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Cal Poly SuPER Project: Progress Report and Plans

Cal Poly SuPER Project: Progress Report and Plans . EE 563 Graduate Seminar October 6, 2006 James G. Harris, Professor EE Department and CPE Program. Cal Poly SuPER Project: Outline. Background: rationale for project Progress Report for Last Year AY 05-06 Plans for This Year AY 06-07

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Cal Poly SuPER Project: Progress Report and Plans

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  1. Cal Poly SuPER Project: Progress Report and Plans EE 563 Graduate Seminar October 6, 2006 James G. Harris, Professor EE Department and CPE Program

  2. Cal Poly SuPER Project: Outline • Background: rationale for project • Progress Report for Last Year AY 05-06 • Plans for This Year AY 06-07 • Conclusion and Invitation to Join Project

  3. Background - Electrification • Electrification – National Academy of Engineering’s top engineering achievement for the 20th Century • Estimated 1/3 of population (now, 6B) do not have access • Significant proportion of remainder does not have reliable access to battery or grid • 18,000 occupied structures on Navajo Nation lack electrical power (2001 legislation)

  4. Background - Significance • Impact of electrification significant • Transformation of Western world • Thomas Hughes: Networks of Power • People who caused change • Social Impact – standard of living • Recognized by National Renewable Energy Laboratory in late 1990s • Village Power Program • Development of microfinancing

  5. Background – Solar Insolation • Goal to provide electrical resources to people in underdeveloped countries • Leapfrog technology – no need for 100 years of development • Example of cell phone in Asia • Review of global insolation map • Poorest people ($1-2 a day income) • Within plus or minus 30 degree of latitude • Highest values of solar insolation (minimum W hr/sq m/day)

  6. Background – DC Power • Solar photovoltaic systems inherently DC • History of DC (Edison) versus AC (Westinghouse and Tesla) at end of 19th century • DC versus AC for generation, distribution, and utilization • Initially, applied to lighting • Lighting today • 60W incandescent bulb and 20W compact fluorescent bulb lumens • Equivalent to 3W LED technology, and improving

  7. Background – DC power loads • Efficiency of electrical motors: few horsepower • Permanent magnet DC motors • Electrical appliances • Computer: 50W laptop (DC) • TVs, radios use DC power • RV 12V DC market: kitchen appliances • Portable power tools – battery powered (DC) • Computers: wireless connection • Internet, phone (voice over IP), TV, radio, • Education: MIT Media Lab $100 laptop project

  8. Background – Moore’s Law • Stand-alone solar photovoltaic system technology is mature, e.g., Sandia Handbook • Application of Moore’s Law to development of SuPER system • Solar cell development: commercial and research lab • Estimate 5% per decade with base of 16% in 2005 • Implies 25% efficiency in 2025 • DARPA RFP: 1000 units of 50% efficiency

  9. Commercial Module Range Laboratory Cells Histories of Silicon Photovoltaic Module and Cell Efficiencies Ref.: Martin A. Green; "Silicon Photovoltaic Modules: A Brief History of the First 50 Years"; Prog. Photovolt: Res. Appl. 2005; 13:447–455 (Published online 18 April 2005 in Wiley InterScience (www.interscience.wiley.com). DOI: 10.1002/pip.612)

  10. April Allderdice and John H. Rogers; Renewable Energy for Microenterprise; National Renewable Energy Laboratory; November 2000

  11. Antonio C. Jimenez, Tom Lawand; Renewable Energy for Rural Schools; National Renewable Energy Laboratory; November 2000

  12. Jonathan O.V. Touryan and Kenell J. Touryan; Renewable Energy for Sustainable Rural Village Power; Presented at the American Scientific Affiliation Conference Arkansas August 1, 1999 National Renewable Energy Laboratory

  13. Background – Solar and DC Power • Conclusion • Solar photovoltaic is poised for leapfrog technology • Many development tools available • Expectation of future efficiencies • Sustainable power source • Digital control of standalone system • DC is power of future • Decentralized • Matched to source and loads

