precision variable frequency drive may 07-13

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Precision Variable Frequency Drive May 07-13 Client: Jim Walker Advisor: Dr. Ajjarapu Team Members: Matt Shriver Jason Kilzer Nick Nation Dave Reinhardt April 24, 2007

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Precision Variable Frequency Drive May 07-13. Client: Jim Walker Advisor: Dr. Ajjarapu Team Members: Matt Shriver Jason Kilzer Nick Nation Dave Reinhardt April 24, 2007. Presentation Outline. Introductory Materials (Nick) Project Approach & Design (Jason) Testing and Implementation (Matt) - PowerPoint PPT Presentation

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Page 1: Precision Variable Frequency Drive May 07-13

Precision Variable Frequency DriveMay 07-13

Client: Jim WalkerAdvisor: Dr. Ajjarapu

Team Members:Matt ShriverJason KilzerNick Nation

Dave Reinhardt

April 24, 2007

Page 2: Precision Variable Frequency Drive May 07-13

Presentation Outline

Introductory Materials (Nick) Project Approach & Design (Jason) Testing and Implementation (Matt) Closing Materials (Dave)

Page 3: Precision Variable Frequency Drive May 07-13

The Prototype

Page 4: Precision Variable Frequency Drive May 07-13

List of Definitions

VFD: Variable Frequency Drive PWM: Pulse Width Modulation IGBT: Insulated Gate Bipolar Transistor

Page 5: Precision Variable Frequency Drive May 07-13

Acknowledgements

Faculty advisor Dr. Ajjarapu Client Jim Walker Graduate Students

Ryan Konopinski Sheng Yang

Page 6: Precision Variable Frequency Drive May 07-13

General Problem Statement

The speed control of an AC synchronous motor.

The synchronous motor and the subsequent drive mechanism do not always keep the correct speed.

A method is needed to control the frequency that is delivered to the synchronous motor.

Page 7: Precision Variable Frequency Drive May 07-13

Solution

A precision variable frequency drive will allow the user to manually change the operating frequency.

Page 8: Precision Variable Frequency Drive May 07-13

Operating Environment

Indoors No extreme conditions Near power outlet

Page 9: Precision Variable Frequency Drive May 07-13

Intended Use

As a drive for a low power AC synchronous electric motor.

This drive was not considered to be used on any other type of electric motor except for a synchronous design.

This drive shall not be used to power any control circuits.

Page 10: Precision Variable Frequency Drive May 07-13

Intended Users

Anyone who desires precise control over a small AC synchronous motor.

An owner of a turntable who needs better control over the speed of their turntable.

No technical knowledge will be required to operate the Precision VFD.

Page 11: Precision Variable Frequency Drive May 07-13

Assumptions

Constant linkage –An increase in motor speed by a certain factor will result in an increase in the speed of the turntable by the same factor.

Plug – the power cord from the record player can plug into a standard three pronged outlet.

Page 12: Precision Variable Frequency Drive May 07-13

Limitations

Minimum Power Output: 75 W Output Frequency Range: 58-62 Hz Frequency Precision: 0.001 Hz Frequency Stability: < ± 0.01 % 12” by 12” by 6” size limitation Cost less than $350

Page 13: Precision Variable Frequency Drive May 07-13

Expected End Product

Precision variable frequency drive Portable strobe system One-page quick users guide Circuit diagrams and parts list

Page 14: Precision Variable Frequency Drive May 07-13

Project Approach

Page 15: Precision Variable Frequency Drive May 07-13

Present Accomplishments

Research technologies (100%) Simulate entire system (100%) Purchase components (100%) Build components (85%) Test components (70%) Build entire system (70%)

Page 16: Precision Variable Frequency Drive May 07-13

Approaches Considered

Crystal Oscillator No prior knowledgeFrequency range was too high

Reverse Engineer(VPI’s Synchronous Drive System)

Difficulty getting hands on productMany partsLittle understanding of parts

Pulse Width Modulation

One group member familiarPrior understanding of partsCould handle low frequencies

Page 17: Precision Variable Frequency Drive May 07-13

Project Definition Activities

Develop a VFD that will provide a precise frequency that can be changed.

A strobe light will also be included to measure the RPM of the electric motor.

