Cal Poly SuPER Project: Progress Report and Plans

1
Cal Poly SuPER Project Progress Report and
Plans

• EE 563 Graduate Seminar
• October 6, 2006
• James G. Harris, Professor
• EE Department and CPE Program

2
Cal Poly SuPER Project Outline

• Background rationale for project
• Progress Report for Last Year AY 05-06
• Plans for This Year AY 06-07
• Conclusion and Invitation to Join Project

3
Background - Electrification

• Electrification National Academy of
  Engineerings top engineering achievement for the
  20th Century
• Estimated 1/3 of population (now, 6B) do not have
  access
• Significant proportion of remainder does not have
  reliable access to battery or grid
• 18,000 occupied structures on Navajo Nation lack
  electrical power (2001 legislation)

4
Background - Significance

• Impact of electrification significant
• Transformation of Western world
• Thomas Hughes Networks of Power
• People who caused change
• Social Impact standard of living
• Recognized by National Renewable Energy
  Laboratory in late 1990s
• Village Power Program
• Development of microfinancing

5
Background Solar Insolation

• Goal to provide electrical resources to people in
  underdeveloped countries
• Leapfrog technology no need for 100 years of
  development
• Example of cell phone in Asia
• Review of global insolation map
• Poorest people (1-2 a day income)
• Within plus or minus 30 degree of latitude
• Highest values of solar insolation (minimum W
  hr/sq m/day)

6
(No Transcript)
7
Background DC Power

• Solar photovoltaic systems inherently DC
• History of DC (Edison) versus AC (Westinghouse
  and Tesla) at end of 19th century
• DC versus AC for generation, distribution, and
  utilization
• Initially, applied to lighting
• Lighting today
• 60W incandescent bulb and 20W compact fluorescent
  bulb lumens
• Equivalent to 3W LED technology, and improving

8
Background DC power loads

• Efficiency of electrical motors few horsepower
• Permanent magnet DC motors
• Electrical appliances
• Computer 50W laptop (DC)
• TVs, radios use DC power
• RV 12V DC market kitchen appliances
• Portable power tools battery powered (DC)
• Computers wireless connection
• Internet, phone (voice over IP), TV, radio,
• Education MIT Media Lab 100 laptop project

9
Background Moores Law

• Stand-alone solar photovoltaic system technology
  is mature, e.g., Sandia Handbook
• Application of Moores Law to development of
  SuPER system
• Solar cell development commercial and research
  lab
• Estimate 5 per decade with base of 16 in 2005
• Implies 25 efficiency in 2025
• DARPA RFP 1000 units of 50 efficiency

10
Commercial Module Range
Laboratory Cells Histories of Silicon
Photovoltaic Module and Cell Efficiencies Ref.
Martin A. Green "Silicon Photovoltaic Modules A
Brief History of the First 50 Years" Prog.
Photovolt Res. Appl. 2005 13447455 (Published
online 18 April 2005 in Wiley InterScience
(www.interscience.wiley.com). DOI
10.1002/pip.612)
11
April Allderdice and John H. Rogers Renewable
Energy for Microenterprise National Renewable
Energy Laboratory November 2000
12
Antonio C. Jimenez, Tom Lawand Renewable Energy
for Rural Schools National Renewable Energy
Laboratory November 2000
13
Jonathan O.V. Touryan and Kenell J. Touryan
Renewable Energy for Sustainable Rural Village
Power Presented at the American Scientific
Affiliation Conference Arkansas August 1,
1999 National Renewable Energy Laboratory
14
Background Solar and DC Power

• Conclusion
• Solar photovoltaic is poised for leapfrog
  technology
• Many development tools available
• Expectation of future efficiencies
• Sustainable power source
• Digital control of standalone system
• DC is power of future
• Decentralized
• Matched to source and loads

15
Background Overall Cal Poly SuPER System Goals

• Design lifecycle of 20 years
• Total Cost less than 500 for 1 sq m PV module
  including battery replacements
• Mean time between failures (MTBF) 25 years
• Mean time to repair (MTTR) 1 hour
• Power depends on PV efficiency and battery
  storage capacity