  14. Background: Overall Cal Poly SuPER System Goals • Design lifecycle of 20 years • Total Cost: less than $500 for 1 sq m PV module including battery replacements • Mean time between failures (MTBF): 25 years • Mean time to repair (MTTR): 1 hour • Power depends on PV efficiency and battery storage capacity

  15. Why? Broader Impact of SuPER Project • Provides family owned electrical power source • Only electrical power source for family • Increasing power resource with time • With financial business plan: $2-3 per month for all electrical power needs • Decentralized, sustainable development of electrical power in poorest countries • SuPER system potential resource for raising standard of living of poorest to par with rest of world

  16. Background: Five Year Plan for Development • Five years for completed design, development, and field testing • Includes business plan, documentation and dissemination • First three years for prototype development • Three generations at one year for each • Last two years for field testing • Establishing contacts overseas now

  17. Progress Report: Technical Description of SuPER System

  18. Prototype Development Phases • Phase 00: use of existing donated PV module (150W) PV system • Phase 0: cart mounted system • Phase 1: cart system with • Laptop computer with USB i/F to sensors • Linux OS • Cart for packaging • Phase 2: cart system performance testing/design enhancements • Phase 3: packaging/manufacturability goals • Port software/electronics to FPGA with microprocessor • Phase 4: system testing/preliminary field testing

  19. Summary -Progress Report:AY 05-06 • Cal Poly SuPER project lab established in 20-101 • Development phases 00, 0 , and 1 planned • Phase 0 implemented resulting in 1 thesis and 3 senior projects by end of Summer • BUS 454 (Spring 06) senior project team develops business/marketing plans: 4 senior projects • Foundation provided for future development of phase 1 prototype

  20. Eran Tal working with prototype SuPER System – June 2006

  21. SuPER Development Team

  22. Weekly Seminar Meeting in Power Senior Project Room (20-101) SuPER Project Laboratory

  23. Cal Poly SuPER Project - Spring 2006 SUPER prototype cart with solar panel, battery, instrumentation and control subsystems Members present in photo: (left to right) Eran Tal, Eric Phillips, Gustavo Vasquez, Alexander Gee, Jennifer Cao, Sam Muehleck, Dr. Jim Harris, Dr. Taufik, Tyler Sheffield, Dr. Ali Shaban; Members missing: Dr. Ahmad Nafisi, Robert Johnson

  24. Prototype SuPER System Cart protection and load distribution 12V DC service panel with five load circuits (four in service)

  25. Prototype SuPER System Cart bottom shelf 12V DC 1/4HP motor load and 12V battery

  26. Prototype SuPER System Cart top shelf view Laptop computer, interface circuits, MX-60 controller

  27. Prototype SuPER System Cart left side switchboard enclosure Main switchboard (bottom) and PV switchboard (top left)

  28. Prototype SuPER System Cart right side view

  29. Comparison of Open Loop and Phase 00 Systems

  30. Plans for This Year AY 06-07 • Recruit new Cal Poly Super Team • Initial meeting this past Wednesday • Develop and test the Phase 1 Prototype • All Cal Poly fabrication except for PV and battery • Continue effort initiated by BUS 454 • Work with consumer community

  31. Plans: Research Opportunities Available on Cal Poly SuPER Project • Undergraduates and graduates: EE, CPE • Graduate students provide leadership/thesis • Undergraduates work on senior project • Others invited • Design/development team environment • Weekly seminar meetings with faculty • Funds available to purchase materials and components for students

  32. Plans: Some Research Areas for Student Projects • Simulation of system with MatLab/Simulink: digital control algorithms • DC-DC converter development: PV to battery, DC output bus to LED lighting • Printed circuit board development: PCBExpress on-line design and fabrication • Battery and ultra-capacitor technology: electrical power storage research and modeling • Modeling of DC loads: white LED lighting, DC motor, battery charging, refrigerator • Power distribution and protection: NEC code compliance

  33. Plans: Some Research Areas for Student Projects (continued) • Sensor data acquisition and processing: voltage, current, temperature and sun insolation • System engineering: PV input modeling and DC output load scenarios for testing • PV array modeling: study of technology and maximum power point tracking algorithms • White light LED system development • DC motor characterization and load performance

