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Executive Summary
The objective of this project was to develop a working prototype for a solar array peak power tracker. Each solar array is a non-linear device which contains a maximum power point. Tracking this point for a solar array allows for an increase in the reliability of a satellites power supply during the sunlight and the achievement of maximum power in order to charge a back up battery. This battery would to be used as the power source during an eclipse [1]. The basic design of the peak power tracker connected a solar array simulator, DC-DC converter chip, and load simulator in a series connected boost converter (SCBC) design. The converter chip included a trim output option allowing for a variable voltage conversion. This option was controlled by an MCH12 microcontroller. The implemented algorithm compared past and present voltage, current, and conductance values. The input current value was sent to the microcontroller by use of a Hall Effect Current sensor, while the input voltage was sent by way of a voltage divider and also was used to power the microcontroller. The desired outcome of this project was to present a stand-alone digital solution. However, difficulty in writing the program led to a project which would require further work to create a design which could be tested.
Table of Contents
1.0 Introduction 1.1 Problem Identification 1.2 System Specifications 1.3 Operational Description 1.4 Design Deliverables 1.5 Implementation Considerations 2.0 Design Decisions 2.1 Design Configuration 2.2 DC-DC Converter Chip 2.3 Microcontroller 2.4 Algorithm 3.0 System Design 3.1 Hardware Solution 3.2 Software Solution
1 1 1 2 2
5 5 6 7
9 11
4.0 Test Results 4.1 Voltage Sensor_______________________________________13 4.2 Current Sensor 14 15 4.3 Solar Array Simulator 5.0 Project Information 5.1 Gantt Timeline 5.2 Budget 6.0 Conclusions
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List of Figures
Figure 1- Basic diagram of solar array peak power tracker Figure 2- Basic SCBC (Series Connected Boost Converter) configuration Figure 3- Basic hardware design Figure 4- Voltage division circuit Figure 5- Hall Effect current sensor Figure 6- Flow chart for microcontroller algorithm Figure 7- Plot of voltage sensor input vs. output Figure 8- Plot of current sensor input vs. output Figure 9- Plot of solar array simulator test results Figure 10- Main tasks for project Figure 11- Gantt timeline for project 2 4 9 10 10 12 14 15 16 17 18
List of Tables
Table 1- Summary of specifications for DC-DC converter chips Table 2- Decision matrix for DC-DC converter chips (3-best, 1-worst) Table 3- Summary for the microcontroller factors Table 4- Decision matrix for microcontroller with values (2-best, 0-worst) Table 5- Design matrix for software implementation method Table 6- Voltage sensor test results Table 7- Current sensor test results Table 8- Estimated project budget 6 6 7 7 8 13 14 18
1.0 Introduction
Use 8051 microcontroller, or a microcontroller with equivalent capabilities Can be packaged in less than four square inch board area Low cost
Solar Array
VICOR SCBC
Load
Microcontroller Figure 1- Basic diagram of solar array peak power tracker The solar array current is tracked by a Hall Effect current sensor, whose location is denoted by a diamond in the figure above. As the solar array input power varies, the sensor sends the values of the current to the microcontroller. The array output voltage is decreased by a factor using a voltage divider which allows for a voltage level the microcontroller can handle. The algorithm uses the IncCond (Incremental Conductance) method, which will be described later. At this step, an algorithm adjusts the DC-DC conversion using a trim option. The optimal conditions for peak power are based upon the solar array output and are accounted for in the microcontrollers algorithm.
limit power loss. Several pieces of equipment were provided by NASA to produce a prototype: a Vicor chip, solar array simulator, load simulator, and Hall Effect current sensor.
The system is designed such that installing, testing, and normal operation do not pose a danger to any persons present. More specifically the product must avoid overheating of the battery or load. This is mainly controlled in the design by the capabilities of the solar array simulator to set a maximum voltage and current. The effect of this in outer space may not affect the safety of individuals, but it may during testing of the product. Social There exists no direct impact on society due to the fact the product will be in space. However, since NASA is a government agency the cost of the product will come out of tax payers pocket.
Political Since NASA is a government funded program, we have abided by the information they have given to us. Also, the need for such research and results was compiled in a form that can be presented to the public and government to show its worth.