16
Why? Broader Impact of SuPER Project

• Provides family owned electrical power source
• Only electrical power source for family
• Increasing power resource with time
• With financial business plan 2-3 per month for
  all electrical power needs
• Decentralized, sustainable development of
  electrical power in poorest countries
• SuPER system potential resource for raising
  standard of living of poorest to par with rest of
  world

17
Background Five Year Plan for Development

• Five years for completed design, development, and
  field testing
• Includes business plan, documentation and
  dissemination
• First three years for prototype development
• Three generations at one year for each
• Last two years for field testing
• Establishing contacts overseas now

18
Progress Report Technical Description of SuPER
System
19
Prototype Development Phases

• Phase 00 use of existing donated PV module
  (150W) PV system
• Phase 0 cart mounted system
• Phase 1 cart system with
• Laptop computer with USB i/F to sensors
• Linux OS
• Cart for packaging
• Phase 2 cart system performance testing/design
  enhancements
• Phase 3 packaging/manufacturability goals
• Port software/electronics to FPGA with
  microprocessor
• Phase 4 system testing/preliminary field testing

20
Summary -Progress ReportAY 05-06

• Cal Poly SuPER project lab established in 20-101
• Development phases 00, 0 , and 1 planned
• Phase 0 implemented resulting in 1 thesis and 3
  senior projects by end of Summer
• BUS 454 (Spring 06) senior project team develops
  business/marketing plans 4 senior projects
• Foundation provided for future development of
  phase 1 prototype

21
Eran Tal working with prototype SuPER System
June 2006
22
SuPER Development Team
23
Weekly Seminar Meeting in Power Senior Project
Room (20-101) SuPER Project Laboratory
24
(No Transcript)
25
(No Transcript)
26
Cal Poly SuPER Project - Spring 2006
SUPER prototype cart with solar panel, battery,
instrumentation and control subsystems Members
present in photo (left to right) Eran Tal, Eric
Phillips, Gustavo Vasquez, Alexander Gee,
Jennifer Cao, Sam Muehleck, Dr. Jim Harris, Dr.
Taufik, Tyler Sheffield, Dr. Ali Shaban Members
missing Dr. Ahmad Nafisi, Robert Johnson
27
(No Transcript)
28
(No Transcript)
29
Prototype SuPER System Cart protection and load
distribution 12V DC service panel with five load
circuits (four in service)
30
Prototype SuPER System Cart bottom shelf 12V DC
1/4HP motor load and 12V battery
31
Prototype SuPER System Cart top shelf view Laptop
computer, interface circuits, MX-60 controller
32
Prototype SuPER System Cart left side switchboard
enclosure Main switchboard (bottom) and PV
switchboard (top left)
33
Prototype SuPER System Cart right side view
34
Comparison of Open Loop and Phase 00 Systems
35
Plans for This Year AY 06-07

• Recruit new Cal Poly Super Team
• Initial meeting this past Wednesday
• Develop and test the Phase 1 Prototype
• All Cal Poly fabrication except for PV and
  battery
• Continue effort initiated by BUS 454
• Work with consumer community

36
(No Transcript)
37
Plans Research Opportunities Available on Cal
Poly SuPER Project

• Undergraduates and graduates EE, CPE
• Graduate students provide leadership/thesis
• Undergraduates work on senior project
• Others invited
• Design/development team environment
• Weekly seminar meetings with faculty
• Funds available to purchase materials and
  components for students

38
Plans Some Research Areas for Student Projects

• Simulation of system with MatLab/Simulink
  digital control algorithms
• DC-DC converter development PV to battery, DC
  output bus to LED lighting
• Printed circuit board development PCBExpress
  on-line design and fabrication
• Battery and ultra-capacitor technology
  electrical power storage research and modeling
• Modeling of DC loads white LED lighting, DC
  motor, battery charging, refrigerator
• Power distribution and protection NEC code
  compliance

39
Plans Some Research Areas for Student Projects
(continued)

• Sensor data acquisition and processing voltage,
  current, temperature and sun insolation
• System engineering PV input modeling and DC
  output load scenarios for testing
• PV array modeling study of technology and
  maximum power point tracking algorithms
• White light LED system development
• DC motor characterization and load performance

40
Plans Interested in Participating?

• Check out SuPER website http//www.ee.calpoly.edu
  /jharris/research/research.html
• Announcement of opportunities
• White Paper
• Graduate Seminar Presentation
• Senior Projects
• Thesis
• Visit with faculty involved
• EE Jim Harris, Ahmad Nafisi, Ali Shaban, Taufik
• OCOB Doug Cerf, Norm Borin

