Integrated Battery Charger and Motor Drive System 混合型电池充电及电机驱动系统 Project Reference No: ITP 040 07 AP Progress Meeting for the Reporting Period From : 1/Oct/08 ~ 31/Mar/09 Supported By: ITC By 1
Overview of the Progress Ø Project Management u. Project Manpower Usage u. Project Milestone V. S. Completed Project Progress ØAchievements to-date of Research and Development Work u. Development of 2 k. W Integrated battery charger u. Development of 3 k. W Integrated motor drive u. Development for the Integrated Version of Charger and Motor Drive System ØDissemination and Promotion Activities ØOther Activities Supported By: ITC By 2
Acknowledgement We express our sincere thanks to the following for their generous support Innovation and Technology Fund, Innovation and Technology Commission Shining Rich Limited Thank You!! General Hope Limited Aoli Ltd Supported By: ITC By 3
Project Manpower Usage Supported By: ITC By 4
Project Manpower Usage Project Coordinators Poly. U Prof. Eric Ka Wai Cheng, Dr. Norbert Cheung Dr. Edward Wai-chau LO, Prof. Tak Chi Lee Project Staff APAS Mr. C. H. Leung Dr. Ding Kai (Poly. U) Research Fellow Task: Project Manager, Drive, Integration Dr. Nelson Chan (APAS) Principle Engineer Task: Battery Charger, System Validation Dr. Wang Shuxiao (Poly. U) Research Associate Task: Drive, Integration Mr. Cheong Chi Keong (Poly. U) Project Technical Assistant Task: Battery Charger, Integration Mr. Wang Daohong (Poly. U) Research Associate Task: Drive, Integration Mr. Wong Man Keung (Poly. U) Research Assistant Task: Battery Charger, Integration Supported By: ITC By 5
Project Milestone V. S. Completed Project Progress Supported By: ITC By 6
Progress of individual milestones Period From (dd/mm/yyyy) 1/2/2008 To (dd/mm/yyyy) 30/6/2008 Planned Revised 1/6/2008 31/10/2008 Planned Revised 1/11/2008 28/2/2009 Planned Revised 1/3/2009 31/5/2009 Planned Revised 1/6/2009 15/7/2009 Planned Revised 1/7/2009 31/7/2009 Planned Revised Supported By: ITC By Milestones Reasons of Deviation (if applicable) Examine the circuit design for stand-alone battery charger and the motor drive. (Completed) Design and develop an integrated version of charger and motor drive that does dual functions, at different times. (Completed) Build the circuit with loaded microprocessor and conduct initial tests for the integrated drives (Completed) Examine the performance for the integrated system in the laboratory at various loading parameters. (On-going) Trial road test on an electric vehicle for data to refine parameters. (On-going) Documentation by filing patent, papers and technical booklet and demonstration to industries and public (On-going) 7
Project Millstone V. S. Completed Project Progress 9 /0 12 7/ /09 22 6/ /09 2 6/ 9 /0 13 5/ /09 23 4/ 09 3/ 4/ 9 /0 14 3/ /09 22 2/ /09 2 2/ 9 /0 13 1/ /08 4 /2 8 12 4/0 / 12 /08 4 /1 8 11 5/0 /2 8 10 5/0 / 10 /08 15 9/ /08 26 8/ /08 6 8/ 8 /0 17 7/ /08 27 6/ /08 7 6/ 8 /0 18 5/ /08 28 4/ 08 8/ 4/ 8 /0 19 3/ Scheduled (Milestone 1). . . Completion (Milestone 1. . . Scheduled (Milestone 2). . . Completion (Milestone 2. . . Scheduled (Milestone 3). . . Completion (Milestone 3. . . Scheduled (Milestone 4). . . Completion (Milestone 4. . . Scheduled (Milestone 5). . . Completion (Milestone 5. . . Scheduled (Milestone 6). . . Completion (Milestone 6. . . Milestone 1: Examine the circuit design for stand-alone battery charger and the motor drive. Milestone 2: Design and develop an integrated version of charger and motor drive that does dual functions, at different times. Milestone 3: Build the circuit with loaded microprocessor and conduct initial tests for the integrated drives Milestone 4: Examine the performance for the integrated system in the laboratory at various loading parameters. Milestone 5: Trial road test on an electric vehicle for data to refine parameters. Milestone 6: Documentation by filing patent, papers and technical booklet and demonstration to industries and public Supported By: ITC By 8