To make the final choice of a converter chip, a decision matrix (Table 2) was formed. In Table 1, the Vicor chips were priced at zero because NASA was able to supply each. Since this was the lowest possible price for a chip, the first two alternatives were rated a 3, or best in the decision matrix. NASA also preferred the use of the Vicor chips, earning the Vicor chips a 3 or the best rating in the manufacturer criteria of Table 2. The input voltage was not included in the decision matrix because all the choices were the same 6 V away from the optimal input voltage. After applying the points method to Table 2, the DC-DC converter chip that we chose to implement was the Vicor VI-2W1-CV. Table 2- Decision matrix for DC-DC converter chips (3-best, 1-worst) Alternative Manufacturer Price Max Power Total 1 3 3 3 9 2 3 3 2 8 3 2 2 2 6 4 2 1 2 5
2.3 Microcontroller
The microcontroller was responsible for regulating the system and assuring the voltage applied to the load would deliver maximum power. The inputs of the microcontroller were the voltage and current values of the solar array. For this application, two main microcontrollers were available for use. They included the Motorola MC68MC68HC12 and the Intel 8051. The MC68HC12 was a readily available system at Ohio Northern University since it was used in the coursework. Hence, there was no development cost, and the team was already familiar with the program. On the other hand, development cost for the Intel 8051 was approximately $200, and the time to purchased, ship, and set up the program had to be accounted for. The familiarity of the microcontroller was also low since it was not used in the universitys coursework. Finally, in the development of the project for real application, the Intel 8051 was advantageous because it
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was available in a hardened material that can protect against radiation. All the above factors were evaluated in the decision matrix in Table 3 [8, 9].
Table 3- Summary for the microcontroller factors Readily AvailableDevelopment Familiarity specially hardened cost no yes $111 ($0) $170 Course work unknown
Table 4- Decision matrix for microcontroller with values (2-best, 0-worst) Readily Available- Development Familiarity Language Microcontroller specially hardened Cost 40% 20% 20% 20% Motorola 1 2 2 2 MC68MC68HC12 Intel 2 1 0 2 8051
Total 1.8 1
In the decision of which microcontroller to choose, familiarity was the most critical factor because it would save both time and money in labor costs. For this reason, the MC68HC12 was chosen.
2.4 Algorithm
Several algorithms were available that could detect the peak power point. The P&O (perturb and observe) algorithm was based on checking voltage and power values. Just as the name of it states, the input voltage would be increased or decreased until maximum power was reached. The drawback was that it would oscillate at that maximum point for a certain amount of time, causing power loss. The IncCond (incremental conductance) algorithm was based on the slope of the power. The slope, also interpreted as the derivative of power, allowed the voltage and current to be checked. This would produce more accurate readings and limit power loss. The combination of the two algorithms would have been the most efficient, but wouldve had approximately the same accuracy. The operation of the combination of each algorithm would involve implementing the P&O algorithm for a certain amount of time then switching to the IncCond algorithm until max power was found [7]. The decision matrix in Table 5 shows a comparison between the different algorithms. They were all feasible algorithms to implement, but as the points indicate, the IncCond algorithm was the best choice. Cost and complexity were two related factors since the more complex the system was, the more time was needed to implement the design. Consequently, the increase in time
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would have increased the labor hours, and therefore increased the cost. The final column in the decision matrix indicates that the IncCond was best choice. Further description of the chosen algorithm can be found later in this report.
Table 5- Design matrix for software implementation method Efficiency Cost Complexity Accuracy Algorithm 20% 30% 30% 20%
1-low, 3-high 1-high ,3-low 1-high ,3-low 1-low, 3-high
1 2 3
2 3 1
2 3 1
2 3 3
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Figure 3- Basic hardware design The solar array simulator provided by NASA supplies an array voltage in the range of 0-30 V. However, sending a value on the high end of the range is not feasible due to the fact that the microcontroller is limited to voltages on the 0-5 V range. For this reason a voltage divider circuit is implemented which uses a known factor to step down the input voltage. The gain necessary was determined to be 0.1, and was determined as follows:
Gain =
(Eq 1)
where Vout is the voltage sent to the microcontroller and Vin is the solar array voltage. The voltage divider circuit is designed based on voltage division seen below. The resulting circuit is found in Figure 4. To summarize, the value sent to the microcontroller is one tenth of the actual solar array voltage.
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Vout = Vin
(Eq 2)
Figure 4- Voltage division circuit The next step was to determine a means for sending the value of the solar array input current to the microcontroller. In discussing this issue with the NASA representative it was recommended that the design implement a non-invasive Hall Effect current Sensor. This is a 3-pin device which allows for a wire to run through the center of its structure. The sensor then sends the current of that wire through a single pin at a fraction of its original value. By connecting a resistor from the pin to ground, a voltage value can be sent to the microcontroller which is proportional to the current. The circuit for the Hall Effect current Sensor is pictured below.
Figure 5- Hall Effect current sensor As seen above, the current out of the current sensor is 1/1000th of the array current. Running this value over a 100 resistor allows for an output voltage that is one tenth of the array current. This value is then sent to the microcontroller.
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(Eq 3)
Testing was also performed on the current sensor and the conversion factor was confirmed as 1000. Details regarding the procedure and results are found later in this report. Finally, the trim option in the Vicor DC-DC converter was investigated. When connecting no voltage to the trim pin the converter simply added 12 V to the input voltage. Varying a voltage value on the trim, however, varied the voltage added to the input. For this particular component, a range of voltage increases from 6-13.2 V is possible given trim voltages in the range of 1.252.75 V. The conversion factor for the trim voltage to the increase in output voltage is linear and is seen below. This conversion factor was also confirmed.