41
Cal Poly SuPER Senior Projects and Thesis
(available at SuPER website)

• Thesis
• Eran Tal, "SuPER System Prototype Design and
  Implementation", July 2006 (pdf file)
• Senior Projects
• Tyson DenHerder, "Design and Simulation of
  Photovoltaic SuPER System using Simulink", March
  2006 (pdf file)
• Gustavo Vasquez Jr., "Data Acquisition and Sensor
  Circuits for the SuPER Project", June 2006 (pdf
  file)
• BUS 454 Client Report Presentation - June 2006
  Student Team - Jessica Hickey, Richard Huskey,
  Heather McGinnis, Nick McMillan Faculty
  Supervisor -Dr. Lynn Metcalf (PowerPoint)
• Alexander Gee, "Printed Circuit Board Design and
  Construction for hte SuPER Project", August 2006
  (pdf file)

42
References

• 1. George Constable, Bob Somerville A Century of
  Innovation Twenty Engineering Achievements that
  Transformed our Lives National Academy of
  Engineering 2003 overview available at
  http//www.greatachievements.org/
• 2. Jonathan O.V. Touryan, Kenell J. Touryan
  "Renewable Energy for
• Sustainable Rural Village Power" Presented at
  the American Scientific Affiliation
• Conference Arkansas August 1999, available from
  NREL as NREL/CP-720-26871
• hybrid system for nrel village power program
  report
• 3. Begay-Campbell, Sandia National Laboratories
  "Sustainable Hybrid System Deployment with the
  Navajo Tribal Utility Authority" NCPV and Solar
  Program Review Meeting 2003 NREL/CD-520-33586
  Page 541 available at http//www.nrel.gov/ncpv_pr
  m/pdfs/33586073.pdf estimated date 2003,
  describes program resulting from "On November 5,
  2001, President Bush signed the Navajo Nation
  Electrification Demonstration Program (Section
  602, Public Law 106-511) into Law. This law
  directs the Secretary of Energy to establish a
  5-year program to assist the Navajo Nation in
  meeting its electricity needs for the estimated
  18,000 occupied structures on the Navajo Nation
  that lack electric power."
• 4. Thomas P. Hughes Networks of Power
  Electrification in Western Society, 1880-1930
  Baltimore Johns Hopkins University Press, 1983
• 5. Thomas P. Hughes American Genesis A Century
  of Invention and Technological Enthusiasm
  1870-1970 Penguin Books 1989
• 6. David Nye Electrifying America Social
  Meanings of a New Technology, 1880-1940 MIT
  Press 1990

43
References

• 7. Antonio C. Jimenez, Tom Lawand "Renewable
  Energy for Rural Schools" National Renewable
  Energy Laboratory November 2000
• report from village power program at nrel
  covers all renewable sources
• 8. April Allderdice, John H. Rogers Renewable
  Energy for Microenterprise NREL November 2000
  available from http//www.gvep.org/content/article
  /detail/8508
• microfinance introduction for renewable energy
  in underdevelopment countries
• 9. Ulrich Stutenbaumer, Tesfaye Negash, Amensisa
  Abdi "Performance of small scale photovoltaic
  systems and their potential for rural
  electrification in Ethiopia" Renewable Energy
  18 (1999) pp 35-48
• authored by locals, but dated example of
  early recognition of possibilities
• 10. Sunwize Technologies http//www.sunwize.com/
  insolation map available at
  http//www.sunwize.com/info_center/insolmap.htm
• on-line catalog and interactive planning
  support global insolation map
• 11. Evan Mills "The Specter of Fuel-Based
  Lighting" Science v. 308, 27 May 2005, pp
  1263-1264
• 12. E. Fred Schubert, Jong Kyu Kim "Solid-State
  Light Sources Getting Smart" Science v. 308, 27
  May 2005, pp 1274-1278
• 13. Thurton, J.P. and Stafford, B "Successful
  Design of PV Power Systems for Solid-State
  Lighting Applications" Fourth International
  Conference on Solid State Lighting 3-6 August,
  2004, Denver. Colorado / Proc. of SPIE v. 5530
  2004 pp284-295
• mainly lessons learned

