Critical Review Project Specs & Challenges Group 6: Jean Pierre Jose Paredes Luigi Evalle Andres Escalante May 25, 2012

Senior Design Group VI Group Members Jose Paredes Picture Electrical Engineering, B.S. Grad: Fall ‘12 Jean Pierre Computer Engineering, B.S. Grad: Summer ‘12 Picture Luigi Evalle Picture Electrical Engineering, B.S. Grad: Summer ‘12 Andres Escalante Electrical Engineering, B.S. Grad: Fall ‘12 Picture

Critical Review Table of Contents Mechanical Aspect Component Breakdown 2. 3. Project Essentials 1. Milestones 4. Financials 5.

Project Essentials Main Project Overview -Solar Panel -Uses Max Power Point Tracking (MPPT) to increase efficiency -Feeds a battery -Goes through a DC to AC Inverter -Supports a Load -MCU Enables PV Panel to Track Energy Source Maximizes available Solar Radiation

Project Essentials Goals & Objectives Source Tracking Source Tracking feature Will increase energy input at small energy expense Portability Enhanced features: Complete Enclosure for ease of Portability AC Output for extended time load-bearing AC Output Mr Jens- Uwe Heinrich: from E F PR Commercial, like Mr Buhlrich Efficiency MPPT Efficiency of at least 90% DC/AC Inverter Efficiency of at least 90%

Project Essentials Block Diagram Project Breakdown

Critical Review Table of Contents Mechanical Aspect Component Breakdown 2. 3. Project Essentials 1. Milestones 4. Financials 5.

Enclosure Project Physical Specs Wooden Enclosure & Ckt Box Rotating Chair Base Light-Weight Aluminum PV Frame

Critical Review Table of Contents Mechanical Aspect Component Breakdown 2. 3. Project Essentials 1. Milestones 4. Financials 5.

Component Information Photovoltaic Panel Luigi E. Status: Acquired Currently @ 60% Component Info.

Solar Panel Types Crystaline v. Thin Film Technologies Crystalline PV Panels Thin Film Higher power per area Output is less affected by temperature More Efficient Lower Cost per Watt More available product options More Shade tolerant Monocrysalline Polycrystalline Thin Film Efficiency 22.5% 11-15% 9% Weight 12.7 lbs 13 lbs 30.2 lbs Dimensions 33.25 in x 21.5 in 30.2 in x 26.38 in 39 in x 39 in Price (w/ shipping) $129.00 $179.99 $143.52

Solar Panel Types Monocrystaline Monocrystalline: -Cheaper, more efficient, Light weight and Smallest Surface Area Specifications: -Max Power: 60 W -Max Power Voltage: 17.6 V -Max Current: 3.41 A -Size: 33.25 in x 21.5 in -Weight: 12.76

PV Panel Incidence Angle Calculation Solar Angle of Incidence: Solar panel's will more efficiently produce greater amounts of power when its oritentation is exactly perpendicular to the light source feeding it. Optimal angle depends on the geographic location of the solar panel and the current time of year. The Solar panel will be adjusted to fixed angles depending on the season (summer, spring, fall or winter) Various solar angle calculators may be found online ”EnergyWorksUs.com calculator was used as reference for this project Once the angle from the horizontal is set, the efficiency of the panels will be further increased by utilizing solar tracking in order to have full exposure to the sun Fixed Angle (from horizontal) for Solar Panel in Central FL Area Summer 13 degrees Spring/Fall 28 degrees Winter 43 degrees

Component Information Battery Component Andres E. Stat: Not Acquired Currently @ 50% Component Info.

Specifications Convenience Battery Component EATON 12V 120 W Sealed Lead Acid Battery (PWHR12120W3FR) *Calculations per cell; 6 cells per unit Specifications 6 cells per unit, 12V total output 30Ah capability Min charge current 1 Amp 400A Maximum discharge Surge current (~5 sec) Battery life ~90,000 hours Mr Jens- Uwe Heinrich: from E F PR Commercial, like Mr Buhlrich Convenience Sealed construction. Flame-retardant design. Compact and low weight per avg. lead acid battery designs (23.6lbs, 4.9”x6.5”x6.9). Wide range of operating temperatures (5°F~104°F).

Component Information Max Power Point Tracker (MPPT) Unit Luigi E Status: PCB On Order Currently @ 40% Component Info.

