osu research program in mechatronic systems · system development issues (2)! fuel cell modeling...

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OSU Research Program In Mechatronic Systems

Ali KeyhaniMechatronics LaboratoryDept. of Electrical EngineeringThe Ohio State University

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Acknowledgement! IEEE FEC’03 Student Competition

Organizer! Ph.D. Students

"Nanda Marwali"Wenzhe Lu"Min Dai"Jin-woo Jung

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Outline! Graduate Program in Mechatronics! New Initiative Fuel cell energy

conversion systems! By Wire Cars! Undergoing research

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Mechanical

EngineeringElectrical

Engineering

ComputerEngineering

Energy Systems

Power Electronics

Electric machines

Control of Variable-Speed Drives

Embedded DSP and Microcontroller Systems

Electric Vehicles

Hybrid-Electric Vehicles

Energy Storage Systems

AutomotiveElectronicSystems

PowertrainSystems

Smart Structures

Electro-MechanicalActuators

System Modeling,Identification and

Diagnosis

Electro-Hydraulic Actuators

Mec

hatr

onic

s

ab

cVdc

+

-

Vt1

+

-

Vt2

T1

T2

T3

T4

T5

T6

M

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Mechatronics in Automotive Mechatronics in Automotive Systems Systems Embedded DSP/microcontrollersEmbedded DSP/microcontrollers

Active suspensioncontrol

Thermal managementsystem control

Electric motor drive controlin hybrid electric car

IC Engine control

Power steering andtraction control

Adaptive comfortcontrol :heat,ventilatiion,air condition

Active noise cancellation

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DSP board

Power Converter & Drive Circuit

Electric motor

Cur

ren t

s

Vol

tage

s

Spee

d

Feed

back

sign

als m

easu

rem

ents

DSP System for Control of Electric Motor DrivesDSP System for Control of Electric Motor Drives

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! What is a fuel cell?"A fuel cell is an electrochemical energy

conversion device that converts hydrogen and oxygen into electricity and heat

"Potential to truly revolutionize power generation by virtue of their inherently clean, efficient, and reliable service

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! How does a fuel cell work?" Produce power electrochemically by

simultaneously passing a hydrogen-rich gas over an anode and air over a cathode.

" By introducing an electrolyte in between the two, an exchange of electrical charges occurs -- ions.

" Hydrogen reacts with oxygen, causes one or the other stream to become charged, or ionized.

" The flow of ions through the electrolyte induces an electric current in an external circuit or load.

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! How does a fuel cell work?

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! Our role in fuel cell applications-Energy Conversions for"Distributed generation

#With or without utility interfacing"Power supplies for critical loads"Automotive

#Zero-emission vehicles! Manpower Training and Research

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Typical System Requirements! Output power capacity, nominal and overload! Output voltage and frequency

" Steady state and transient" Robustness to load disturbances

! Protections! Utility interaction and parallel operation! Efficiency! EMI! Automotive Requirements: Cost, Volume, and

Weight

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FC Energy Conversion System Development Issues (1)! System configuration and auxiliary

source

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FC Energy Conversion System Development Issues (2)

! Fuel cell modeling" The electrochemical

process can be modeled for simulation or FC simulator development purpose.

" An example of a V-I curve of a PEM FC model

PEM Output Voltage vs. Current for Different Fuel Flow Rates

0

10

20

30

40

50

60

70

0.0 10.0 20.0 30.0 40.0 50.0

Output Current (A)

Out

put V

olta

ge (V

)

100% Flow75% Flow50% Flow25% Flow

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FC Energy Conversion System Development Issues (3)! Internal power flow control

"DC/DC converter operated in parallel"Power flows

#FC $ load and auxiliary source#FC and auxiliary source $ load

"Load sharing with transient requirements

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FC Energy Conversion System Development Issues (4)! DC/AC conversion

"3-ph or single phase"Voltage regulation (steady state)"THD"Transient response"Overload protection"Robustness to various disturbances

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FC Energy Conversion System Development Issues (5)! Utility interfacing