Master Work Schedule 2008 -09 -30 Supported By: ITC By 9
Achievements to-date of Research and Development Work 1) Development of 2 k. W Integrated battery charger 2) Development of 3 k. W Integrated motor drive 3) Development for the Integrated Version of Charger and Motor Drive System Supported By: ITC By 10
1. Development of 2 k. W Integrated battery charger Supported By: ITC By 11
Table A 1: Specification for Battery Charger Product: Input: Output: Efficiency: Battery Type: Charging Time: Protections: Control Algorithms: Supported By: ITC By 2000 W Battery Charger Single Phase 220 Vac, 50 Hz 2000 W 60 Vdc (max) 33 Adc (max) >85% at full load Lead Acid Battery, 48 V, 200 Ah 6 Hours for 100% SOC 1. Output over-current limit 2. Output over-voltage limit 3. Battery and charger overtemperature protections 4. Input over-current protection 1. Phase-shift controlled method for power stage 2. Constant-current-constant-voltage for battery charging 12
PCB Drawing for Main board of Charger Top Layer Supported By: ITC By Bottom Layer 13
PCB Drawing for Main board of Charger Top Overlay Supported By: ITC By Bottom Overlay 14
Bill of Materials for Battery Charger (1 st part) Comment Description Designator Footprint Lib. Ref Quantity 100 V Polarized Capacitor (Radial) C 1 RB. 2/. 4 Cap Pol 1 1 100 V Polarized Capacitor (Radial) C 2, C 3 RB. 4/1. 0 Cap Pol 1 2 450 V Polarized Capacitor (Radial) C 4, C 5 RB. 4/1. 4 Cap Pol 1 2 100 v Polarized Capacitor (Radial) Cap Pol 1 2 Capacitor Cap 4 100 V Capacitor Cap 3 100 V Capacitor C 6, C 7 RB 7. 6 -15 C 8, C 9, RAD-0. 2 C 12, C 13 C 10, C 18, RAD-0. 3 C 21 C 11 RAD-0. 2 Cap 1 50 V Capacitor Cap 2 50 V Capacitor Cap 3 450 V Capacitor Cap 1 AC 275 V Capacitor Cap 3 630 V Capacitor Cap 4 ACV Capacitor C 14, C 15 RAD-0. 2 C 16, C 19, 0805 a C 22 C 17 RAD-1. 0 C 20, CX 1, RAD-1. 0 CX 2 Crs 1, Crs 2, RAD-0. 3 Crs 3, Crs 4 CY 1, CY 2 RAD-0. 4 Cap 2 UF 5402 Default Diode 1 HER 107 Default Diode 3 1 N 4148 Default Diode 4 UF 5408 Default Diode D 1 DIODE-0. 7 D 2, D 4, DIODE-0. 4 D 10 D 3, D 5, DIODE-0. 4 D 8, D 9 D 6, D 7 DIODE-0. 7 Diode 2 Supported By: ITC By 15
Prototyping and test for 2 k. W Charger Supported By: ITC By 16
Conversion Efficiency of Battery Charger Supported By: ITC By 17
Measured Zero Voltage switching waveforms of Battery Charger Supported By: ITC By 18
2. Development of Integrated 3 k. W motor drive Supported By: ITC By 19
Specification of Motor Drive Nominal Input Voltage Operating Voltage Range PWM Operating Frequency Armature Current Rating, 2 Minute Armature Current Rating, 1 Hour Field Current Rating, 2 Minute Field Current Rating, 1 Hour Rated Output Power Braking Current Limit Operating Ambient Temperature Range Supported By: ITC By 48 Vdc 32 -60 Vdc 10 -30 KHz 300 A 125 A 30 A 15 A 3 k. W 250 A -25 C to 55 C 20
Schematic of IGBT driver for Motor Drive(new version) IGBT driver IC M 57962 L Supported By: ITC By 21
PCB Drawing version) Top Layer Supported By: ITC By for IGBT driver board of drive(new Bottom layer 22
PCB Drawing for IGBT driver board of drive (new version) Top Overlay Supported By: ITC By 23
PCB Prototype for IGBT driver board (new version) Supported By: ITC By 24