  34. Plans: Interested in Participating? • Check out SuPER website: http://www.ee.calpoly.edu/~jharris/research/research.html • Announcement of opportunities • White Paper • Graduate Seminar Presentation • Senior Projects • Thesis • Visit with faculty involved: • EE: Jim Harris, Ahmad Nafisi, Ali Shaban, Taufik • OCOB: Doug Cerf, Norm Borin

  35. Cal Poly SuPER Senior Projects and Thesis (available at SuPER website) Thesis: Eran Tal, "SuPER System Prototype Design and Implementation", July 2006 (pdf file) Senior Projects: Tyson DenHerder, "Design and Simulation of Photovoltaic SuPER System using Simulink", March 2006 (pdf file) Gustavo Vasquez Jr., "Data Acquisition and Sensor Circuits for the SuPER Project", June 2006 (pdf file) BUS 454 Client Report Presentation - June 2006 Student Team - Jessica Hickey, Richard Huskey, Heather McGinnis, Nick McMillan; Faculty Supervisor -Dr. Lynn Metcalf (PowerPoint) Alexander Gee, "Printed Circuit Board Design and Construction for hte SuPER Project", August 2006 (pdf file)

  36. References • 1. George Constable, Bob Somerville; A Century of Innovation: Twenty Engineering Achievements that Transformed our Lives; National Academy of Engineering; 2003; overview available at http://www.greatachievements.org/ • 2. Jonathan O.V. Touryan, Kenell J. Touryan; "Renewable Energy for • Sustainable Rural Village Power";Presented at the American Scientific Affiliation • Conference ArkansasAugust 1999, available from NREL as NREL/CP-720-26871 • [hybrid system for nrel village power program report • 3. Begay-Campbell, Sandia National Laboratories; "Sustainable Hybrid System Deployment with the Navajo Tribal Utility Authority"; NCPV and Solar Program Review Meeting 2003 NREL/CD-520-33586 Page 541; available at http://www.nrel.gov/ncpv_prm/pdfs/33586073.pdf [estimated date 2003, describes program resulting from "On November 5, 2001, President Bush signed the Navajo Nation Electrification Demonstration Program (Section 602, Public Law 106-511) into Law. This law directs the Secretary of Energy to establish a 5-year program to assist the Navajo Nation in meeting its electricity needs for the estimated 18,000 occupied structures on the Navajo Nation that lack electric power."] • 4. Thomas P. Hughes; Networks of Power: Electrification in Western Society, 1880-1930; Baltimore: Johns Hopkins University Press, 1983 • 5. Thomas P. Hughes; American Genesis A Century of Invention and Technological Enthusiasm 1870-1970; Penguin Books; 1989 • 6. David Nye; Electrifying America Social Meanings of a New Technology, 1880-1940; MIT Press; 1990

  37. References • 7. Antonio C. Jimenez, Tom Lawand; "Renewable Energy for Rural Schools"; National Renewable Energy Laboratory; November 2000 • [report from village power program at nrel – covers all renewable sources] • 8. April Allderdice, John H. Rogers; Renewable Energy for Microenterprise; NREL: November 2000; available from http://www.gvep.org/content/article/detail/8508 • [microfinance introduction for renewable energy in underdevelopment countries] • 9. Ulrich Stutenbaumer, Tesfaye Negash, Amensisa Abdi; "Performance of small scale photovoltaic systems and their potential for rural electrification in Ethiopia"; Renewable Energy 18 (1999) pp 35-48 • [authored by locals, but dated – example of early recognition of possibilities] • 10. Sunwize Technologies; http://www.sunwize.com/; insolation map available at http://www.sunwize.com/info_center/insolmap.htm • [on-line catalog and interactive planning support; global insolation map] • 11. Evan Mills; "The Specter of Fuel-Based Lighting"; Science; v. 308, 27 May 2005, pp 1263-1264 • 12. E. Fred Schubert, Jong Kyu Kim; "Solid-State Light Sources Getting Smart"; Science; v. 308, 27 May 2005, pp 1274-1278 • 13. Thurton, J.P. and Stafford, B; "Successful Design of PV Power Systems for Solid-State Lighting Applications"; Fourth International Conference on Solid State Lighting; 3-6 August, 2004, Denver. Colorado / Proc. of SPIE; v. 5530; 2004; pp284-295 • [mainly lessons learned]

