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Anodizing Power Source Group 35

Anodizing Power Source Group 35. ECE 445 – Senior Design TA – Bryan Dobbs. Group Members. Peter Hwang Hung Chung Kofi Kwarteng. Objectives of our design. To be able to build a complete packaged anodizing power source for use in the anodizing shop in Everitt Laboratory.

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Anodizing Power Source Group 35

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  1. Anodizing Power SourceGroup 35 ECE 445 – Senior Design TA – Bryan Dobbs

  2. Group Members Peter Hwang Hung Chung Kofi Kwarteng

  3. Objectives of our design To be able to build a complete packaged anodizing power source for use in the anodizing shop in Everitt Laboratory.

  4. Benefits to the customer (Anodizing shop in Everitt Laboratory) • Ability to supply power to the anodizing shop • Adjustable current so that the client can adjust the current to his/ her needs • Low cost • High efficiency • Safety features to prevent injury to user

  5. Product Features • Clean, adjustable dc current via a user-controllable knob • Start/ Stop switch • Ground referenced output and isolated from the input • Fuses for over current protection • Fan for temperature regulation

  6. Design – Block Diagrams 3 phase Rectifier and Filter 3 phase AC source Full-bridge AC link and Forward Converter Current Sensor DC Load Feedback and Switch Control

  7. Phase Shift Delay Control • Main aspect control of the converter will come from the voltage source inverter (VSI) which has phase shift delay. • By adjusting the phase shift delay δ, the average value of the output voltage can be controlled. • The δ parameter is controlled by a PWM chip through the feedback signal of the output current.

  8. Step Down Transformer • The main transformer to be used is a high frequency transformer • This transformer will step the inverted voltage down from about 160V to 40V.

  9. Feedback Control • The equation that models the feedback control is given as K = ki∫ (Vref-vout) dt + kp(Vref-vout) • This integral control compares the reference signal to the measured signal and the signal (Vref-vout) will rise when the error is positive, fall when negative and remain constant even when the error is zero.

  10. Output Current Ripple • Our design encompasses limiting the current ripple to 2%. At 120A, current ripple is +/- 1.2A. • At a switching frequency of 20kHz, the required inductance is L = V(DT)/Δi =40V(0.5)(5E-5)/2.4 =416.7uH

  11. Performance Requirements Expected output includes: • 120A dc current output • About 40V dc voltage output • Output current to be controlled by the user • User interface incorporates a start/ stop switch pair • Input source of 208V ac which will be three phase • Output to be ground referenced and isolated from the input • Current ripple to be less than 2% • Efficiency to be greater than 75%

  12. Initial Testing Procedures • PSPICE simulations • Testing of individual components • Assembling individual components and testing at small current levels

  13. Challenges and Difficulties • Getting PWM chip to work • Non-availability of high current for testing parts • Getting certain parts, e.g. type of wire to be used in winding transformer and inductor

  14. What were done and could have been done • We got the right transformer core finally and winding wire • PWM problem was not solved conclusively

  15. That’s pretty much it Questions?

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