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Hybrid Go-Kart University of Connecticut Department of Electrical Engineering

Hybrid Go-Kart University of Connecticut Department of Electrical Engineering. Team Members: Jonathan Blake (EE), Nathan Butterfield (EE), Joshua Calkins (EE), Anupam Ojha (EE) Advisor: Prof . Sung- Yeul Park 11/18/2013. Outline. Introduction Power Sources Boost Converter Revisions

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Hybrid Go-Kart University of Connecticut Department of Electrical Engineering

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  1. Hybrid Go-KartUniversity of ConnecticutDepartment of Electrical Engineering Team Members: Jonathan Blake (EE), Nathan Butterfield (EE), Joshua Calkins (EE), AnupamOjha (EE) Advisor: Prof. Sung-YeulPark 11/18/2013

  2. Outline • Introduction • Power Sources • Boost Converter Revisions • Flyback Converter • EIS Characteristics • Timeline/Next Steps

  3. What is Our Project? • Design a power electronics system to combine three separate power sources in order to drive an electric go-kart.

  4. The Power Sources • We will use three power sources: • A 30V Lead Acid battery • Four ultra-capacitors, wired in series, at 14V across bank • Photovoltaic Panel, 8->40V output, 200W

  5. System Overview

  6. Boost Converter Design • The design of our boost converter has changed drastically. • The driving factor of these changes has been the input current. • All of the following topologies were designed for 1.2kW.

  7. Initial Design: 12V->36V • Two boost converters in parallel, one for the ultra-capacitors, one for the battery. • Input current of 100A. • Finding an inductor rated for this current within out budget proved impossible.

  8. Parallel Current Paths • Placing multiple power stages in parallel is one way to handle the current.

  9. Parallel Paths (cont.) • Again, the inductors caused problems. • 8 inductors were required • An integrated circuit controller solution was found.

  10. Integrated Circuit Controller

  11. PCB Implementation • Some of the paths shown in the previous diagram would have currents of 100 A. • The cost of a PCB capable of handling these currents may be cost prohibitive.

  12. Boost Power-Stage Platform • High-current sections of a boost converter placed on separate platform, connected by cables. • Current and voltage sensor output to microcontroller. • Gate switching would determined by microcontroller, sent through gate drive circuit.

  13. Boost Power-Stage Platform (cont.)

  14. Flyback Specifications • High current caused for multiple design alterations. • 4:7 turns ratio • Voltage Primary 8V-40V. Secondary Voltage 14V. • 16.7% to 50% Duty cycle • Current max 5A in 14.3A • Inductance on primary 20μH

  15. Flyback Schematic

  16. Flyback Transformer • Selection of core geometry and material. • Toroid, E I core with gap • Kool mμ, ferromagnetic material, MPP • Core loss due to eddy currents and hysteresis , where k,m and n are constants that pertain to specific core material, is frequency and is the maximum flux density.

  17. Core saturation • Residual flux • Gauss • Units used for B and H are not consistant

  18. Litz Wire • High frequency increases wire loss due to skin effect. • MultistrandLitz wire distributes current • Small wire gauge allows signal to penetrate into the wire. • Higher cost • Window fill

  19. EIS Testing • Measure impedance at different frequencies • Different sources and loads have different electrochemical characteristicsthat can change overtime • Humidity, temperature, oxidation & electrode corrosion • Diffusion creates impedance at low frequencies (Warburg)  makes impedance difficult to determine • Electron & ion transport, gas & solid phase reactant transport, heterogeneous reactions different characteristic time-constants  exhibited at different AC frequencies.

  20. EIS Setup • The device under test (DUT) will be the battery, PV panel and ultra-capacitor. Block diagram required for FRA to preform tests and obtain data.

  21. FRA & eLoad • FRA injects a range of frequencies along with a perturbation into the test device & signals the programmable load • Measures voltage and current; creates Bode and Nyquist Plots • Programmable eLoad varies impedance throughout the test. Frequency Response Analyzer (FRA) Programmable eLoad

  22. EIS Setup Phases • FRA  Computer interface • Manuals, Drivers, XP OS • FRA out signal • Frequency sweep test • Cooling T connector • Battery, ultra-capacitors, PV panel • C2E2 EIS testing setup • Battery & ultra-capacitors FRA  Computer interface

  23. Timeline Updated • Blue = Original Plan • Yellow = Updated Plan

  24. Next Steps • PCB Design of Flyback and Gate Drivers • Physical Layout of Boost Power-Stage Platform • EIS of Battery and Ultra-Capacitors • Software algorithm and MPPT

  25. Questions?

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