1 A. Software The TI 2401A DSP is made to do power inversion, so it includes many registers to simplify the programming of sinetriangle PWM. A complete set of programming files used in this project can be seen in Appendix G and on the attached Hydrofly: Fuel Cell Project CD. TI’s Code Composer Studio was used to develop the software and program the DSP. Project files for Code Composer Studio and data sheets on the TI 2401A DSP are also on the Hydrofly: Fuel Cell Project CD. 1) Overall Flow Diagram The DSP software used in this design is based on a looping switch statement as shown below in Figure 21. Initially, the PWM State will be disabled, so the software will evaluate Case 1 through Case 4 sequentially. The system will loop through a given case until specified to move to a new state. For example, the software will not move from Case 1 to Case 2 until specified in the Case 1 code. The software will evaluate Case 1 through Case 4 a total of 180 times (30 sine waves x 6 pulses per sine wave) before initializing the PWM State. During the 180 loops, the system collects and averages data for each of the six pulses and calculates the average half period timing for each of the 3-phase signals. For each pulse, the system will record the pulse width and the pulse-to-pulse timing. After starting the PWM State, there is delay programmed in to only start incrementally adding in DELTA after 10sec. The same 10sec delay is used to keep the Fault Check function, which shuts off the PWM in case of a fault, inactive so the user can connect the interface to AMPS without having to worry about the interface shutting off due to the initial connection. If the Fault Check function were to be active when connecting to the AMPS, the Zero Detection data used in the Fault Check will usually see the shift caused by switching in as a fault. Start System Initialization While (1) Yes Switch State Case 1 Yes Waiting for Pulse sine-triangle PWM to be continually updated with the correct sine values. During a given loop in the switch statement, calculations are always performed on the previous position on the pulse stream. For HPTiming calculations, data from the previous three pulses from the serial pulse stream are used. 2) Case 1 – Waiting For Pulse In the “Waiting for Pulse” state, the system begins by checking the Phase 1 Falling Edge Reference Signal for a pulse to initially synchronize itself with the AMPS and know what signal in the Serial Pulse Signal is the falling edge of the first phase. Until the system is synchronized, no other operation will be performed, and the system will continually loop through this state. A very basic flow diagram for this state can be seen below in Figure 22. Once the system is synchronized, the system will looks at the Serial Pulse Signal for a rising edge. When one is found, several functions occur including: Storing the Timer 2 Value in a variable which represents the Pulse-to-Pulse time on the Serial Pulse Signal. Stops, Resets, and Restarts Timer 2 Increments Position Pointer in the array By stopping and resetting the Timer, the variables stored for the pulse wide and pulse-to-pulse timings already equal the correct number, since we’re storing the ending value and the starting value is 0. To prevent overflow in the timer, Timer 2 increments every 4 CPU clock cycles. After performing it various functions, it sets the next state, which is to “Waiting For Falling Edge”. The PWM Calculation/PWM Sync Check contains some simple checks including: Initially starting the PWM only when system is synchronized A simple PLL check that resets the sine wave to keep it locked in with the AMPS A function that, when the PWM is active, sets the system up to jump to the PWM State and then return to the appropriate next state Start No Case 2 Yes Waiting for Falling Edge No Case 3 Yes Yes Phase 1 Falling? System Synced Calculations No No Case 4 Yes Zero Crossing Analysis No Case 5 Yes Pulse Detected and System Synced? PWM State No Record Times/Reset Counters Yes No Set Next State Default Figure 1 - Overall Software Flow Diagram After the system has collected 180 pulses and corresponding data, the PWM state is enabled. The system continues to evaluate Case 1 through Case 4 in order, but will begin to poll PWM State between Case 1/Case 2, Case 2/Case 3, etc. This polling allows the Compare Registers used in PWM Calculations/ PWM Sync Check Break Figure 2 – Waiting for Pulse Flow Diagram 2 3) Case 2 - Waiting for Falling Edge In the “Waiting For Falling Edge” state, the system is looking for the falling edge of a pulse on the serial pulse signal. When a falling edge is detected, the system will record the time on Timer 2 for pulse