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Phase Converter Simulator AKA Voltron. Group 8 Anthony McCorvey Ronnie Lalchan Chris Beck George Thompson. Problem. The power companies are converting the old mechanical meters to Smart meters. Wireless Communication Accurate Readings KWH every hour Power Factor Connect/Disconnect
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Phase Converter SimulatorAKAVoltron Group 8 Anthony McCorvey Ronnie Lalchan Chris Beck George Thompson
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
Goals • To design a product that the power companies can use for their renovations • Cost efficient • Safe • User Friendly • Test and Train
Design Requirements Hardware • Meter Cans • Potential Transformers • Variable Transformer • Toggle Switches/Relays • Fuses • Control Box
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
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)
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
115 50 11580 11542 S3 S3 S3 Variable Transformer Secondary Secondary Secondary Primary Primary Primary Step-Up PT Schematic
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
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
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
Relays • -
Testing • Tested relays by realizing the schematic • For the microcontroller, we applied a steady voltage. • Connected to relays to microcontroller. • Replaced switched with relays.
Building • First attempt: • Diode parallel with relay • Purpose: • Protect circuit from feedback current when relay switched • Diode shorted out the transistors • Solution: • Remove diode
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
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
Software Components • Microcontroller • Voltmeter Circuit • LCD Screen 2 line X 20 characters
LCD System Flow Chart Push Button Voltmeter Circuit
Switches to Switching Relays • Microcontroller changes configurations • Eliminates need for the user to know switch combination • Configurations can switch when required or prompted automatically
Voltmeter Circuit(Feedback) • Input Voltage (120-240) | • Probes | • Transformer | • Full Wave Rectifier w/ Capacitor | • Voltage Divider | • A/D converter(microcontroller) • Problems….
PCB • 2 Layer PCB • .10” Traces • Ground Plane • Using PCB Express • Schematic • PCB Board
Microcontroller Vs. FPGA PIC16F876A ATmega168 FPGABasys
Microcontroller Vs. FPGA • ATmega168
Budget • Current Cost $550 • Development Budget $565 • Prototype Budget $725
Thanks • Family • Faculty • Friends