Bill of Materials for IGBT driver Comment 25 V Cap Diode 1 N 4934 BZT 52 C 15 BZT 52 C 30 Header 3 Header 6 Res 2 2 W NMF 1205 SC NMF 1212 SC PC 817 M 57962 L Supported By: ITC By Description Designator Polarized C 141, C 142, Capacitor (Radial) C 143, C 144 C 145, C 146, Capacitor C 147, C 148 1 Amp Fast Recovery D 28, D 49 Rectifier D 29, D 48, D 50, Zener Diode D 52 Zener Diode D 30, D 51 Header, 3 -Pin P 7, P 8 Header, 6 -Pin P 9, P 10 R 174, R 176, Resistor, R 177, R 178, Semiconductor R 180, R 181, Resistor R 182, R 183 Resistor R 175, R 179 Header, 6 -Pin U 15, U 19 Header, 6 -Pin U 16, U 20 Optoisolator U 17, U 21 U 18, U 22 Footprint Lib. Ref Quantity 94 SP-E' Cap Pol 1 4 CAPR 2. 545. 1 x 3. 2 Cap 4 DIO 10. 46 -5. 3 x 2. 8 Diode 1 N 4934 2 DIODE-0. 4 D Zener 4 DIODE-0. 7 HDR 1 X 3 HDR 1 X 6 D Zener Header 3 Header 6 2 2 2 AXIAL-0. 4 Res 2, Res Semi 8 AXIAL-0. 7 HDR 1 X 6 DIP-4 M 57962 LPIN Res 2 Header 6 Optoisolator 1 M 57962 L 2 2 25
Schematic of Main board for Motor Drive(new version) Control IC Atmega 8 H-bridge converter for Field winding excitation Supported By: ITC By 26
PCB Drawing Main board for Motor Drive(new version) Top Layer Supported By: ITC By Bottom layer 27
PCB Drawing for Main board for Motor Drive(new version) Top Overlay Supported By: ITC By Bottom Overlay 28
Bill of Materials for Main board (new version) Supported By: ITC By 29
PCB Prototype of the main board for drive (new version) Supported By: ITC By 30
Performance Test of Motor Drive Indoor motor drive performance test Supported By: ITC By 31
Performance Test of Motor Drive Outdoor road test for drive system Supported By: ITC By 32
Performance Test of Motor Drive Maximum motor speed with light load Supported By: ITC By 33
Performance Test of Motor Drive Field current, 6 A ( 2 A/div) Supported By: ITC By 34
Performance Test of Motor Drive Armature current when accelerating (20 A/div) Supported By: ITC By 35
Software Programming for Atmega 8 Micro processor /********************* This program was produced by the Code. Wizard. AVR V 1. 24. 8 d Professional Automatic Program Generator ? Copyright 1998 -2006 Pavel Haiduc, HP Info. Tech s. r. l. http: //www. hpinfotech. com Project : Version : Date : 5/4/2009 Author : F 4 CG Company : F 4 CG Comments: Chip type : ATmega 16 Program type : Application Clock frequency : 16. 000000 MHz Memory model : Small External SRAM size : 0 Data Stack size : 256 *********************/ #include <mega 16. h> #define LED PORTD. 6 #define F 2_CON PORTC. 6 #define SD_CON PORTC. 7 #define MAIN_CON PORTC. 1 #define REVERSE PINC. 2 #define FORWARD PINC. 3 unsigned int adc_data[7]={0, 0, 0, 0}; unsigned char adc_index=6; unsigned char speed_number=0; unsigned int rate=0; unsigned int *OV=&adc_data[0]; unsigned int *UV=&adc_data[1]; unsigned int *PEDAL=&adc_data[2]; unsigned int *TEMP=&adc_data[3]; unsigned int *FC_COM=&adc_data[4]; unsigned int *FC=&adc_data[5]; unsigned int *CS=&adc_data[6]; unsigned int pedal_pwm=0; unsigned char rev_flag=1; bit oc_flag=0; bit wait_flag=0; bit stop_flag=1; bit slope_flag=0; bit pi_flag=0; bit newdata_flag=0; bit fault_flag=0; // External Interrupt 0 service routine interrupt [EXT_INT 0] void ext_int 0_isr(void) { unsigned int time_base=15625; unsigned int frequence=0; //oc_flag=0; #asm("cli"); frequence=speed_number*256+TCNT 0; rate=time_base/frequence; speed_number=0; TCNT 0=0; #asm("sei"); } // External Interrupt 1 service routine interrupt [EXT_INT 1] void ext_int 1_isr(void) { #asm("cli"); oc_flag=1; //过流保 护 fault_flag=1; #asm("sei"); } // External Interrupt 2 service routine interrupt [EXT_INT 2] void ext_int 2_isr(void) { Main Routine of C Program (part 1) Supported By: ITC By 36
