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Solar Powered FDM 3D Printer

Solar Powered FDM 3D Printer. P18462. Team Members. From left to right:. Agenda.

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Solar Powered FDM 3D Printer

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  1. Solar Powered FDM 3D Printer P18462

  2. Team Members From left to right:

  3. Agenda Problem Statement Recap………………………………………………………………………………………………………………4Supplies…………………………………………………………………………………………………………...…………………………..5-8Feasibility Calculations……………………………………………………………………………………………………………………9Design 2 Overview ………………………………………………………………………………………………………………………..10 Design 2 Subsystems…………………………………………………………………………………………………..………..……...11Electrical Schematic Design 2 …………………………………………………………………………………………………10-16Bill of Materials………...…………………………………………………………………………………………………………………....17Battery Weight vs Capacity/Time………..……………………………………………………………………………………18-19Test Plan………………………………………………………………………………………………………………………..…………20-22 Risk Assessment……………………………………………………………………………………………………………………………23Goals for MSD II…………………………………………………………………………………………………………….……………...24Timeline for MSD II………………………………………….…………………………………………………………….……………...25

  4. Problem Statement Key Deliverables • Modify power systems in a 3D Printer to function in Colombia • Grid power not reliable • Possible use case • Skills Trading • Goods Production • Wheel out to customer • A prototype and tested design of a solar-powered 3D printer • Documents pertaining to the development and design of the product • Troubleshooting guide to allow customers/operators to service and maintain printer

  5. Supplies • Supplies from old MSD team • Supplies include: • Battery (75 amp/h) • 2 x solar panel (100 W) • MPPT controller

  6. Supplies - Battery • Duracell Ultra Deep Cycle • 75 amp/h • Can successfully hold a charge and power

  7. Supplies - Solar Panel • 2 x GrapeSolar Photovoltaic Modules • Max Peak Power = 100W • Max Power Point Voltage = 18V • Max Power Point Current = 5.56A

  8. Supplies - MPPT Solar Charge Controller • Helps regulate solar power coming in • Has ports for PV and Battery power

  9. Feasibility Calculations Component Power Consumption (from testing) • Printer: 60 W average • Laptop: 50 W Assuming: 90% efficiency for MPPT module and DC-AC converter 4 hours of optimal solar charging time Laptop will not regularly run on system after print starts Battery Capacity Desired Solar Panel Output 60 W 60 AH

  10. Design Overview 2 Laptop Grid Power Maximum Power Point Tracker Controller (MPPT) Solar Power Printer Arduino Mega Battery

  11. Design 2 Subsystems Main Electrical Subsystems: • Switching Circuit - needed to automatically control which power source should be used • Powering Arduino - Arduino must always be running • Temperature Sensor - used as safety precaution for battery overheating • Battery Charging - battery needs to be constantly charged or charging in case other sources are not available

  12. Electrical Schematic - Design 2 • MPPT module requires constant battery connection. • Current flow to and from the battery is monitored as well as battery voltage • The transistor circuitry controls the current flow from the AC source • The Arduino controls the transistor to balance power needs with solar power

  13. Electrical Schematic Design 2 - Detailed

  14. Electrical Schematic Design 2 - Simulation

  15. Electrical Schematic Design 2 - Simulation

  16. Design 2 changes from PDDR to DDR • Relays were replaced with transistors to perform the needed switching. This removes the need for digital logic coding conducted by the Arduino and allows for analog current control. • Added Op Amps to monitor current throughout the systems • Added capacitor in between the printer and AC to DC loads to increase protection by delaying quick voltage changes due to switching • From testing our acquired parts, we learned that the MPPT controller needs to always be connected to the battery to function properly

  17. Bill of Materials (BOM)

  18. Battery Weight vs Capacity/Time • Use Time Before Dying was determined using the equation in the Feasibility Calculations Slide (9) • Laptop Power was considered in the calculations to show the the approximate amount of time the battery will run with the highest possible power consumption value

  19. Battery Weight vs Capacity/Time Graph Focus here for ideal weight and time

  20. Preliminary Test Plan What we won’t test: • ER #1: Print Volume • ER #2: Print Speed • ER #6: Print Resolution • ER #8: Filament Diameter What we’ll test: • ER #4: Wattage/Power Consumption • ER #9: Assembly Time • ER #10: Operation Start-up Time • ER #11: Intervention rate • Maintenance/diagnostics • Components function • Packaging effectiveness Important things to watch: • ER #3: Device Size • ER #5: Cost • ER #7: Weight

  21. Preliminary Test Plan

  22. Preliminary Test Plan - cont. Responsibilities will be assigned and refined once our schedules are known for next semester.

  23. Risk Assessment MSD I

  24. MSD II Goals • Build switching system circuit • Improve durability • Improve portability • Implement packaging • Create Repair Manual • Reduce user intervention • Implement solution to allow print to “fail gracefully” • Debug and test • Complete needed Deliverables

  25. Timeline

  26. Thank you.

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