Page 18: Precision Variable Frequency Drive May 07-13

Research Activities (1 of 2)

Pulse Width Modulation Needs small signal variable frequency

sine wave Need small signal triangle wave Comparator produce pulses from

comparison of sine and triangle wave PWM would create the control signals

for the IGBT bridge

Page 19: Precision Variable Frequency Drive May 07-13

Research Activities (2 of 2)

IGBT Bridge Provides power separation between

PWM circuits and power supply circuitry Generates pulses

Page 20: Precision Variable Frequency Drive May 07-13

Precision Variable Frequency Drive

Ready to use design Delivers precise frequency control for low

power AC synchronous motors Strobe light included to measure RPM of

motor

Page 21: Precision Variable Frequency Drive May 07-13

Design

Pulse Width Modulation Circuits IGBT Bridge and Filter Circuits Power Supply Circuits

Page 22: Precision Variable Frequency Drive May 07-13

Overall Block Diagram (1 of 2)

Sine Wave

Triangle Wave

Comparator

IGBT Bridge

Inverter

Page 23: Precision Variable Frequency Drive May 07-13

Overall Block Diagram (2 of 2)

IGBT Bridge

Low Pass Filter

Frequency Counter

OutputTransformer

Page 24: Precision Variable Frequency Drive May 07-13

Pulse Width Modulation Circuits

Sine Waveform (Variable

Frequency)

Comparator

Triangle Waveform

Inverter

Page 25: Precision Variable Frequency Drive May 07-13

IGBT Bridge and Low Pass Filter

IGBT Bridge

Low Pass Filter

Page 26: Precision Variable Frequency Drive May 07-13

Power Supply Components

Astrodyne Power Supply (PT-45C) Input: 120 VAC Outputs: +/-15V, +5V

Filament Transformer Primary Winding: 117V Secondary Winding: 8V

Page 27: Precision Variable Frequency Drive May 07-13

Testing and Implementation

Page 28: Precision Variable Frequency Drive May 07-13

PWM Circuits

InvertedGate SignalU2

uA741

3

2

74

6

1

5+

-

V+V-

OUT

OS1

OS2

Comparator

-Vcc

V1

TD = 1p

TF = 249.99999uPW = 1pPER = .5m

V1 = .5

TR = 249.99999u

V2 = -.5

Triangle Wave0

Inverter

+Vcc

V2

FREQ = 60VAMPL = .375VOFF = 0

00

U3

uA741

3

2

74

6

1

5+

-

V+V-

OUT

OS1

OS2

+Vcc

-Vcc

0

V35Vdc

Sine Wave

-Vcc

+Vcc

V4-5Vdc

0

Gate Signal

Page 29: Precision Variable Frequency Drive May 07-13

Comparator Input/Output Waveforms

Page 30: Precision Variable Frequency Drive May 07-13

Inverter Input/Output Waveforms

Page 31: Precision Variable Frequency Drive May 07-13

IGBT Bridge and Low Pass Filter

Page 32: Precision Variable Frequency Drive May 07-13

Filter Input/Output Waveforms

Input and Output Waveforms of the Low Pass Filter

Page 33: Precision Variable Frequency Drive May 07-13

Implementation and Testing

Function generator chips Amplifiers Comparator and Inverter IGBT’s Filter Strobe light system

Page 34: Precision Variable Frequency Drive May 07-13

Sine & Triangle Generator Chips

Built and tested on breadboard

Page 35: Precision Variable Frequency Drive May 07-13

Amplifiers, Comparator, and Inverter Circuits

Built and tested on breadboard

Page 36: Precision Variable Frequency Drive May 07-13

Comparator Testing

Comparator Chips UA741 Op Amp LM319N High Speed Comparator

Sources Lab Function Generators Function Generator Chips

Page 37: Precision Variable Frequency Drive May 07-13

IGBT Bridge

build and test on breadboard

Page 38: Precision Variable Frequency Drive May 07-13

IGBT Bridge Testing

Design overlooked need for delay circuitry

Tried multiple timing circuits NE555 Timer Circuit UA741 Op Amp Circuit

Page 39: Precision Variable Frequency Drive May 07-13

Strobe Light System

Strobe Light Schematic

Page 40: Precision Variable Frequency Drive May 07-13

Closing Material

Page 41: Precision Variable Frequency Drive May 07-13

Resources

Item W/O Labor With Labor

Miscellaneous Parts & Materials  $20.00  $20.00

Device Components $66.90 $66.90

Project/Poster Printing $0.00 $0.00

Subtotal $86.90 $86.90

Labor at $15.00 per hour:    

