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Phase Converter Simulator AKA Voltron

Designing a cost-efficient, safe, user-friendly product for power companies undergoing meter renovations. Includes meter cans, transformers, switching configurations, safety precautions, control box, and software components. Hardware and software components aim to create a training simulation interface for contractors. The goal is to optimize the renovation process with accurate readings and wireless communication.

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Phase Converter Simulator AKA Voltron

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  1. Phase Converter SimulatorAKAVoltron Group 8 Anthony McCorvey Ronnie Lalchan Chris Beck George Thompson

  2. Problem • The power companies are converting the old mechanical meters to Smart meters. • Wireless Communication • Accurate Readings • KWH every hour • Power Factor • Connect/Disconnect • No jobs for meter readers • Hiring untrained contractors • Cheaper • Looking for a cost efficient method to train contractors

  3. Goals • To design a product that the power companies can use for their renovations • Cost efficient • Safe • User Friendly • Test and Train

  4. Design Requirements Hardware • Meter Cans • Potential Transformers • Variable Transformer • Toggle Switches/Relays • Fuses • Control Box

  5. Thinking about the Design • 2 Phase Configurations • Delta • Wye • Single Phase • Three Phase • How can we convert single phase to three phase? • Rotary motors etc • Too expensive • Defeats our goal • “Trick the Voltage” • That’s when Simulator was added to the name

  6. Meter Cans • (2) Three Phase Meter Cans • 2 Wire Delta • Junction Meter • 3 Wire Delta • 3 Wire Wye • LED Lights • (3) Single Phase Meter Cans • 2 Wire Delta • 3 Wire Delta • 3Wire Wye • LED Lights (Safety Precautions)

  7. Potential Transformers • 6 total potential transformers • 3 Step-down PT’s “Configuration” • 115:50 (Phase to Phase - Delta) and (Phase to Ground – Delta and Wye) • 115:80 (Stinger leg Delta) • 115:42 (Phase to Phase – Wye) • 3 Step-Up PT’s “Multiplier” • 2.4:1

  8. 115 50 11580 11542 S3 S3 S3 Variable Transformer Secondary Secondary Secondary Primary Primary Primary Step-Up PT Schematic

  9. Voltage Calculations • Phase to Ground for Wye and Delta (115:50) • 50 x 2.4 = 120 Volts • Power leg to Ground (Delta) (115:80) • 80 x 2.4 = 192 Volts • Specific to needs • Found a solution • Phase to Phase for Wye to Delta • Subtractive Polarity • Delta • 50 x 2.4 = 120 volts • Different terminals • 120 <0 – 120 <180 = 240 Volts • Wye (115:42) • 42 x 2.4 = 100.8 Volts • 100.8 <0 – 100.8 <180 = 201.6 Volts

  10. Control Box • Variable Transformer • 4 Fuses • (1) 5 Amps • (3) 2 Amps • ON/OFF switch • Safety Precautions • 5 toggle switches for selection of configuration • 3PDT

  11. Delta Switching Sequence

  12. Wye Switching Sequence

  13. Phase Converter Simulator Hardware 1

  14. Changing Switches to Relays • Mechanically changes configurations • Allows microcontroller to control switching • A lower voltage device can now control the voltages of the meter cans • Eliminates need for the user to know list of combinations

  15. Relays • -

  16. Schematic of Relay Connection

  17. Testing • Tested relays by realizing the schematic • For the microcontroller, we applied a steady voltage. • Connected to relays to microcontroller. • Replaced switched with relays.

  18. Building • First attempt: • Diode parallel with relay • Purpose: • Protect circuit from feedback current when relay switched • Diode shorted out the transistors • Solution: • Remove diode

  19. Building • Second attempt: • 1K resistor • Limited current to microcontroller • Too much impedance on breadboard • Switch to 100 ohms • Blew transistors 2n2222 • 2n2222 didn’t have a high enough rating • Solution: • Changed transistor to TIP120

  20. Software Objective • Create a Interface to compliment the Training Simulation • To allow the user to interact with the system. • To give a visual reference to the user of his or her actions • Control Relays for Configuration Purposes • Approve or Decline Users Certification

  21. Software Components • Microcontroller • Voltmeter Circuit • LCD Screen 2 line X 20 characters

  22. LCD System Flow Chart Push Button Voltmeter Circuit

  23. Switches to Switching Relays • Microcontroller changes configurations • Eliminates need for the user to know switch combination • Configurations can switch when required or prompted automatically

  24. LCD/system Code

  25. Voltmeter Circuit(Feedback) • Input Voltage (120-240) | • Probes | • Transformer | • Full Wave Rectifier w/ Capacitor | • Voltage Divider | • A/D converter(microcontroller) • Problems….

  26. A/D Converter

  27. PCB • 2 Layer PCB • .10” Traces • Ground Plane • Using PCB Express • Schematic • PCB Board

  28. Schematic

  29. PCB Board

  30. Microcontroller Vs. FPGA PIC16F876A ATmega168 FPGABasys

  31. ATmega168

  32. PIC16F876A

  33. FPGABasys

  34. Microcontroller Vs. FPGA • ATmega168

  35. Budget

  36. Budget Analysis

  37. Budget • Current Cost $550 • Development Budget $565 • Prototype Budget $725

  38. Thanks • Family • Faculty • Friends

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