Circuit Breaker Calibration

Transcription

1 Circuit Breaker Calibration Philip Simonin (EE) Kyle Weber (EE) Louis Leblanc (EE) Tyler Lyon (EE) Advisor: Ali Gokirmak Sponsor: Carling Technologies

2 Outline 1. Design objective and approach 2. Hardware specification 1. Circuit Breakers 2. PSoC 3. Stepper Motor 4. Pneumatic rig 5. Relays 6. Load bank 3. Circuit Design Diagram 4. Alternative Design Possibilities 5. Budget 6. Timeline

3 Objective Design and create functioning circuit calibration unit Comprised of pneumatic press, stepper motor, PSoC, load bank, relays Breakers of 5, 10, 15, or 20 Amperes must be brought to proper trip point PSoC will be the microcontroller

4 Problems To Address Calibration currently done manually Introduces unwanted human error +/- 30% error Effects manufacturing production rate Makes testing difficult for technicians

5 Our Solution Reduce margin of Error to +/- 10% (goal) Can be integratable into mass production More reliable product delivered to customer Simplified testing for engineers and technicians

6 What is Being Calibrated? The spring attached to the actuation arm Controls magnetic flux in the plunger Alters current let-through and trip-point Adjusts spring force on actuation arm

7 Applications Minimizes inaccuracies between products Allows engineers and technicians to test products and achieve a repeatable threshold Allows for testing of breakers before shipment Modifiable for other product lines Can be applied to multiple poles potentially

8 Circuit Breaker Specifications: Specifications A-Series Circuit Breakers 5, 10, 15, 20A rated breakers Max Voltage Current Rating: 80 VDC Resistance values from Line to Load Terminal Single Pole 10,000 ON/OFF 6 per min. Trip free

9 Breaker Architecture Adjustment screw Magnetic Sensing Coil

10 PSoC PSoC 4 CY8CKIT C code programmable, via USB Monitors current Signals relays and stepper (bidirectional) Conducts calibration adjustments Automates system Complete in 30 seconds or less

11 Top Design and Control Clock can be adjusted to speed of stepper motor ADC with follower input configuration from op-amp and protected by Zener. by Zener, looks for contact open/close Provisions for breaker in position are TBD Outputs kept at low level current and drive optocouplers and LEDs

12 PSoC Pinout Approximately 35 pins for I/O Data paths available Easy to program

13 PSoC MiniProg PSoC programmer via USB 5 pin docking and programs in seconds Alternate ten pin or direct USB available

14 Stepper Motor Nema 11 Motor Step angle: 1.8 ± 5% Two Phase Bidirectional Holding Torque Current / Phase Voltage / Phase Phase Resistance Phase Inductance (1KHz) 0.6 Kg*cm 0.67 A 3.8 V 5.6 Ω± 10% 4.2 mh± 20%

15 Physical Dimensions: Stepper Motor

16 Motor Driver Bi-polar Microstepping Driver 2A/Phase Max A/Phase w/o Heatsink Max Motor Drive Voltage: 30V On-board 5V/3.3V Regulation

17 opto + opto + opto opto a opto c b d + + opto opto opto

18 Pneumatic Press/Rig Pneumatic activated to contain breaker vertically (50 psi) Spring loaded compress for horizontal containment Yellow: Stepper Motor Red: Armature Blue: Adjustment screw Green: Horizontal Support Orange: Connectors to breaker Not shown: Solenoid to interrupt trip

19 Power Relay Coil Voltage: 6-600V Current Max: 40A Response Time: 30 ms Average Power Dissipation: 4 W

20 Optocoupler 4N26 Input Reverse Voltage Forward Current Parameters 5 V 60 ma Surge Current 3 A < 10µs Power Dissipation 100 mw Output Collector Emitter Breakdown Voltage Emitter Base Breakdown Voltage Collector Current Power Dissipation 70 V 7 V 50 ma (100 ma < 1ms) 150 mw

21 Taps: One tap for 200% Current Another for 115% Current (for calibration) Load Bank

22 Breaker Test Diagram

23 PSoC Operating Red on for 10 seconds during 200% load Clear LED indicates activated relay, calibration commence Yellow flashes indicating power to motor Green Alive pin Blue Test done

24 Alternative Designs In place of the PSoC, use an Arduino, PLC or FPGA Construct our own mechanical unit in place of the rig provide by Carling Technologies

25 Budget Quantity Item Model Specifics Cost (1) Programming Unit for PSoC CYPRESS CY8CKIT- 002 PSoC MiniProg3 Program and Debug Kit $82.43 (1) Stepper Motor Model NEMA-17, product code: RB-Ada- 138 $14.00 (1) Alternative Stepper Motor Model NEMA-11, product code: 11HS12 $16.99 (1) USB oscilloscope From Analog Discovery, to be used with LabVIEW $ (1) Analog Parts Kit $49.99 (w/ academic discount)

26 Budget Continued Quantity Item Model Specifics Cost (1) NI Multisim & NI Ultiboard (1) Analog Discovery BNC Adapter Board (1) BNC Oscilloscope Probes (pair) (1) Mini "Grabber" test hooks (1) Project Box + StickerSheet NI Circuit Design Suite $9.95 (w/ academic discount) $19.99 $19.99 $14.99 $7.00 (2) Relay Schneider Electric/Magnecraft Model 119DBX-3 $37.70

27 Budget Continued Quantity Item Model Specifics Cost (3) Signal Relays Kemet EE2-5NU-L, 3.75 V $1.81 (3) Signal Relays Kemet EC2-12NU, 9 V $1.97 (6) Optocouplers Part number: 4N26 $0.59 Total: $484.61

28 Timeline of Project

29 Questions?