width. A counter is also decremented to prevent HPTiming calculations from occurring before it has 3 previous pulses’ data to use for calculations. The same PWM calculations/PWM sync check is performed at the end of this state. A simple flow diagram for the “Waiting For Falling Edge” state can be see below in Figure 23. Start Calculate Pulse Width Calculate Time Between Pulses Yes Half Period? Calculate Half Period No Set Next State Start Pulse Ended? PWM Calculations/ PWM Sync Check Yes Record Times Break No Increment Position/ Decrement Counter Set Next State PWM Calculations/ PWM Sync Check Break Figure 3 – Waiting for Falling Edge Flow Diagram 4) Case 3 - Calculations In the “Calculations” State, data from the previous pulse is used to calculate and store the pulse width and pulse-topulse timing in an array for averages. The arrays are a 6 position area, one spot for each pulse location. When new pulse widths are calculated, for example, the valued is added to what is in the array position, and then will be averaged later using a counter that keeps track of how many data values are summed. If enough data has been collect, the system will calculate the HP Timing for the previous three pulses. Since there are 6 pulses in the serial pulse stream, any three sequential pulse give you the HPTiming for one of the phases. After the HPTiming is calculated, the PWM Calculation/PWM Sync Check is performed again. A flow diagram for the “Calculations” State can be seen below in Figure 24. Figure 4 – Calculations Flow Diagram 5) Case 4 – Zero Crossing Analysis In the “Zero Crossing Analysis” state, the pulse width is divided to get an estimate of the actual zero crossing. The system will then decrement a counter that counts the number of pulses received in the code. This counter is important as it determines when the PWM will start. The system will then perform a Fault Detection check by looking at the previous pulse-to-pulse timing. If the data is outside the set values, the system will shut off. After the HPTiming is calculated, the PWM Calculation/PWM Sync Check is performed again. A flow diagram for the “Zero Crossing Analysis” can be seen below in Figure 25. Start Calculate Actual Zero Crossing Decrement Iteration Counter Yes Detect Fault? System Shutdown No Set Next State PWM Calculations/ PWM Sync Check Break Figure 5 – Calculations Flow Diagram 6) Case 5 – PWM State In the “PWM State”, the main function is to calculate the values needed to create a reference sine wave and pass the values to Compare Registers, which control the PWM Outputs. When the DSP first enters this state, if enough data has been taken, it averages the pulse width and pulse-to-pulse time data. 3 The main calculations performed by the “PWM State” are split into two sections: one part is calculated on the rising edge of the triangle wave and on the other on the falling edge. On the rising edge of the triangle wave, the inputs for the sine lookup table are calculated for the three phases. These inputs incorporate the relative position of the sine wave, DELTA shift, transformer shift, and 120-degree phase shift, into the calculation. The result is a number between –1 and 1 (input range for sine lookup table) that is in Q15 format (multiply the number by 2^15). During the falling edge, the inputs are sent into the sine lookup table and the outputs are converter back to a decimal from Q15 format and then multiplied by a factor to set the magnitude. The magnitude of each of the three phases is controllable by the user. The PWM output is then turned on and the counter which control the relative position of all the reference sine waves in incremented. In the PWM Calculations/PWM Sync Check section of this state, the same functions as previously stated are performed with one addition. There is a function that slowly increments the DELTA after a 10-sec delay. Start Calculate Timings/Update Calculate Average Carrier Frequency Timings No Yes Triangle Wave Rising Edge? Calculate/Load Sin Positions in CMPR Registers Calculate Phase Counts Turn on PWM Output Convert to Q15 Format Increment Counters Increment Counters PWM Calculations/ PWM Sync Check Break Figure 6 – PWM State Flow Diagram II. MANUFACTURING AND SUPPORT A. Product Life Cycle Report 1) INTRODUCTION a) Hardware Components and General Interface Design In order to transfer power from the Avista SR-12 hydrogen fuel cell to the Analog Model Power System (AMPS), this interface design uses four main components: a DC/DC converter, DC/AC power inverter, Zero Detection Circuitry (ZDC), and a delta to wye transformer. The interface does not include the fuel cell. The DC/DC converter regulates and steps up the