3. Development for the Integrated Version of Charger and Motor Drive System Supported By: ITC By 37
Design of Integrated Battery charger and Motor drive Supported By: ITC By 38
Prototyping of Integrated battery charger and motor drive Supported By: ITC By (first version) 39
Dissemination Activities Supported By: ITC By and Promotion 40
Seminar on the Integrated Battery Charger and Motor Drive Systems Supported By: ITC By 41
Organizing a number of visits to Power Electronics Research Centre Visit of Mr. Michael W. K. Lam from E&K International (Holding) Group Ltd. (7 Nov 08) Supported By: ITC By 42
Organizing a number of visits to Power Electronics Research Centre Visit of K W Li , Principal advisor CGN Asia. Pacific (07 Nov 08) Supported By: ITC By 43
Organizing a number of visits to Power Electronics Research Centre Visit of Professor Han Yingduo, Academician of The Chinese Academy of Engineering, Chairman, PEERC of Tsinghua University (21 Nov 08) Supported By: ITC By 44
Organizing a number of visits to Power Electronics Research Centre Visit of Prof. Gang WAN from Chinese Government (Minister of Science & Technology Ministry) (12 DEC 08) Supported By: ITC By 45
Organizing a number of visits to Power Electronics Research Centre Visit of Wuyi University from Mainland China. (17 DEC 08) Supported By: ITC By 46
Organizing a number of visits to Power Electronics Research Centre Visit of MIT students (9 Jan 09) Supported By: ITC By 47
Organizing a number of visits to Power Electronics Research Centre Visit of John LEE from Rootec (14 Jan 09) Supported By: ITC By 48
Organizing a number of visits to Power Electronics Research Centre Visit of members from China Electrotechnical Society (26 -Mar-09) Supported By: ITC By 49
Other issues/concerns Supported By: ITC By 50
Summary • Development of 2 k. W charger has been finished. • Battery charger was able to operate under zero-voltage switching condition • The preliminary firmware of battery charger was completed. • Development of 3 k. W motor drive has been finished. • Control Algorithm and MCU programming for drive has been completed. • Performance test of motor drive at various load conditions has been carried out. • Integrated battery charger and motor drive system has been prototyped. Supported By: ITC By 51
Publication • Paper of IEEE AUPEC Five-level Cascaded Multilevel Motor Driver for Electrical Vehicle with Battery Charge Management • papers for PESA 2009 (May) 1) Design of CAN board Circuits Based on SJA 1000 for Vehicle Motor Drives Systems 2) Design of the Temperature and Humidity Instrument Based on 1 -wire Sensor for Electric Vehicle Motors Supported By: ITC By 52
Planned work for next reporting period (31 Mar 2009 -31 July 2009) • Examine the performance for the integrated system in the laboratory at various loading parameters • Trial road test on an electric vehicle for data to refine parameters • Documentation by filing patent, papers and technical booklet and demonstration to industries and public Supported By: ITC By 53
Financial (Preliminary, Expenditure used: 51% unaudited) Budge Expend Bala t iture nce Salary 1, 53 3, 052, 1, 521, 7 1, 09 836 39 7 Direct cost 820, 6 416, 44 404, 178 466 Audit 10, 00 0 Spons orship 200, 0 00 200, 000 240, 0 00 0 Supported By: ITC By 10, 000 0
Other issues • Waiting from New sponsor Aoli Ltd to send money • Procurement stop and salary stopped form University • Need extension for 3 months for cover up the difficulty in the last few months and the late start of the project. Supported By: ITC By
Thank you Supported By: ITC By 56
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