  38. References • 14. MIT Media Lab; http://laptop.media.mit.edu/ • 15. Sandia National Laboratories, Solar Programs and Technologies Department; Southwest Technology Development Institute, New Mexico State University; Daystar, Inc., Las Cruces, NM; "Stand-Alone Photovoltaic Systems: A Handbook of Recommended Design Practices"; Sandia National Laboratories, SAND87-7023 Updated July 2003 • [revised handbook first published in 1988] • 16. Kyocera Solar, Inc., Solar Electric Products Catalog , August 2005 • [available on web – prices for small modules only] • 17. IEA PVPS International Energy Agency Implementing Agreement on Photovoltaic Power Systems Task 3 Use of Photovoltaic Power Systems in Stand-Alone and Island • Applications Report IEA PVPS T3-09: 2002 "Use of appliances in Stand-Alone PV Power supply systems: problems and solutions; September 2002 • [dos and don'ts for design] • 18. Alison Wilshaw, Lucy Southgate & Rolf Oldach; "Quality Management of Stand Alone PV Systems: Recommended Practices" IEA Task 3, www.task3.pvps.iea.org • [another report of iea agreement] • 19. Martin A. Green; "Silicon Photovoltaic Modules: A Brief History of the First • 50 Years"; Prog. Photovolt: Res. Appl. 2005; 13:447–455 (Published online 18 April 2005 in Wiley InterScience (www.interscience.wiley.com). DOI: 10.1002/pip.612) • [history and use of moore's law with darpa rfp; also figure] • 20. Defense Advanced Research Projects Agency (DARPA) BAA05-21 posted Feb. 25, 2005 RFP—Very High Efficiency Solar Cell (VHESC) program announcement with deadline on 3/29/2005, which will be open at least a year from this date; see http://www.darpa.mil/ato/solicit/VHESC/index.htm

  39. References • 21. H. Spanggaard, F.C. Krebs; "A brief history of the development of organic and • polymeric photovoltaics"; Solar Energy Materials & Solar Cells 83 (2004) 125–146 • [overview in context of inorganic (si) pv's) • 22. T. Givler, P. Lilienthal; "Using HOMER® Software, NREL’s Micropower Optimization Model, to Explore the Role of Gen-sets in Small Solar Power Systems Case Study: Sri Lanka"; Technical Report NREL/TP-710-36774; May 2005. • 23. David L. King, Thomas D. Hund, William E. Boyson, Mark E. Ralph, Marlene Brown, Ron Orozco; "Experimental Optimization of the FireFly. 600 Photovoltaic Off-Grid System"; Sandia National Laboratories, SAND2003-3493 October 2003 • [system and component test with ac inverter; measurement parameters; standards and codes identified, e.g., grounding] • 24. R. Akkaya*, A. A. Kulaksiz; "A microcontroller-based stand-alone photovoltaic power system for residential appliances"; Applied Energy 78 (2004) 419–431; available at www.elsevier.com/locate/apenergy • [microbased control, but focused on AC output]

  40. References • 25. Angel V. Peterchev, Seth R. Sanders; "Digital Loss-Minimizing Multi-Mode Synchronous Buck Converter Control"; 2004 35th Annual IEEE Power Electronics Specialists Conference Aachen, Germany, 2004 • [dc to dc for cell phone/computer using digital techniques] • 26. Jason Hatashita, "Evaluation of a Network Co-processing Architecture Implemented in Programmable Hardware." EE MS Thesis, February 2002; available at http://www.netprl.calpoly.edu/files/phatfile/papers/masters/jasonH.pdf • 27. Homepage for Cal Poly Marketing Program: http://buiznt.cob.calpoly.edu/cob/Mktg/Borin/ ; see client application in lower right hand space • 28. EE 460/463/464 Senior Seminar/Senior Project Handbook available at: • http://www.ee.calpoly.edu/listings/29/sphand.pdf] • 29. Muhammad H. Rashid; Power Electronics: Circuits, Devices and Applications(3rd Edition); Prentice-Hall; 2004

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