DC output voltage from the fuel cell. This regulated voltage is fed through a DC/AC power inverter to create a three-phase AC signal at 60Hz. This three-phase signal, which contains third harmonics from the switching of the inverter, is filtered by a delta to wye transformer. This transformer also steps up the AC voltage to an appropriate magnitude, matched with the AMPS voltage. The final component in the interface design is the zero detection circuitry. This circuitry is used to determine the positions and timings of the three voltage phases on the AMPS. b) Power Flow Control The DSP used to operate and control the DC/AC power inverter has been programmed to accept signals from the ZDC. The DSP uses these signals to adjust the generated voltage phase such that the signal from the inverter can be synchronized with the voltage signals on the AMPS. Once synchronized, the phase angle is adjusted to control the power flow from the fuel cell to the AMPS, completing the interface process. c) Protection Protection schemes are located throughout the interface to protect each of the components from damage. The DC/DC converter contains input/output isolation, overvoltage protection, current limiting protection, and short circuit protection. The DSP on the DC/AC inverter monitors each of the phases on the AMPS using the ZDC. If there is a sudden change in frequency on any of the phases, the DSP will quickly stop the inverter from generating the three-phase signal. This prevents possible current spikes or other unwanted transients from occurring. Fuses were placed after the DC/AC power inverter for protection in case of a current spike. The ZDC also contains protection. An optocoupler isolates the analog input circuitry from the output that connects to the I/O pins on the DSP. This isolation prevents current spikes from damaging the DSP. 2) Design a) Selection of Hardware Components The fuel cell used in this design is capable of reliably providing 100W of power. In order to provide a certain level of device safety and upgradeability, the DC/DC converter was chosen to have a power rating of 200W. This specification also helps ensure that the current ratings on the device won’t be exceeded due to reactive power transferred through the interface. The DC/AC power inverter, obtained from Tier Electronics, has 600V IGBTs for switching rated at 3A RMS at 5kHz and 2A RMS at 10kHz with a peak current of 6A. The transformer, obtained from the UI ECE department, is rated at 8.5kVA and was chosen because of its availability in the lab. The ZDC was built from the ground up to meet this system’s specifications. It utilizes an op amp with active feedback and a several logic gates to output a series of pulses that can be interpreted by the DSP to determine the inverter switching timings. b) Software Programming and System Control In order to allow the DSP to adjust the inverter output voltage and phase, it was reprogrammed. The reprogramming 4 process involved analyzing the current programming, modifying it to adjust the voltage magnitude, and adding additional code to accept the input from the ZDC. The software used to accomplish this task was the TI Code Composer Studio. c) Hardware and Software Costs Once appropriate components were chosen for this design, the DC to DC converter, the inverter, and the components used to create the ZDC were all purchased with funding from the ECE department power lab budget and the Corbit Senior Design Fund. The TI Code Composer Studio and J-TAG emulator used to program the DSP were donated by TI. The three-phase transformer and inductor bank are the property of the ECE department, and will serve as removable, standalone devices that are easy to connect and disconnect. These items were provided at no cost. 3) Implementation and Testing a) Component Testing Each of the four components were individually tested for their input/output relationship. A major factor in component testing is correcting problems with the individual components in the implementation stage. As expected in the prototype design, the implementation stage has a high probability of errors in its early stages. The DC/DC converter was tested to see how much the output voltage varies over the entire input voltage range. The inverter accepted artificial ZDC signals from a function generator to generate a pulse width modulated voltage signal before the actual ZDC was implemented. The transformer was tested for leakage reactance and input/output voltage characteristics. The ZDC was tested first with low voltage signals, then with the actual voltage signals from the AMPS. The output of the ZDC showed the pulse sequences sent to the DSP I/O