Reinhardt, Dave, 142 hrs   $2,130.00

Kilzer, Jason, 166 hrs   $2,490.00

Nation, Nick, 148.5 hrs   $2,227.50

Shriver, Matt, 245 hrs   $3,675.00

Subtotal   $10,522.50

Total $86.90 $ 10,609.40

Page 42: Precision Variable Frequency Drive May 07-13

Schedule

Detailed Gantt Chart

Page 43: Precision Variable Frequency Drive May 07-13

Deadline Schedule

Deadlines Schedule

Page 44: Precision Variable Frequency Drive May 07-13

Project Evaluation (1 of 2)

MilestoneDegree of

Achievement Comments

1. PVFD Project partially met Some milestones were fully achieved while others were not

A. Produce PVFD partially met Some of the items below were attained with others only partially attained or not at all

1) Develop Design for PVFD fully met The design met all technical requirements, when simulation test were complete

2) Simulation of PVFD partially met Full simulation was completed. However two programs were needed to complete simulation

3) Implementation of PVFD partially met The design was completely implemented into a prototype

4) Technical requirements satisfied by prototype partially met See items below.

a) Provide minimum power output of 75 W fully met  

b) Output continuously selectable between 58 and 62 Hz exceeded Output is selectable between 57.5 and 62.5 Hz.

c) Short-term stability less that 0.01% not attempted Client not concerned

d) Frequency display accurate to 0.001 Hz not met PVFD has a frequency display accurate to 0.01 Hz.

B. Portable strobe system partially met  

Page 45: Precision Variable Frequency Drive May 07-13

Project Evaluation (2 of 2)

MilestonesRelative

ImportanceEvaluation

ScoreResultant

ScoreProblem Definition 15% 100% 15.0

Research 10% 90% 9.0

Technology Selection 5% 100% 5.0

End Product Design 15% 70% 10.5

Prototype Implementation 15% 60% 9.0

End Product Testing 10% 50% 5.0

End Product Documentation 5% 70% 3.5

Project Reviews 5% 90% 4.5

Project Reporting 10% 100% 10.0

End Product Demonstration 10% 50% 5.0

Total 100%   76.5

Page 46: Precision Variable Frequency Drive May 07-13

Commercialization

Not produced for commercialization Precision variable frequency drive

could be implemented for much less than current market price (~$250)

Page 47: Precision Variable Frequency Drive May 07-13

Additional Work

Resolve comparator issues Resolve IGBT issues Combine Precision VFD and strobe

light system into one product Include feedback loop for total

autonomy

Page 48: Precision Variable Frequency Drive May 07-13

Lessons Learned (1 of 2)

What did not go well•Problem definition and planning (needed a new plan when we started implementing)•Having everyone on the same page (team members, advisor, vendor)

What went well•Design/Simulation of project•Testing

Page 49: Precision Variable Frequency Drive May 07-13

Lessons Learned (2 of 2)

Technical•Implement and test one component at a time•Keep it simple•Comparator troubleshooting•IGBT implementation

Non-technical•Should have planned a lot more time for implementation•Everyone must be on the same page•Have a good plan to start

Page 50: Precision Variable Frequency Drive May 07-13

Risk and Risk Management

Potential Risks Planned Management

Cost (Over Budget)

The group was given $300 ($150 - senior design; $150 - client). If the cost was less than $75 over budget the group members would chip in some money.

Lazy Group Member

E-mails would be sent detailing group members responsibility along with due date.

Design does not meet Client’s specifications

The client would be contacted and the lack of performance would be discussed. Input for client will determine where the project is to go.

Page 51: Precision Variable Frequency Drive May 07-13

Unanticipated Risks

Unanticipated Risks Attempts to Manage Risks

Strobe light difficultyThe group found a simple "Do It Yourself" strobe light design with complete parts list and schematics.

Comparator not working

The group sought advice from advisor, graduate students, and other faculty.

Difficulty of producing output voltage of 120 VAC

Planned to use a transformer to step-up the voltage.

Page 52: Precision Variable Frequency Drive May 07-13

Closing Summary

An incomplete prototype was produced due to difficulties with the comparator and the IGBT bridge.

Estimated final product could be commercialized and sold for $250.

Page 53: Precision Variable Frequency Drive May 07-13

Demonstration and Questions