Future Energy Challenge Three-Phase Inverter

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					Future Energy Challenge: Three-Phase Inverter



               ECE 445 Project Proposal
                      9/15/04
                  Quasar Hamirani
                     Duke Gray
                    Nathan Brown

                  TA: Chad Carlson
I.    Introduction
1.    Title
The 2005 Future Energy Challenge (FEC) is a worldwide student competition aimed at
producing innovations that can potentially reduce residential electricity use dramatically.
The objective of this year’s project is to develop a low-cost 500W, 150-5000 RPM motor
and electronic motor drive system with a power efficiency of at least 70% that can make
a significant decrease in power losses and costs in home appliance applications. The
FEC: Three-Phase Inverter senior design project will provide the University of Illinois
Future Energy Challenge Team with an inverter that makes up the final stage of the
electronic motor drive. Due to the total power costs associated with motors used in
household appliances such as refrigerators, washing machines and air conditioners, a
successful overall FEC project translates to an enormous worldwide impact in energy
savings.

2.    Objectives
The primary objective of this project is to design a three-phase inverter circuit that will
meet the requirements of the FEC. Major considerations in the design include size, heat
dissipation, cost and efficiency. A successful project is essential to the UIUC FEC
team’s performance in the competition.


II. Design
1.    Block Diagram




                                Recifier/          3-phase             Motor
             120 Vac
                                 PFC               Inverter




                                Power              Control
                                Supply             System



2.     Block Descriptions
      120Vac: Standard residential wall-outlet power source (120V at 50 or 60Hz)
      Recifier/PFC: ac-dc converter that provides full-wave input rectification and
       corrects the power factor to maximize efficiency
      Power Supply: dc-dc converter that provides dc voltage levels required by the
       inverter and control system
      Control system: takes speed feedback from the motor to digitally control the input
       signals that will drive the motor
      Three-phase inverter: operated the control system, delivers a 3-phase balanced set
       of sinusoidal waveforms to drive the motor
      Motor: three-phase induction machine that provides mechanical output power

3.   Performance Requirement
The three-phase inverter must meet the following specifications:
    Input: 200V DC ± 5V
    Output: Three-phase 100 V AC (line-to-line) sine wave
    Control input: Digital TTL commands at 2-10 kHz
    Power supply: 12V, 5V supplies available
    Power efficiency of at least 70% for loads ranging from 50W to 500W
    The inverter project will aide the motor in meeting the FEC performance
       specification of 150-5000 RPM


III. Verification
1.     Testing Procedures
      Assemble circuits to test components of the inverter
      Develop control signals for test purposes and observe hex-inverter gate signals with
        an oscilloscope
      Measure input and output power levels to calculate the power efficiency
      Measure the power factor
      Observe various signals in the inverter with an oscilloscope and plot efficiency and
        power factor measurements over the desired power range

2.    Tolerance Analysis
The output of the inverter must supply a sinusoidal three-phase current to the motor. It
will be verified that signal noise and harmonic distortion contributes to a relatively
insignificant portion of the output signal. Current waveforms must conform to IEC1000-
3-2 standards. The overall specifications of the FEC must be met under a full range of
loads. Specifically, the operating speed of the motor must remain within ±5% of the
voltage command setting from no-load to full-load.


IV. Cost and Schedule
1.    Cost Analysis

      Labor Cost: $45.00/hour * 2.5 * 250.hours = $ 28,125
      Total Labor Cost: $28,125/member * 3.members = $84,375
Part        Manufacturer          Vendor        Qty           Price
Resistors   General               ECE Shop      ?             $ 20.00
Diodes
Capacitors
Misc.
IGBT/MOSFET Fairchild             Pioneer       8             $ 9.60
            Semiconductor         Electronics
DSP         TI                    TI            1             $14.00
Gate Drive  IR                    Avnet         1             $7.00
PCB         -                     -             1             $100.00
                                                TOTAL PARTS   $ 150.60

Grand Total = Parts + Labor = $150.60 +$84,375 = $84525.60


2.   Schedule

Week            Task
8/23            Initial Ideas
8/30            Component Selections /
                Order Parts
9/6             Control Techniques
9/13            Hardware Implementation
9/20            Software Implementation
9/27            Phase 1 Testing
10/4            Phase 1 Optimization
10/11           Phase 2 Testing
10/18           Phase 2 Optimization
10/25           PCB Layout
11/1            Mock Demos
11/8            Test Drive with FEC Team
11/15           Optimization with FEC
11/29           Final Demos
12/6            Final Papers/ Checkout