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2003 Future Energy Challenge “Energy Challenge in the Home”

2003 Future Energy Challenge “Energy Challenge in the Home”. Matt Pagendarm, Mark Wu Boost PFC, Team 41 4/30/03. 2003 FEC Background. Create a Motor and Drive System Motor System Characteristics: Output power range 50W - 500W (<1HP) Motor Speed ranges from 150RPM - 5000RPM Efficiency > 70%

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2003 Future Energy Challenge “Energy Challenge in the Home”

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  1. 2003 Future Energy Challenge“Energy Challenge in the Home” Matt Pagendarm, Mark Wu Boost PFC, Team 414/30/03

  2. 2003 FEC Background • Create a Motor and Drive System • Motor System Characteristics: • Output power range 50W - 500W (<1HP) • Motor Speed ranges from 150RPM - 5000RPM • Efficiency > 70% • Power Factor > 0.8 • Operate from a single phase 120 Vac source • Cost less than $40 (per million quantity)

  3. UIUC Motor Drive System

  4. Motivation for PF Correction • Lowers Peak Currents • Lowers Total Losses • Power Grid Friendly

  5. Why Choose Boost PFC? • Keep It Simple • Average Current Mode Control • Boost Converters Naturally Drive Current • Component Ratings Inverter Drive • Cost Effective

  6. Boost PFC System Specifications • True Specifications • Voltage Ripple +/- 10V • Input Current Ripple +/- 1 Amp • >95% Efficiency • Near 1 Power Factor • Actual output 80W - 800W • Inrush Current < 150% Rated Load (<15 Amps)

  7. System Design & Calculations • PWM Boost ~ Backwards Inverter • Desired Duty on Diode • Duty on Transistor

  8. System Design & Calculations • Inductor • Hand wound Ferrite inductor • 1.5mH • Capacitor • Size Driven by Necessary Ripple Current (10A) • 3 – 2200uF capacitors (3.5A each)

  9. System Design & Calculations • Fairchild 17N40 Mosfet • Cheap - $0.91 (Qty: 1000) • 17 Amp conduction, 400V blocking • Low Rds(on) • MUR1540 Ultrafast Diode • 15 Amp conduction, 400V blocking • GSIB1540 Vishay Rectifier • Cheap - $0.79 (Qty: 1000) • 15 Amp conduction, 400V blocking

  10. PFC Controller Block Diagram • Unitrode UCC3817

  11. Voltage Loop Slow Response Filter 120Hz Input Current Loop Fast Response Match Current to Vin Feedback Control

  12. System Protection • Over Voltage on Bus • Set to 230 V • Verified in Testing • Over Current on Input • Set to 10 Amps • Verified in Testing • Open load (Bus disconnected) • Discharge of 6.6mF capacitors • Verified in Testing • Input Fuse • Incorporated with IEC320 Package

  13. Build System • Build 42V • Convenience • Low Voltage • Scaled System of 200V • Build 200V • Learn from 42V • Finalize Device Selections

  14. 42V Boost PFC Operation 17 Watts Rsense – 0.25 Ohm Classical Rectifier Power Factor Corrected Rectifier

  15. 200V Boost PFC Operation Rsense – 0.10 Ohm Peak Limit Verified 100 W Load 200 W Load

  16. Challenges - Voltage Loop Rsense – 0.10 Ohm Over Voltage Verified 100 W 160 W

  17. Challenges – Ground Loops 200V Layout 42V Layout

  18. Challenges – Noise & Rsense • 42V Rsense 0.25 Ohms • Vrsense = 800mV • 200V Rsense 0.05 Ohms • Minimun load, Vrsense = 50mV • Needs filtration • Moved to Rsense 0.10 Ohms

  19. 200V System Results

  20. Recommendations • Utilize DSP’s extra PWM controller • Lower cost • Smaller layout, size • Ultra-low Rsense or transformer current sensing

  21. Upcoming Events • PC Board Layout Submitted • Induction Motor Laminations Cut • Integration with Inverter & Motor Team • Final Competition Event: • May 21-24, 2003 • Raleigh, North Carolina

  22. Questions?

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