Vtrim 4.8 = Voutput
(Eq 4)
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start
Initialize
Store
Vpast I past
Retrieve
Vpresent
Transfer to
A/D Converter
Stage 1
V
Calculate
and
Stage 2
yes
V < 1
no
yes
I I + < 2 V V
I < 3
no
yes
no
yes
I I > +2 V V
I > 3
no
yes
no
Increase
Vref
Decrease
Vref
Decrease
Vref
Increase
Vref
D/A converter
To trim
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Sensor Input
Figure 7- Plot of voltage sensor input vs. output Slight deviations from an ideal 0.1 gain could be attributed to resistance within the wires or measuring instrument precision.
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Figure 9 - Plot of solar array simulator test results These results confirm that the solar array simulator does indeed have a maximum power point for different load settings.
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5.2 Budget
Cost was not a major issue for the project since the goal was to develop a proof-of-concept using off-the-shelf parts. Most of the more expensive components of the system were provided by NASA and are not be included in the budget. These items included the solar array simulator, the load bank, the Vicor DC-DC converter chip, and Hall Effect current sensor. Equipment borrowed from ONU, such as the MC68HC12 microcontroller, oscilloscopes, and multimeters, also are not included. Hardware costs and labor costs were included in the budget. Hardware costs consisted of a D/A converter, resistors, and miscellaneous parts. Labor costs were $25 per hour and total hours spent on the project were 350 hours. A summary of the costs associated with the project are shown in Table 8. Table 8 - Estimated project budget Part Quantity Cost per item D/A Converter 1 $30 Resistors Misc Parts Labor 350 hrs $25/hr Total Cost
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6.0 Conclusions
The objective of this project was to develop a solar array peak power tracker that would be able to provide a load with maximum power. It was our teams desire to design a stand-alone digital solution. This project uses several pieces of equipment borrowed from NASA. These include the solar array simulator, Vicor DC-DC converter chip and a load bank, which acts as the satellite load. The basic design of the peak power tracker is to read the voltage and current levels at the solar array simulator output, process these values using the IncCond algorithm, and then adjust the voltage in order to obtain maximum power. This program is developed on an MC68HC12 microcontroller. It is concluded that the objectives of this project were not met. A running program was necessary for further work involving this system. Further analysis and testing would be needed to overcome these issues. With a working program, the software and hardware could be combined to create a complete system. Future considerations for this project would include using a higher level language for the implementation of the algorithm. With this higher level language, logical and syntax errors would be easier to debug. Such languages could include C or C++. With more time and properly functioning software, the entire system could be tested to verify it is working in all aspects.
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7.0 References
Cho, Bo H., and Phuong T. Huynh. "Design and Analysis of a Regulated Peak-Power Tracking System." IEEE Transactions on Aerospace and Electronic Systems 35 (1999): 84-92. Button, Robert M., Theodore W. Iler, and Mark E. Liffring. A Modular, Peak Power Tracking Solar Array Regulator. Society of Automotive Engineers, Inc. 1998. Button, Robert M. An Advanced Photovoltaic Array Regulator Module. NASA Technical Memorandum. August 1996. Lewis Research Center. VI-200, DC-DC Converters. Vicor Corporation. 1 Nov. 2005. <http://www.vicorpower.com/documents/datasheets/ds_vi-200.pdf> Artesyn Technologies DC/DC Converters Isolated: BXB100-24S12FLT. Mouser Electronics. 3 Nov. 2005. <http://www.mouser.com/index.cfm?handler=displayproduct&lstdispproductid=628125&e_categ oryid=100&e_pcodeid=82602> VKA100xS DC-DC Converters. C&D Power Electronics, Inc. 3 Nov. 2005. <http://www.cd4power.com/data/power/ncl/pdc_vka100.pdf> Wu, Wenkai, N. Pongratananukul, Weihong. Qiu, K. Rustom, T. Kasparis, and I. Batareh. DSP-based Multiple Peak Power Tracking for Expandable Power System. IEEE (2003): 525-530. "microMODUL-8051." Phytec America, LLC. 3 Nov. 2005. <http://www.phytec.com/sbc/8bit/um8051.htm> M69EVB912 Evaluation Board. Freescale Semiconductor M68MC68HC12 Development Tools. 2 Nov. 2005. < http://www.newark.com/product-details/text/catalog/52973.html>
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CHAD ALBERTS - Chad Alberts is currently a senior Computer Engineering major at Ohio Northern University, Ada, OH. He currently looking for a temporary job for the summer and a permanent job after November of 2006.
JUSTIN BRAUN - Justin Braun is currently a senior Electrical Engineering major at Ohio Northern University, Ada, OH. Following graduation he plans on working at Wright Patterson Air Force Base in Dayton, OH for the Air Force Research Laboratory.
ANNA FOWLER - Anna Fowler is currently a senior Electrical Engineering major at Ohio Northern University, Ada, OH. She is also a member of Society of Women Engineers. Following graduation she plans to work for WD Partners, Inc., a consulting firm located in Dublin, OH.
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