Team HydroFly: Fuel Cell

Team Members:Adam Lint

Chris CockrellDan Hubbard

Sponsors: Dr. Herb Hess

Dr. Brian Johnson

Overview

• Project Purpose

• Project Objective

• Background (Fuel Cell and AMPS)

• Basic Design Description

• Additional Design Considerations

• Schedule and Budgeting

Purpose:

Why are we interfacing the fuel cell to the Analog Model Power System?

Alternative Energy Source

Flexibility for the AMPS

Objective:Interface the Fuel Cell to the Analog Model Power System

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What is a Hydrogen Fuel Cell?Different Types

•Phosphoric Acid•Proton exchange membrane (PEM)•Solid Oxide (SOFC)•Molten Carbonate (MCFC)•Alkaline

Proton exchange membrane (PEM)

•Low temperature•Low Noise•Zero Harmful Emissions (water and heat)•Portable•Capacity of up to 10KW

What is a Hydrogen Fuel Cell?Operation of a PEM fuel cell

•Chemical reaction similar to a battery

•Does not need to be “charged” as long as hydrogen is supplied

Avista SR-12 PEM Hydrogen Fuel CellDonated by Genesis FuelTech in 2003

•500W Peak Power

•DC output (23V - 43V)

•12 Fuel Cell Cartridges

•Spare Parts Available

•80°C Operating Temp.

Analog Model Power System•Acquired from Idaho Power in the mid 1990’s

•Models a typical power transmission system

Added Features:

1. A fault matrix in which three faults can be placed on the system, either simultaneously or in an evolving manner.

2. The ability to load impedance faults onto the system.

3. SEL (Schweitzer Engineering Labs) relays into the system.

23-43V DC

12V/24V DC

DCDC

DC to DC Converter

DC/DC Converter

• Purpose: Regulate output voltage from fuel cell to a constant DC voltage

• Requirements– Input Voltage: 23-43 VDC (min)– Input Current: 25 A (min)– Power Rating: 500 W (min)– Output Voltage: 12/24 VDC

DC/DC Converter

• Wide Input Range

(20-45 V)• 600 W Power Rating• 12 VDC Output• Audible/Visual Indicators

MajorVTC600-32-12 DC/DC Voltage Converter

DC/DC Converter

MajorVTC600-32-12 DC/DC Voltage Converter

DCDC

DCAC

23-43V DC

12V DC

12V AC 3-phase

Synchronous Freq.

DC to AC Converter

DC to AC Converter

•Purchase from Tier Electronics in Oconomowoc, WI

•Specifications:

•Input Voltage: 12 VDC +/- 0.5 VDC

•Input Current: 50 A Continuous/ 55 A Peak

•Power Rating: 500 W

•Output Voltage: 12 VAC 3-phase @ 60 Hz

Mini Universal Power Converter (UPC) from Tier Electronics

Features:• 40MHz Re-Programmable TI-2400 series DSP• 24KHz PWM Switching frequency (offers greater control)• Communication Module for asynchronous serial communication• Expansion capabilities for monitoring and controlling external signals

DC to AC Converter

Filtering

•Why?–Distortion on the 3-phase AC voltage

Corrected by using a simple LC Filter

0 1 2 3 4 5 6 71

0.5

0

0.5

1

y x( )

x

DCDC

DCAC

Trans-former

23-43V DC

12V DC

12V AC 3-phase

Synchronous Freq.

12:208

208V AC 3-phase

Synchronous Freq.

Transformer: 12V to 208V AC

:

Transformer•3 Phase•Delta to Delta Configuration

•Input: 12 Volts AC•Output: 208 Volts AC

DCDC

DCAC

Trans-former

Synchronous Signals

Voltage/Current Readings

23-43V DC

12V DC

12V AC 3-phase

Synchronous Freq.

12:208

208V AC 3-phase

Synchronous Freq.

BLOCK DIAGRAM

:

Synchronization

• To correctly provide supplemental power to AMPS, our AC signal must be in phase with the system

• Why?– If the two signals are out of phase when connected to

each other, massive current spikes will appear and it will take longer for the signal to stabilize.

Synchronization

• Phase-Lock Loop• Fast Response

• Will accurately correct any error

– Zero-Point Crossings• Sample Rate

• Frequency

• 3-Phase Timings

Microprocessor

TI 2400 Series DSP– 16-bit data Fixed-Point– 20-40 MIPS– On-Chip Flash Memory– Other Features: A/D

Converter, CAN Module, SCI, SPI,

Device Protection

•Protect from what? –Incorrect power flow–Exceeding component rating

•How to protect it?–Switches (Control)–Fuses

Schedule

Initial Design for Prototypes

Project Briefings (w eekly - Semester 1)

Design Review

Simulation: Interfacing Components to AMPS

Ordering Voltage Inverter and Buck Converter

Demonstrate Working Simulation

Project Report and Notebook Due (Semester 1)

Summer Break

Project Briefings (w eekly - Semester 2)

Interface Fuel Cell Components to AMPS

Revise Voltage Control System

Finalize Protection Circuitry

Complete/Debug Interfacing to AMPS

Final Product Demonstration/Release/Final Report

BudgetItem PriceDC/DC Converter $800DC/3-Phase AC Converter $2,000Transformer $125Hydrogen $45Design Poster/Report Binding* $15Project Display Costs* $35Protection Circuitry $100Filtering $50Miscellaneous $300

Total $3,470

*Cost divided evenly between Fuel Cell and Flywheel Groups

Questions?