pins. c) d) Release Plans The interface will be a package that consists of: a DC/DC converter, a DC/AC inverter, three-phase zero detection circuitry board, three single phase transformers, inductors, cables for connections between components, a DSP software package, and complete documentation in both paper and electronic format. The supplied documentation will outline each part of the interface, troubleshooting techniques, PCB construction, safety and operation methods, and maintenance. This interface will be used solely for power system research and education, so the system is set up to be adaptable and/or upgradeable to changing needs. This documentation will include contact information should any issues or problems arise and require the attention of the original designers. Component Implementation The components implemented in this project can be viewed as one of two types: commercially manufactured or designed from the ground up. Each component serves an individual function in the interface design and works together with the other components to create a fully functional system. The DC/DC converter takes a variable DC input voltage and outputs a constant DC voltage. The implementation of the inverter was more involved since it needs to control the power flow and isn’t just a black box that functions as desired. For this reason, its implementation requires more time and effort to prevent possible functionality problems. The transformer is also a pre-manufactured component, providing the final connection to the AMPS. The zero detection circuitry was designed and assembled from the ground up. It has been implemented on a printed circuit board to organize its functionality and finalize its design. b) and goals. Extensive interface testing was not needed to meet these goals. In addition, the usage of this product will not be frequent enough and the operating conditions will not be stressful enough justify rigorous testing of this design. Interface Testing Connecting the four main components together made the completed interface ready for testing. The goal of the interface testing was to meet the basic project requirements 4) Maintenance a) Zero Detection Board The interface requires occasional maintenance. Most of the maintenance will involve replacing parts on the zero detection circuit PCB board as they age. The time between this maintenance will be greatly dependent on the amount of time the system is in use. The ECE department will have complete documentation on the zero detection circuitry and PCB board to provide easy maintenance or construction of new boards should it be required. b) Software Other maintenance will include DSP software updates to fix any bugs or flaws in the programming. These bugs could arise under abnormal conditions when tests are being performed on the AMPS or under normal conditions because of aging components. There may also be bugs in the release software that were not found during final testing. Every effort has been made to ensure durability of the system in case there is a problem within the interface design. TI provides extensive documentation on the DSP used in the DC/AC inverter; this documentation will be included in the final design package. c) Other Maintenance on the DC/DC converter and DC/AC inverter will require contact with appropriate vendors for support. The DC/DC Converter includes a twelve-month warranty, subject to application within good engineering practice. 5) End of Life This interface, while designed for use with a hydrogen fuel cell, is capable of providing an interface from any alternative energy source or other power source to the AMPS, as long as it does not exceed the specifications of the interface. In the case that the hydrogen fuel cell it was designed for is worn beyond feasible repair, this interface will still be useable in other energy supply research or education. As time passes, the 5 world’s power requirements have been ever increasing. With the design of this system, individual components can be replaced or upgraded to modify the overall specifications of the interface and prolong its life cycle. This interface will become obsolete when all alternative sources exceed the specifications and capabilities of this interface or when parts become expensive or impossible to repair. The life of the system is also somewhat dependent on the availability of software to communicate with the TI DSP. The current programming software requires the Windows operating system to function. Without the necessary software, it will be impossible to communicate with the DSP and provide updates to the code. 6 3) Failure Modes and FMECA Analysis B. Hardware Reliability Analysis 