44
References

• 14. MIT Media Lab http//laptop.media.mit.edu/
• 15. Sandia National Laboratories, Solar Programs
  and Technologies Department Southwest Technology
  Development Institute, New Mexico State
  University Daystar, Inc., Las Cruces, NM
  "Stand-Alone Photovoltaic Systems A Handbook of
  Recommended Design Practices" Sandia National
  Laboratories, SAND87-7023 Updated July 2003
• revised handbook first published in 1988
• 16. Kyocera Solar, Inc., Solar Electric Products
  Catalog , August 2005
• available on web prices for small modules
  only
• 17. IEA PVPS International Energy Agency
  Implementing Agreement on Photovoltaic Power
  Systems Task 3 Use of Photovoltaic Power Systems
  in Stand-Alone and Island
• Applications Report IEA PVPS T3-09 2002 "Use of
  appliances in Stand-Alone PV Power supply
  systems problems and solutions September 2002
• dos and don'ts for design
• 18. Alison Wilshaw, Lucy Southgate Rolf Oldach
  "Quality Management of Stand Alone PV Systems
  Recommended Practices" IEA Task 3,
  www.task3.pvps.iea.org
• another report of iea agreement
• 19. Martin A. Green "Silicon Photovoltaic
  Modules A Brief History of the First
• 50 Years" Prog. Photovolt Res. Appl. 2005
  13447455 (Published online 18 April 2005 in
  Wiley InterScience (www.interscience.wiley.com).
  DOI 10.1002/pip.612)
• history and use of moore's law with darpa rfp
  also figure
• 20. Defense Advanced Research Projects Agency
  (DARPA) BAA05-21 posted Feb. 25, 2005 RFPVery
  High Efficiency Solar Cell (VHESC) program
  announcement with deadline on 3/29/2005, which
  will be open at least a year from this date see
  http//www.darpa.mil/ato/solicit/VHESC/index.htm
  

45
References

• 21. H. Spanggaard, F.C. Krebs "A brief history
  of the development of organic and
• polymeric photovoltaics" Solar Energy Materials
  Solar Cells 83 (2004) 125146
• overview in context of inorganic (si) pv's)
• 22. T. Givler, P. Lilienthal "Using HOMER
  Software, NRELs Micropower Optimization Model,
  to Explore the Role of Gen-sets in Small Solar
  Power Systems Case Study Sri Lanka" Technical
  Report NREL/TP-710-36774 May 2005.
• 23. David L. King, Thomas D. Hund, William E.
  Boyson, Mark E. Ralph, Marlene Brown, Ron Orozco
  "Experimental Optimization of the FireFly. 600
  Photovoltaic Off-Grid System" Sandia National
  Laboratories, SAND2003-3493 October 2003
• system and component test with ac inverter
  measurement parameters standards and codes
  identified, e.g., grounding
• 24. R. Akkaya, A. A. Kulaksiz "A
  microcontroller-based stand-alone photovoltaic
  power system for residential appliances" Applied
  Energy 78 (2004) 419431 available at
  www.elsevier.com/locate/apenergy
• microbased control, but focused on AC output

46
References

• 25. Angel V. Peterchev, Seth R. Sanders
  "Digital Loss-Minimizing Multi-Mode Synchronous
  Buck Converter Control" 2004 35th Annual IEEE
  Power Electronics Specialists Conference Aachen,
  Germany, 2004
• dc to dc for cell phone/computer using
  digital techniques
• 26. Jason Hatashita, "Evaluation of a Network
  Co-processing Architecture Implemented in
  Programmable Hardware." EE MS Thesis, February
  2002 available at http//www.netprl.calpoly.edu/f
  iles/phatfile/papers/masters/jasonH.pdf
• 27. Homepage for Cal Poly Marketing Program
  http//buiznt.cob.calpoly.edu/cob/Mktg/Borin/
  see client application in lower right hand space
• 28. EE 460/463/464 Senior Seminar/Senior Project
  Handbook available at
• http//www.ee.calpoly.edu/listings/29/sphand.pdf
  
• 29. Muhammad H. Rashid Power Electronics
  Circuits, Devices and Applications(3rd Edition)
  Prentice-Hall 2004