MPPT Component Maximum Power Point Tracking: -Important because the voltage and current produced from the solar panel is variable depending on the amount of sun exposure to the solar panel. - The battery charges most efficiently 12V and 3 A. - purpose is to obtain the largest amount of voltage vs. current from a solar array. -voltage from solar panel goes to dc/dc converter which is parallel to MCU and battery -MCU chooses the maximum point at which the voltage and current will create the maximum power output as depicted by the equation P = IV. -Our goal: MPPT is to obtain efficiency of 90%

Microcontroller used: -Use the PIC16f88 microcontroller from Microchip MPPT Component PIC16F88 Microcontroller used: -Use the PIC16f88 microcontroller from Microchip -Program Memory: 7168 bytes Flash, 4096 Single Word Instructions -Data Memory: 368 bytes SRAM, 256 EEPROM bytes -16 I/o Pin -1 CCP (PWM) -2 Comparators -10-bit A/D -Timers 8/16 bit: 2/1

MPPT Component MPPT Schematic

Component Information DC/AC Inverter Jose P. Status: Designed and Prototype. Currently @ 55%

DC/AC Inverter Specs -100 watt. -Uses a pic16f628a microcontroller pic assembly lang -60 hertz produced by two waves from microcontroller. -Stp55nf06l logic mosfet, 50 amps max current. -Transformer wired backwards to attain high voltage. -PCB space is 6 inches, 4 inches. -Any AC load, no more than 2 amps.

Pic of switching regulator

DC/AC Inverter Schematics Design will be replaced

DC/AC Inverter Prototype

Component Information PV Panel Output Monitoring Unit Luigi E. Status: Acquired; Awaiting Testing Currently @ 55% Component Info.

Monitoring the Solar Panel Specifications Why is it important: -Efficiency calculations when comparing the efficiency of the MPPT. -Observe the effect of temperature on the solar panel's performance Voltage Coming from Solar Panel: -A voltage divider circuit will be used to calculate the voltage produced by the solar panel Current Coming from Solar Panel: -ACS714 a hall effect-based linear current sensor which will be surface mounted to the main PCB. Chosen because it is accurate for low current readings which range up to 5 A. Specifications: -Size: 0.7" x 0.8" -Weight: 1.3 g -Current Sensitivity: 0.185V/A -Max Logic Voltage: 4.5 - 5.5V -VCC: 5 V -Current input: -5A - 5A

Component Information MicroController Unit Jean P. Status: Acquired Currently @ 60%

Microcontroller Development Board Comparison Chart MCU Component MCU Development Board Comparison Chart Microcontroller Development Board Comparison Chart Development Board Chip used Comes with Chip? Power jack w/ Voltage Regulator USB Or Serial Interface Programming Language Price Arduino UNO - R3 ATMEGA328P YES USB C $29.95 Parallax Board of Education Development Board Basic Stamp 2 NO Basic $60.00 MSP430 Launchpad MSP430Fxx2 $4.30 PICKit 2 Debug Express PIC16F887 C/Assembly/Basic $49.99 Arduino Mega 2560 ATmega2560 $53.95 40 Pin PIC Deveopment Board PIC18F4550 Serial/USB C/Assembly $37.95

Comes with PICkit 2 Development Programmer/Debugger MCU Component Microchip PICkit 2 Debug Express Comes with PICkit 2 Development Programmer/Debugger Needed to program PIC microcontrollers in our program. 44-pin Demo board with PIC16F887 Midrange PIC microcontroller Has 12 lessons on assembly programming to cover I/O, A/D converters, timers, interrupts, etc. Several lessons on using C language to program microcontrollers

MCU Component Microcontroller ATmega328P Operating Voltage: 5V Input Voltage (recommended): 7-12V Input Voltage (limits): 6-20V Digital I/O: 14 (of which 6 provide PWM output) Analog Input Pins: 6 DC Current per I/O: Pin40 mA DC Current for 3.3V: Pin50 mA Flash Memory: 32 KB of which 0.5 KB used by bootloader SRAM: 2 KB(Atmega328p) EEPROM: 1 KB(ATmega328p) Clock Speed: 16 MHz

Component Information Tracking Component (Photoresistor) Jean P. Status: Construction phase Currently @ 45%