1) INTRODUCTION This multi-faceted report provides a reliability analysis for the interface created to provide power to the Analog Model Power System (AMPS) from an Avista SR-12 fuel cell. The interface consists of four main parts: a DC/DC converter, DC/AC inverter, Zero Detection Circuitry (ZDC), and a transformer. This analysis provides a list of possible failure modes, an examination of the Mean Time Between Errors (MTBF) for each of the components in the interface, and a Failure Mode and Effects Criticality Analysis (FMECA). This reliability analysis is important in the design of any new product. It can be used to plan the operation of the interface around its product and individual component life expectancy. It also helps with troubleshooting since it provides information regarding which components are more likely to fail first. 2) System Failure Rate Calculations The overall failure rate of the system was calculated using the Relex Analytical Tools, component failure rate data, and Microsoft Excel. The Relex Analytical Tools and component failure rate data were used to find the average failure rate for each of the components in our system for every 10 9 hours of operation. The average component failure rate information was entered into Excel to calculate the MTBF for each of the subsystems, individual components, and the interface as whole. To find the total MTBF for our system, each components was weighted based on the number of components of that type in the entire interface and then took the sum of the MTBF of each of the subsystems. Through the research performed, it was difficult to find exact failure rate data for all components. When exact failure rate data could not be found, similar components were used to estimate a reasonable failure rate of each component. The interface design is divided into five main subsystems: DC/DC Converter, DC/AC Inverter, Transformer, Fuses, and ZDC. The DC/DC converter and DC/AC inverter are packaged subsystems purchased for the interface. The ZDC is comprised mainly of an op amp circuit utilizing resistors, feedback capacitor, supply voltage source, switching transistor, optoisolator, and output logic gates to produce the necessary output signals. Table 1 illustrates the results of the MTBF calculations. TABLE 1. MTBF GRAPH - OVERVIEW Total Failure Number of Component Failure Rate Components Rate DC/DC Converter 0.0028 1 0.0028 DC/AC Inverter 0.041 1 0.041 Transformer Percent of Total Failure Rate 0.36 5.25 0.013 1 0.013 Fuses 0.00015 3 0.00045 0.06 ZDC 0.7244 1 0.7244 92.67 Total MTBF (hours) 1.66 a) Potential Failure Modes The components used in the design of this system have the potential for failure at some point in their lifecycle. User error or non-ideal operating conditions are also likely to occur. The following table lists these potential failure modes. These failure modes focus on the individual subsystems, the user, and the operating conditions present during system operation. TABLE 2. POTENTIAL FAILURE MODES 1. Internal Component Failure 2. Improper Use 3. Physical Damage 4. AMPS noise/transients 5. DSP Software Failure 6. Insulation Failure 7. Reverse Power Flow 8. Thermal Shock 9. DC Input Voltage 10. Protection Circuitry 11. External Component Failure 12. Excessive Loading b) Ratings (1) Risk Priority Number Each of the items in Table 2 has been given a Risk Priority Number (RPN) based on its severity, occurrence, and detectability. To determine the RPN, each category was assigned a severity, occurrence and detection rating (1-10). These ratings are multiplied together to calculate the RPN. A higher RPN means that the failure mode is more likely to cause a system-wide problem or safety issue. The method for determining the ratings is discussed in detail in the remainder of this section. All ratings and RPNs for the potential failure modes are listed in Table 3 at the end of this section. (2) Severity The severity rating for each potential failure mode was based upon how much damage would be caused if the failure mode occurred. A high severity rating indicates a failure that would cause irreparable damage or would require component replacement or expensive design alterations. A high severity rating may also indicate a significant safety risk associated with the failure mode. A low severity rating indicates little to no damage or possibility of damage to the system. (3) Occurrence The occurrence rating indicates the likelihood of entering into a potential failure mode. A low occurrence rating indicates that the failure mode may never occur, and a high rating indicates that the failure mode may occur frequently. 