"Load sharing issue"Possible solutions

#Master/slave#Droop method

"Line impedance issues! Communication with the FC and the

closed-loop performance

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! Specifications of a 5kW system as an example" Manufacturing cost: <US$40/kW" Package size: convenient shape, volume < 88.5dm3

" Package weight: < 15kg" Output capacity (nominal) : 5kW@displacement factor

0.7" Output capacity (overload): 10kW overload for 1

minute (5kW from FC, 5kW from battery)@d.f. 0.7

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! Specifications of a 5kW system as an example" Current limit: 110% of max. overload condition" Output voltage: single phase 120V/240V nominal" Output frequency: 60Hz±0.1Hz" Output harmonic quality: THD < 5%" Output voltage regulation quality: within ±6% over the

full allowed line voltage and temperature range, from no load to full load

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! Specifications of a 5kW system as an example" FC source: 22-41VDC, 29VDC nom., 275A max" Max. input current ripple: 3% rms of rated current" Battery auxiliary power: 48VDC +10% -20% with

nominal rating of 500 Wh, 5kW peak for 1 min." Overall energy efficiency: > 94% for resistive load" Protection: Overcurrent, overvoltage, short circuit" EMI: Per FCC 18 Class A

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! Specifications of a 5kW system as an example" Grid interaction: None" Communication interface: RS232" Environment: indoor and outdoor in domestic appl." Storage temperature: -20 ~ 85°C" Operating ambient temperature: 0~40 °C" Enclosure type: NEMA 1" Cooling: Air cooled

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Undergoing Research (1)! Single 3-ph inverter control system

"Low steady state error"Low harmonics (THD)"Fast transient"Robustness to load disturbances

! Parallel operation of two 3-ph inverters"Load sharing with phase angle droop

technique"Passive load only

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Undergoing Research (2)! Parallel operation of two 3-ph inverters

"With utility interfacing"Testbed under construction

! DC/DC converters and internal power flow control

! FC simulator and closed-loop system analysis

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OSU Research Test Bed

L o a d2 4 0 VM a i n

A B C D

E

C i r c u i tB r e a k e r

M 1

C o n t a c t orM 2


M 2

2 0 8 V M a i n

L o a d2 4 0 VM a i n

A B C D

E

C o n t a c t or

M 4


M 4

C i r c u it

B r e a k er

L 1

C i r c u it

B r e a k er

L 2

C o n t a c t orL 1

C o n t a c t orL 2

M e a s u r e m e n t s :A : 2 C , 2 V ; A ? 2 C , 2 V ;B : 1 C , 1 V ; B ? 1 C , 1 V ;C : 2 C , 2 V ; C ? 2 C , 2 V ;D : 3 C , 3 V ; D ? 3 C , 3 V ;E : 3 C , 3 V ; E ? 3 C , 3 V ;

T o t a l : 2 2 C + 2 2 V = 4 4 C h a n n e l s

U n i t1

U n i t2


M 3

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Utility Mains

Microturbine

Fuel Cell

Power Converter

Transformer

Loads(Linear/Nonlinear)

ControllerPWM

3 φφφφAC240/480 V

50 or 60 Hz

ControllerPWM

V, I, f

Sensors

Sensors

V, I, f

DistributedControlCenter

Communications

Communications

Power Converters supplying power in a StandPower Converters supplying power in a StandPower Converters supplying power in a StandPower Converters supplying power in a Stand----alone alone alone alone mode or feeding it back to the utility mainsmode or feeding it back to the utility mainsmode or feeding it back to the utility mainsmode or feeding it back to the utility mains

2. Five Different Configurations for DES2. Five Different Configurations for DES2. Five Different Configurations for DES2. Five Different Configurations for DES

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! By-Wire Cars! Application of Embedded Systems to

Brake-By-Wire! Application of Embedded Systems to

Steer-By-Wire

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By-Wire Cars! Replacing a car’s hydraulic system with wires,

microcontrollers (DSP’s) and computers! Using electric motors (PM, IM, SRM) for

actuators! No hydraulic backup to the electronic system! Having been used successfully for several

years in aircraft

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Goal of By-Wire Cars! The goal of “by-wire” is to make the

average driver as skilled as a professional test course driver in bringing the vehicle back to a safe and stable condition from an unsafe one.