Tracking Component PHOTORESISTOR Size: 5.00x4.00mm Resistance on light: 5k-20k ohm Resistance in darkness: 1M ohm Max Voltage: 150V (DC) Peak Sensitivity: 560nm Sensitivity Range: CdS cells respond to light between 400nm (violet) and 600nm (orange) wavelengths, peaking at about 520nm (green). Power Supply: use less than 1mA for up to 100V (depending on power supply) Max power consumption: 100mW Operating temperature: -30 to +70°C

Component Information Load Control Monitoring Unit Jean P. Stat: Design Phase Currently @ 15%

Load Control Monitoring Porpuse With MCU, we will display: Current being consumed by the load Current out of PV panel Temperature of PV panel Voltage output of PV panel

Component Information Motor Controller Jean P. Status: Acquired Currently @ 65% Component Info.

Motor Controller Stepper Motor Big Easy Driver: Bi-Polar Stepper Motor Driver -- Designed by Brian Schmalzhaus -- from Sparkfun.com Specification: Bi-polar Micro stepping Driver use for Bi-Polar Stepper Motors Drive motor up to 2A/Phase Max Max Motor Drive Voltage: 35V On-board 5V/3.3V Regulation to use for Microcontroller Board can drive motor in Full Step, Half-Step, Quarter-Step, 1/8th –Step, 1/16th –Step Motor with 200 steps per revolution, require 3200 steps/rev for full revolution Comes with Eagle board files and schematic

Component Information Motor Component Jean P. Status: Acquired Currently @ 65% Component Info.

Motor Component Comparison Stepper Motors Comparison Chart Stepper Motor TYPE Website Manufacturer ID Holding Torque Oz-in Voltage Current Rating A/phase Type Weight kg Cost Nema 23 Ebay 57BYGH41-601B 55.00 12 Vdc 1.00 SIZE 23 0.47 $30.11 57BYGH41-401B 76.00 2.80 57BYGH56-401A 175.00 0.71 $37.99 Lin Engineering Alltronics.com 5718M-05E-04 124.21 2.00 N/A $19.95 NI NEMA 23 National Instrument 780073-01 180.00 0.40 $139.00 23HS6410-02A 212.00 0.85 $45.00 AMCI AMCI.com SM23 240.00 0.99

Stepper Motor Specifications: Motor Component Specs Stepper Motor Specifications: Size: Nema 23 Step Angle: 1.8 deg Voltage: 7.5 VDC Current/Phase: 1.0 Amp/phase Resistance/phase: 20.0 mH/ phase Holding Torque: 212 oz-in 150 N-cm Detent Torque: 7.0 oz-in 5.0 N-cm Rotor Inertia: 2.08 on-in2 380 g-cm2 Weight: 1.87 lbs 0.85 kg Available step Modes: Full, Half, Quarter, 1/8th and 1/16th Step

Motor Component Stepper Motor Schematic

Motor Component Stepper Motor  Tracking Algorithm

Component Information Liquid Crystal Display Andres E. Status: Acquired Currently @ 70% Component Info.

Liquid Crystal Display Specs HD44780 2004 20x4 LCD Module W/ Blue backlight LCD specs: Module Size(W×H×T): 98.0×60.0×14.0mm Viewing Area(W×H): 76.0×26.0 mm Character Size(W×H): 2.94×4.74 Dot Size(W×H): 0.54×0.54mm Operating Voltage: 4.5 – 5.5 V Operating Current: 1.0 – 2.2 mA Can run in 4-bit or 8-bit mode. Easily interface with Arduino using LiquidCrystal library. Sturdy enough for outside use

Liquid Crystal Display Pin Schematic of 20X4 LCD Module

Critical Review Table of Contents Mechanical Aspect Component Breakdown 2. 3. Project Essentials 1. Milestones 4. Financials 5.

Milestone Schedule Per Semester

Progress By Component Percent Completion

Critical Review Table of Contents Mechanical Aspect Component Breakdown 2. 3. Project Essentials 1. Milestones 4. Financials 5.

Budget Pivot Table of Actuals vs. Forecast

Points of Concern Possible Technical Problems to Come Stepper Motor torque output DC/AC transformer efficiency MPPT actual efficiency

Thank you for your attention! …Any Questions?

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