
(especially during discharge cycle)•Losing balancing time by limiting
maximum temperature (limit to bypass resistance)
•Minimum charge and discharge currents
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
ESS Controller Board
ESS Controller Board … redesigned
NC
NC
PIC 18F4525
HV Lines
12/5 V Supplies
Safety
RS-485
I2C
Temp Safety Loop
NC
To ABS(Aggregate
Battery Stack)
ESS Controller Board :: Key Features
•Fuel Gauge Algorithm (FGA)•I2C Interface Communication with OBPP•I2C Interface LCD Screen•4 LEDs indicating state of CMS•Current Sensing•RS-485 Communication with SCADA•Redundant Temperature Safety System
(RTSS)
ESS Control BoardPRELIMINARY DESIGN
ESS Control Board• Primary Functions:
▫Transmit CMS information (Voltage, Temperature, Current) to SCADA system
▫Monitor current Fuel Gauge Algorithm
▫High Voltage Indicator▫CMS Display (LED’s and/or LCD)▫Safety Loop▫Override OBPP’s if necessary
ESSCB Continued…•Re-use PIC18F4525
• Re-use code from last year• Re-use power sources, sensors, terminals,
LED’s, etc from last year• Re-use safety loop
•Communication• RS-485 Interface with SCADA system (SPI)• I2C Interface with OBPP’s and LCD• For the PIC I2C and SPI share the same line
TI I2C I/O Expander
ESSCB Continued…•Fuel Gauge Algorithm
• Coulomb counting Use current sensor to measure charge in and
out of cells Reset to full capacity at full voltage threshold
ESSCB Continued…•Display
• Several LED’s: Charging, Discharging, Fault, 30V Indicator
• LCD Display I2C interface System Reset System Power
ESS Bill of MaterialsPart number Description Price Quantity Subtotal
CFA533-YYH-KC LCD Panel/ Keypad $54.84 1 $54.84 LCD Cable $5.00 1 $5.00
PIC18F4525 Microntroller $5.60 1 $5.60
ADUM2250 Opto $6.00 3 $18.00
LM2901 Comparator $1.20 1 $1.20
HLMP-1790-A0002 LED-Green $0.62 6 $3.72
HXS 20-NP Current Sensor $14.00 1 $14.00M57184N-715B Voltage Regulator $7.81 1 $7.81
LM2936 Voltage Regulator $1.93 1 $1.93
555-1058-ND Voltage Regulator $12.10 1 $12.10
PCB $66.00 1 $66.00
6N135 Optoisolator $0.73 1 $0.73SN75240P EDS Protection $1.15 1 $1.15
BS170 Mosfet $0.23 1 $0.23
tca9554a I/O Expander $2.84 1` $2.84
Caps, Resistors, Connectors $15.00 1 $15.00
TOTAL: $210.15
LPRDS Software Architecture 2010
SCADA Communication
SCADA Communication• Add additional parameters for query
• Increase polling times/ polling delay
• Poll ESS ESS Poll OBPP OBPP Respond ESS Respond to OBPP
System Communication
RPI EMU ESS SIB FitPC
1 162345678
1514131211109RS-485
SCADA Communication (half-duplex & daisy-chained)
I2C Communication (half-duplex)
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
Mechanical Design
Pack Indicators & Heatsink Possibilities
Heatsink
CELL 1 BYPASS CELL 2 BYPASS
CELL 3 BYPASS CELL 4 BYPASS
CHARGE
DISCHARGE
MODE
Negative
Terminal
Positive Termina
l
Nylon Stando
ff
2-Position Terminal
Block
Female Wire
Connector
Male Wire
Connector
Female Plug
Wire harness 1 (packs 1-8)
Wire harness 2 (packs 9-16)
Physical Dimensions
117 mm
107 mm
53 mm
15 mm
160 mm
21 mm
8 mm
Energy StorageManual Battery Disconnect
Status of ESS
DANGER
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
Acceptance Test Plan (ATP)• Modified the requirements of the system
▫Agreed upon by Professor Nadovich• Testing at the highest level: full CMS• All requirements not verified at top level:
▫Low-level Testing (QA Audit)▫Analysis (Technical Memos)
• Requirements are checked off on the Acceptance Test Report (ATR) as they are met
• ATR is based on the ATP
Expected Tests• ATP Test 001
• Demonstrates per cell battery management• Charge every cell to maximum capacity• Stand alone operation • Operate for at least 24 hours autonomously
• QA Test 001• Prevent over-charge or over-discharge
• QA Test 002• Verifies operation of SCADA system
• QA Test 003• 30V Indicator LED
Enhanced Requirement Analysis•Breakdown of the ATP•Matches each of the requirements with its
respective top-level or low-level test
ATP T001 QA Audit R002-4 QA Audit R002-6 QA Audit R002b-10
R002-2 X
R002-3 X
R002-4 X
R002-5 X
R002-6 X
R002b-2 X
R002b-10 X
R002b-13 X
GPR006-4 X
Brief Maintainability Analysis•Recommended Spare Parts: fuses,
connectors, wires, full boards•Troubleshooting scenarios in User’s
Manual using parts in Maintenance Manual▫How to replace a blown fuse▫Reset buttons on system boards▫Reprogram OBPP/ESS microcontrollers
Brief Manufacturability Analysis•All components listed on Bill of Materials can
be purchased from at least two independent suppliers.
•Critical components are identified and tolerances of these components are considered.▫RTSS resistor to set activation temperature▫Voltage threshold for cell balancing algorithm▫Resistors to manage the bypass loop▫Components for fuel gauge algorithm -> NOT
critical (only used for general measurements)
Reliability Analysis• Accomplishments
▫ Simplified schematic of OBPP board to be used for analysis
▫ MTBF of each isolated component
• Upcoming tasks▫MTBF for Temperature
Sensor ▫Determine failure criteria▫Calculate overall MTBF
ATMEGA 16
257 Series Blade Fuse
LM2936
+12V
+5V
TC1023
+5V
SIMPLIFIED OBPP CIRCUIT BOARD
TLC2254
TLC2254
TLC2254
TLC2254
6N135(Opto-
Isolator)
HV
FusePower
OP-Amps
Voltage Regulato
r
Temp. Sensor
μprocessorOptoisolator
Bypass mechanisms
(resistor + BJT)
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
Budget
ESSOBPPWiringHardwareRemaining Budget:
$1915.85
$418.86$257.70
$208.60
$198.99
ESSOBPP (scaled)WiringHardwareRemaining Budget:
Budget – With 14 Added OBPPs
$2061.60
$418.86
$111.95
$198.99$208.60
Presentation Outline•Introduction•Project Goals•One Board Per Pack•ESS Controller Board•System Communication•Mechanical Design•ATP / Requirements Analysis•Budget•Schedule
Schedule•We made several complete design
changes which caused us to stray from the initial schedule.
•Initial schedule was incredibly vigorous and less reasonable.
•Current schedule is more reasonable, but we have still fallen behind due to redesigns of the OBPP and fine-tuning our stand-alone operation.
Most of schedule slip occurred because design took longer than expected.
Questions?•Thank you for your attention.