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Advantages! Basic functionality without complex

mechanical or hydraulic parts! Better safety, stability, and handling! Better fuel economy! Cost reduction by easier construction

and package

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Challenges! How drivers will react to the wires,

computers, and microcontrollers (DSP’s)

! No industry-wide standard for by-wire system

! Cooperation of by-wire parts! Electric power storage and supply

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Brake-By-Wire! Brake-by-wire does everything:

"Braking"ABS – Antilock brake system"Brake power assisting"Vehicle stability enhancement control"Parking brake control"Tunable pedal feeling

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Application of Embedded System to Brake-By-Wire

! Plug-in modules for Brake-By-Wire

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! EMB: Electromechanical Brake Actuators! BBWM: Brake-By-Wire Manager

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! System structure

DSP based Controller

Motor Gear and Screw

Caliper

Force Sensor

TV FclFd

Position Sensor

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! Electromechanically actuated disk brake by ITT Automotive

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Application of Embedded System to Brake-By-Wire! Control of brake-by-wire system

"Four-quadrant operation of servo-motor"Desired clamping force response"Torque ripple minimization"Elimination of rotor position sensor"Elimination of clamping force sensor"Fail-safe operation

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Steer-By-Wire! Not just electrically assisted power

steering! Steer-by-wire comes in two flavors:

"Front steer"Rear wheels

! Cars with steer-by-wire may not even have a driver’s wheel

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Application of Embedded System to Steer-By-Wire

! Only wires may relay signals from a car’s steering wheel to its front wheels in a front steer-by-wire system. And an electrically actuated motor, not a mechanical link with the steering wheel, turns the front wheel.

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Application of Embedded System to Steer-By-Wire! Rear steer-by-wire tightens the turning

radius and increases vehicle stability.! With rear steer-by-wire, the rear wheels

don’t just follow the lead of front wheels. In contrast, they turn in the opposite direction to the front wheels during tight turns, providing any size car with the agility of a small car.

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Research @ OSU! Sensorless control of induction motor

using variable frequency models for propulsion

! Sensorless control of induction motor for power steering and steer-by-wire

! Four-quadrant sensorless control of switched reluctance motor for brake-by-wire system

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Research @ OSU! Sensorless torque control of IM

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Research @ OSU! Adaptive sliding mode observer for IM

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Research @ OSU! Experimental setup

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Liebert's TMS320C50Evaluation Board

-Executes DSP nativecodes- Communicates withsimulator program on PC

-Runs simulation programincluding : a. Circuit simulations b. FPGA Timings c. User Interface-Controls the simulation timing

Host PC

DSP board for Native CodeImplementation

Hardware in the loop TestBedHardware in the loop TestBed

" Windows 95/NT program written in C++" Object oriented design

ControllerObject

CircuitsObject

TimerObject

ScopeObjects

OtherGUI Objects

User Interface Object

WaveformAnalyzer

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Research @ OSU! Experimental setup

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Research @ OSU! Sliding mode observer based controller for

SRM (switched reluctance motor)

I

I

DSP basedController

DSP basedController SRMSRM

SRMmodelSRMmodel

ObserverObserver

V

+_

θ ω

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Research @ OSU! Clamping force control for brake-by-wire

" Four-quadrant operation" Force control and torque ripple minimization" Sensorless operation (no rotor position

sensors)

SRMSRMDSP basedController

DSP basedController

PowerInverterPower

Inverter BrakeBrake

V,I T,θθθθFFcmd

θθθθ, ωωωωObserverObserver

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Research @ OSU! Experimental setup for brake-by-wire

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Research @ OSU! Experimental setup for brake-by-wire

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Conclusions! Tough Economic Conditions! Support form Industry has gone down ! Currently, We have three NSF Grants! We are teaming up with National Fuel Cell

Research Center in California for new initiative in “ Design, Modeling and Control of Fuel Cells” An Industry-University NSF Proposal.

! We appreciate your support.

osu research program in mechatronic systems · system development issues (2)! fuel cell modeling...

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