1279344975 (4) Detectablilty 7 The detection rating indicates how difficult it would be, in the event of a system failure, to detect a given failure mode. A high rating indicates that it would be impossible to detect a failure mode without a meticulous system analysis. A low rating indicates that a failure mode would be easily detected by the system operator. TABLE 3: FMECA TABLE OF RATINGS Internal Component Failure Improper Use Severity Occurrence Detection RPN 10 3 9 270 7 6 3 126 Physical Damage AMPS noise/transients DSP Software Failure Insulation Failure Reverse Power Flow Thermal Shock 9 7 2 126 5 6 4 120 5 4 5 100 9 1 10 90 7 2 6 84 6 2 5 60 DC Input Voltage 5 9 1 45 Protection Circuitry External Component Failure Excessive Loading 6 2 3 36 4 8 1 32 5 2 2 20 4) Conclusion A hardware reliability analysis helps determine which subsystems in the fuel cell/AMPS interface are most likely to encounter problems: ZDC, DC/AC Inverter, DC/DC Converter, or transformer. With this FMECA, the most probable failure modes could be determined. The top three failure modes, as seen in the FMECA Table 2, are internal component failures, improper use of the interface, and physical damage to the system. Since the purpose of the reliability analysis report is to supply the design group with an idea of where potential failures will occur, design adjustments can be made to improve the design reliability by using the results of the FMECA. Based on this report, the following design adjustments have been made to reduce the risk of a system failure: 1. Use a system enclosure to prevent physical damage to the system. 2. Minimize improper use by supplying a well-written operation manual. Other adjustments, though out of the scope of this project, may be made to further reduce the RPN for specific failure modes. This FMECA should be used to determine how to achieve a more reliable system and understand where reliability issues in the system will occur. III. BUDGET Table X shows a summary of our project budget. A more detail Budget/Bill of Material can be seen in Appendix X. TABLE 6 – BUDGET SUMMARY Item DC/DC Converter Predicted Cost Actual Expenditures $318.00 $398.00 DC/3-Phase AC Inverter $500.00 Hydrogen $45.00 Poster/Report Binding $70.00 Protection Circuitry $50.00 Filtering (Inductor Bank) $50.00 Transformer $125.00 Printed Circuit Boards $350.00 Circuit Components $150.00 Utility Cart $100.00 Miscellaneous $300.00 Code Composer Studio $495.00 XDS510PP-Plus Parallel Port Emulator $999.00 Total Predicted Budget Total Expeditures Total Budget Left $500.00 $65.00 $102.30 $28.80 Donated Donated $180.00 $159.96 $58.00 $0.00 Donated Donated $3,552.00 $1,492.06 $2059.94 8 Appendices 9 Appendix A – Absopulse BAP265 Series DC/DC Converter Data Sheet 10 11 Appendix B – Tier Electronics DC/AC Inverter I/O Pins and Pinouts 12 DC Power In J2 and J3 are DC power in AC Power Out J1 is AC out 1 (Controlled by DSP pin 27 and pin 10) J5 is AC out 2 (Controlled by DSP pin 11 and pin 28) J6 is AC out 3 (Controlled by DSP pin 29 and pin 12) Communications Board (Connecter J7) Pin 1 = 15V Pin 2 = RX (goes to DSP pin 2) Pin 3 = TX (comes from DSP pin 3) Pin 4 = Data in line (goes to DSP pin 31) Pin 5 = Data out line (comes from DSP pin 22) Pin 6 = Aux 1 (goes to DSP pin 15) Pin 7 = Aux 2 (goes to DSP pin 14) DSP pin 32 is controlled by Q1 pin 3(of the main board with the heatsink on it) 13 Appendix C – Zero Crossing Circuit Feedback Derivation 14 15 16 Appendix D – Zero Detection Circuitry Simulation Results 17 18 19 20 21 22 23 Appendix E – Zero Detection Circuitry PCB Board Design, Parts/Build List 24 25 26 27 28 29 Appendix F – Zero Detection Circuitry Test Point Reference 30 ______________________________________________________________________ Test Point Locations (Labeled on PCB Board) TP(X) – X Phase(1,2,3) Test Point Location Location Number ______________________________________________________________________ Pin Assignments (Refer to Schematic Above) TP(X) – X Circuit(1,2)* Phase(1,2,3) *Circuit = 1 refers to ZDC that triggers at +0.7V Circuit = 2 refers to ZDC that triggers at -0.7V For each phase, the +0.7V circuit is above the –0.7V circuit 31 Test Point Reference is oriented as if you were looking down on the PCB board with the Phase 1,2,3 inputs on your left, and +/- Vcc inputs top. TP(x)-1 VOOP(1)-x GND V+(1)-x V-(1)-x 32 GND V-(2)-x VOOP(2)-x V+(2)-x TP(x)-2 VIISO(1)-x GND TP(x)-3 VIISO(2)-x GND 33 TP(x)-4 GND VIXOR(1)-x GND VIXOR(2)-x TP(x)-5 Not shown on schematic above. It gives you the output of the XOR Gate. GND XORx TP(x)-6 Not shown on schematic above. It gives you the output of the Inverter Gate. INVx GND 34 Appendix F – DSP Software
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